In order to turn mineral raw materials into cement clinker, mortar or refractory material, energy-intensive intermediate steps are required in which the structure and chemical composition of the raw materials are changed at high temperatures. Various preliminary products and finally materials for the construction, ceramics and metal industries are produced. In an innovative rotary kiln, researchers at TU Bergakademie Freiberg are now testing how conventional gas burner systems can be replaced by electrically heated induction plasma burners for the manufacturing process of the preliminary products in the future.
In order to confirm the predictions regarding environmental friendliness, the team is building a new type of rotary kiln with an induction plasma burner in the technical centre of the project coordinator, XERION BERLIN LABORATORIES GmbH - a specialist in kiln units equipped with induction plasma technologies: "Together, we are developing both the new type of electrically heated furnace including innovative refractory lining and the manufacturing process for the three model materials cement clinker as well as magnesium aluminates and zircon mullite aluminium oxides - as lining materials for iron and steel production," explains Professor Christos Aneziris, project manager at TU Bergakademie Freiberg. "We are particularly interested in how the refractory lining of the furnace and the raw materials sintered in the furnace react to the plasma atmosphere." The subsequent operation is planned at the Centre for Efficient High-Temperature Material Conversion in Freiberg.
At the end of the three-year joint project, the energy balance, a CO2 emissions analysis, research into the material qualities generated and a profitability analysis of the new technology will be carried out. "This will enable us to verify the industrial suitability and long-term stability of the innovative technology and further develop it for other fields of application in energy-intensive industries," says Aneziris.
- The research project entitled "Rotary kiln induction plasma sintering technologies (DIP-S)" is being funded by the Federal Ministry of Research, Technology and Space until the beginning of 2029 as part of the directive "Avoidance of climate-relevant process emissions in industry (KlimPro-Industrie II)".
- Projektträger: DLR
- Verbundpartner:
- XERION BERLIN LABORATORIES GmbH (network coordinator)
- TU Bergakademie Freiberg, Institute of Ceramics, Refractory and Composite Materials
- Imerys Murg GmbH
- Sintering is the most energy-intensive process in the production of ceramics, accounting for around 70 per cent of total energy consumption. Thermal energy is predominantly used in the cement industry, accounting for around 88 per cent of total energy consumption.
