Sintered SAW Flux Rotary Kiln
Customizable Capacity Continuous Operation EPC ProjectSintered SAW flux, also called agglomerated flux or sintered flux, is a commonly used granular auxiliary material that provides protection during the submerged arc welding process. It helps stabilize the arc, reduce spatter, and improve the appearance of weld seams. In addition, its formulation can be adjusted flexibly, and its production process features low energy consumption and minimal pollutant emissions. Therefore, it is widely used in various high-demand welding applications.
The sintered SAW flux rotary kiln is the core equipment specifically designed for producing this type of auxiliary material. It is mainly responsible for the sintering stage in the production process, during which the flux particles undergo physical and chemical changes at high temperatures to achieve the required strength and performance. Its key advantages include continuous, uniform, and large-scale production, ensuring consistent product quality within the same batch, which is difficult to achieve with static furnaces.
AGICO has extensive experience in the production and export of rotary kilns. Our sintered SAW flux rotary kilns feature high capacity, customizable design, stable operation, energy efficiency, and environmental friendliness. They can produce various standard sintered fluxes, including SJ102D, SJ64, SJ601, SJ501Y, SJ501, SJ303, SJ205, and SJ114D. In addition to rotary kilns, we also provide other equipment required for sintered flux production, dedicated to offering customers customized sintered flux production solutions.
Kiln Output: customizable
Type: automatic, continuous working
Sintering Temperature: 750-1000°C
Rotational Speed: 0-2 r/min
Temperature Accuracy: ±3-±5°C
Material Residence Time: 45-90 minutes (adjustable)
Fuel Type: natural gas, coal, coal powder, diesel, etc.
Finished Product: SJ102D, SJ64, SJ601, SJ501Y, SJ501, SJ303, etc.
Reasons To Choose AGICO Sintered SAW Flux Rotary Kiln
Uniform Heating For Consistent Flux Quality Traditional fixed sintering equipment often suffers from uneven temperature distribution. Our rotary kiln, however, ensures thorough contact between flux particles and hot gas flow through continuous 360° rotation, achieving uniform sintering. This guarantees stable chemical composition and physical properties for each batch of flux, while significantly reducing the rejection rate.
Precise Temperature Control Different types of sintered fluxes (such as SJ101 and SJ501) have different requirements for basicity, particle strength, and melting properties. Our equipment adopts a zoned temperature control system, real-time temperature monitoring, automatic combustion control, and dynamic adjustment of heating curves to help customers produce flux with consistent particle strength, low moisture absorption, and excellent welding performance.
High Output For Large-scale Production AGICO agglomerated flux rotary kiln is specifically designed for 24-hour continuous industrial production. Its high level of automation and large production capacity provide reliable support for medium- and large-scale production lines.
High Particle Integrity The optimized inclination angle of the rotary kiln, low-impact feeding system, and controllable rotational speed minimize the impact force on flux particles during the heating process. The particle strength of the finished sintered flux is increased by 3–5 times, with a moisture absorption rate below 0.5%, significantly reducing pulverization during transportation and use.
Sintered Welding Flux Production Process
In addition to rotary kilns, we also provide complete-process equipment covering raw material preparation, batching, wet mixing, granulation, drying, screening, dust collection, and packaging. Customers can choose to purchase a complete sintered flux production line, ensuring smoother technical connection and faster production.
Step 1: Raw Material Preparation: Sintered flux production requires various minerals (such as fluorite, magnesite, bauxite, and quartz) and ferroalloys (such as ferrosilicon and ferromanganese). These lump raw materials must first be crushed and ground into fine powders that meet the required specifications to ensure uniform mixing in subsequent processes.
Step 2: Batching & Dry Mixing: According to the type (such as fluoride-basic type and high-alumina type) and performance requirements of the target flux, various powders are accurately weighed and then thoroughly mixed in a mixer to ensure uniform distribution of all components. This is a critical step in determining the final chemical composition of the flux.
Step 3: Wet Mixing: The mixed dry materials are blended with a certain proportion of binder. The commonly used binder is water glass (an aqueous solution of sodium silicate or potassium silicate). The amount of binder added is typically around 20%–24% of the weight of the dry materials. At this stage, a wet mixture is formed.
Step 4: Granulation: The wet mixture is fed into a pelletizing disc to produce uniformly sized wet granules. The granule size usually serves as the basis for controlling the particle size of the final product, generally ranging from approximately 0.5-2 mm.
Step 5: Drying: The granules have low strength and require preliminary curing. They are fed into a dryer operating at 150–350°C for drying. This process removes most of the free moisture, making the granules harder and preparing them for high-temperature sintering.
Step 6: Sintering: The dried granules are fed into a rotary kiln for sintering at high temperatures. Complex physical and chemical reactions occur inside the particles, including mineral decomposition, solid-state reactions, and partial melting. Ultimately, porous ceramic granules with sufficient strength, low moisture absorption, and specific welding metallurgical properties are formed.
Step 7: Cooling & Screening: After sintering, the flux is at a very high temperature and needs to be cooled down using cooling equipment. The cooled flux is then processed through a screening machine to separate finished products that meet the required particle size specifications and prepare them for packaging. Particles that do not meet the size requirements are recycled and reprocessed.
AGICO Sintered Welding Flux Production Machines
Rotary Kiln
Belt Conveyor The above production process and equipment configuration are for reference only. Based on factors such as the required output, material type, and application field, we provide customized solutions tailored to each customer’s needs. If you are interested in our rotary kiln or production lines, please feel free to contact us for detailed information and a quotation. Send An Inquiry For Quotation!
Why Choose AGICO
Free One-to-one Consultation
Layout Design Service
Safe & On-time Delivery
Plant Construction
Equipment Installation & Debugging
Staff Training Service
Spare Parts Supply
Vertical Lathe Group
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φ5m Vertical Lathe
CNC Cutting Machine
Shot Blasting Machine
Since 2004, the company has been certified under the ISO 9001 quality management system, and our products comply with international standards such as CE, ensuring reliable quality. We are equipped with large-scale, complete sets of advanced processing equipment, enabling us to manufacture all components independently, from core structural parts to control systems, ensuring product quality and delivery schedules. From the preliminary project planning and equipment selection to installation guidance and operator training during the mid-stage, as well as spare parts supply and production capacity upgrades at the later stage, we provide comprehensive EPC contracting and turnkey engineering services. Our equipment and solutions have been successfully applied in many countries and regions worldwide. Numerous successful overseas projects serve as the best proof of our capabilities.
