#neverstopINNOVATING
Flexibility & Innovation in QualiCal’s Synthesis Lime Kiln Production
Maximizing Efficiency and Sustainability Through Advanced Design, Versatile Operation and A.I. analytics
Synthesis PRF kiln Original Design
The Synthesis kiln represents the original PRF (Parallel Flow Regenerative) design by QualiCal for lime production, born from our #neverstopINNOVATINg R&D vision.
QualiCal has continuously evolved this design to ensure maximum flexibility and production efficiency. The flexibility of the Synthesis kiln brings significant advantages, including the ability to handle a wide range of materials, operate efficiently across various production capacities, and use multiple fuel types. These features optimize the production process, reduce operational costs, and enhance sustainability, ultimately leading to more effective and efficient lime production.
Flexibility in Material Usage
The Synthesis kiln is designed to handle materials of varying granulometries, from fine (20mm) to coarse (120mm) particles, including combinations of both.
This capability enhances production efficiency, optimizes the use of natural resources, and reduces material waste from quarries.
Flexibility with Suboptimal Combustion Materials
The kiln can also process materials that have suboptimal decrepitation during combustion or exhibit fragility, leading to significant amounts of fine material during the lime production process.
Wide Production Range
One of the main advantages of the Synthesis kiln is its ability to operate across a wide production range, from less than 50% to 110% of nominal capacity, without compromising the quality of the finished product.
This allows for great operational flexibility, effectively responding to market demand variations and optimizing resource use. The innovative shaft design, with variable geometry that facilitates optimized material flow, further ensures high-quality standards.
Utilization of Various Fuels
The Synthesis kiln supports the use of various types of fuels, including biomass.
This versatility in the combustion system not only reduces operational costs but also increases environmental sustainability by significantly reducing CO2 emissions. The high-density lance combustion system ensures uniform material firing, optimizing energy efficiency.
Specific Features Contributing to Flexible Lime Production in QualiCal’s Synthesis PRF Kilns
CARGO Limestone Loading System
The CARGO loading system by QualiCal allows optimal material distribution, including fine particles.
This system is designed to handle a wide range of material sizes, ensuring uniform distribution within the kiln. The ability to process materials of varying sizes without compromising production efficiency is fundamental to the kiln’s versatility.
Optimized Material Flow in Shafts
The variable geometry of the Synthesis kiln shafts ensures optimized material flow.
The innovative design, which includes a natural enlargement of the cross-section, facilitates the movement of materials within the kiln, even for those raw materials that have a tendency to break and decrepitate more easily than others, thereby improving overall process efficiency.
Optimization of Fine Material Usage
The high-density lance combustion system in the Synthesis kiln ensures uniform firing of fine materials.
This advanced technology allows the use of fine granulometry materials without compromising the quality of the final product, while also improving the process’s energy efficiency.
Versatile Production Management
The Synthesis kiln is designed for highly versatile production management.
With the HP (High Production) mode, it is possible to increase operational production while optimizing fuel consumption. This mode allows for quick response to market demand variations, maintaining high efficiency levels.
Use of Various Fuels
Another key aspect of the Synthesis kiln’s flexibility is its ability to utilize a variety of fuels, including biomass.
This feature not only enhances operational versatility but also contributes to environmental sustainability by reducing CO2 emissions.
Efficient Discharge System
The discharge system, designed along the sides of both internal and external drawers, ensures optimal material flow during discharge.
This system effectively handles materials with varying sizes and residence times, ensuring a smooth and uninterrupted discharge process.
Enhancing Flexibility with AI Analytics
Achieving such high flexibility is further supported by advanced AI analytics through our MOSAICO platform. Utilizing A.I. tools like AERO and ABACO we optimize air blower efficiency and combustion processes.
AERO helps minimize electric consumption by fine-tuning air blower operations, while ABACO enhances combustion efficiency through detailed burning analysis.
These AI-driven solutions ensure the Synthesis kiln operates at peak efficiency, adapting seamlessly to different production demands and fuel types, thereby maximizing operational effectiveness and sustainability.
“The combination of these technical and digital solutions makes the QualiCal Synthesis kiln an example of excellence in production flexibility. Each component is designed to improve efficiency and sustainability, meeting the diverse needs of the market.”- Says Francesco Cella QualiCal CTO
Bibliography:
- [Cargo Loading and Feeding System](https://medium.com/qualical/cargo-loading-and-feeding-system-3ee86e0e6a90)
- [Optimization of Material Flow in Shafts](https://medium.com/qualical/synthesis-lime-kiln-original-design-with-patented-shafts-variable-shape-direct-cross-over-channel-2078facebf9e
- [Optimization of Fine Materials](https://medium.com/qualical/synthesis-hp-fine-lime-kiln-bfd876a334dd)
- [Versatile Production Management](https://medium.com/qualical/higher-lime-kiln-production-optimized-fuel-consumption-by-synthesis-hp-operation-5f2b79af36fe)
- [Use of Various Fuels](https://medium.com/qualical/reach-co2-neutrality-with-improved-synthesis-lime-kiln-firing-system-equipped-with-new-carbotechnik-310250eca1b7)
- [Discharge System](https://medium.com/qualical/synthesis-lime-kiln-with-easy-and-simple-lime-discharging-solution-b59f6ef9e7e4)
- [Digital Lime Plant](https://medium.com/qualical/digital-lime-plant-8aaaec3a0751)
- ABACO: Advanced Burning Analysis and Combustion Optimization
© Published with passion and dedication by QualiCal 05.2024
