Spent Catalyst Regeneration Rotary Kiln Furnace 1TPH-80TPH Capacity

Spent catalyst regeneration rotary kiln furnace

1.Product Introduction Calcination Rotary Kiln

The Spent Catalyst Regeneration Rotary Kiln Furnace is a continuous high-temperature thermal treatment system specifically designed for the regeneration of deactivated catalysts used in the petrochemical, oil refining, and automotive emission control industries. The equipment consists of an inclined rotating refractory steel cylinder, a multi-zone temperature control heating system, an off-gas purification unit, and automated feeding/discharging systems. It operates within a temperature range of 800–950°C to achieve the complete oxidative removal of carbon deposits (coke) from the catalyst surface while simultaneously restoring the active structure of precious metals (such as Platinum, Palladium, and Rhodium). Supporting atmosphere switching between nitrogen and air, the furnace is suitable for regenerating various spent catalysts with metal oxide or silica-alumina carriers, featuring high throughput, low material loss, and automated operation.

2.Application Calcination Rotary Kiln

• Automotive Catalyst Recovery: Regenerating Platinum Group Metal (PGM) catalysts from Three-Way Catalytic Converters (TWCs) for efficient recovery and reuse.
• Chemical Catalyst Cycling: Regenerating deactivated Vanadium or Molybdenum-based catalysts used in nitric acid production or phthalic anhydride synthesis.
• Environmental Resource Disposal: Replacing landfilling or incineration with resource recovery, complying with hazardous waste utilization regulations.
• Metal Recovery Enterprises: Serving as a critical pretreatment unit prior to precious metal extraction to enhance the efficiency of subsequent hydrometallurgical processes.

3.Working Principle Calcination Rotary Kiln

1. Feeding & Preheating: Spent catalysts enter the kiln head via a hermetic conveyor. In the low-temperature zone (300–500°C), moisture and light organic compounds are evaporated and desorbed.
2. High-Temperature Oxidative Regeneration: As the kiln rotates, material enters the primary heating zone (750–900°C). Excess air is introduced to combust carbon deposits into and oxidize metal sulfides into oxides, restoring the porous structure of the carrier.
3. Atmospheric Regulation & Reduction: Some systems introduce reducing gases like Hydrogen or Methane in the final stage to reduce oxidized precious metals (e.g., ) back to their metallic state, reactivating the catalytic centers.
4. Off-gas Treatment: Exhaust gases pass through quenching, dust removal, SCR (Selective Catalytic Reduction) denitrification, and activated carbon adsorption to ensure emissions comply with standards and prevent the escape of dioxins or heavy metals.
5. Automated Discharge & Cooling: Regenerated materials are naturally or forced-air cooled at the kiln tail and discharged via a sealed unit, ensuring continuous and pollution-free operation.

4.Advantages Calcination Rotary Kiln

• High Regeneration Rate: Catalyst activity recovery exceeds 90%, and precious metal recovery rates are over 95%, significantly outperforming fixed-bed or fluidized-bed processes.
• Continuous Efficiency: Daily processing capacity ranges from 5–50 tons, making it ideal for large-scale industrial applications and avoiding the intermittent losses associated with batch operations.
• Environmental Compliance: The integrated fully enclosed gas treatment system meets GB 16297–1996 and EU BREF standards, eliminating the risk of secondary pollution.
• Intelligent Control: Equipped with a PLC + AI temperature control model, it regulates rotational speed, airflow, and fuel ratios in real-time to adapt to fluctuations in catalyst composition.
• Superior Economics: The cost of regeneration per ton is 60–70% lower than purchasing new catalysts, with an investment payback period typically under 18 months.
• Localized Support: In regions such as Zhengzhou, Henan, China, multiple industrial manufacturers provide customized regeneration systems with localized installation and O&M (Operation and Maintenance) services.

5.Technical Specifications

6.Our Solutions

Henan Staurk Machinery Co., Ltd. is headquartered in Zhengzhou, Henan Province. With a leadership team boasting over 20 years of industry expertise, we are a premier enterprise specializing in the R&D, manufacturing, and sales of large and medium-sized mining, metallurgical, and construction machinery.

Our comprehensive product portfolio encompasses dozens of series and hundreds of specifications, categorized into four core industrial pillars:

• Gold & Mineral Processing: We provide complete Gold Ore Processing Equipment solutions, including advanced Gold CIL & CIP Plants for chemical extraction. For gravity separation, we offer high-precision Gold Concentrators, Shaking Tables, and specialized Alluvial Washing Equipment for placer gold recovery.

• Calcination & Grinding: High-efficiency Energy-Saving Ball Mills (optimized for Spodumene/Lithium ore), large rotary kilns, industrial dryers, and complete production lines for cement and lime.

• Crushing & Sand Making: Heavy-duty Jaw Crushers, Impact Crushers, Cone Crushers, and VSI Sand Making Machines (Impact Crushers).

• Screening & Conveying: Vibrating Feeders, high-performance Vibrating Screens, Sand Washing Machines, and integrated Belt Conveyor systems.

These complete sets of equipment are extensively utilized globally in mining, chemical engineering, metallurgy, and sustainable construction (including Concrete Recycling).

Staurk Machinery has built a formidable international presence, exporting to more than 20 countries and regions, including France, Canada, Australia, Russia, Uzbekistan, UAE, Vietnam, Indonesia, Chile, Kenya, and the Philippines. Our commitment to high-yield, energy-saving, and reliable solutions has earned us a stellar reputation in the global market.

Official Website of Henan Staurk Machinery Co., Ltd.