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Higher Lime Kiln Production & Optimized Fuel Consumption by Synthesis_HP Operation

Higher Pressure operation, together the well known Synthesis_HP plus points, for the most effective lime production experience.

Background

Much of the world’s lime production is now carried out in PFR kilns. The quality of the finished product together with the reduction of operating costs in terms of energy and the use of a 𝐰𝐢𝐝𝐞 𝐫𝐚𝐧𝐠𝐞 𝐨𝐟 𝐫𝐚𝐰 𝐦𝐚𝐭𝐞𝐫𝐢𝐚𝐥 𝐬𝐢𝐳𝐞 𝐟𝐫𝐚𝐜𝐭𝐢𝐨𝐧𝐬 are key factors in ensuring efficient and sustainable production.

HP — High Pressure operation

QualiCal proposes the HP High Pressure Synthesis Kiln operation
maximizing the kiln capacity production

Increase lime kiln production rate does it mean to deal with higher pressure drop generated by the higher fuel demand and consequently higher combustion air and lime cooling air, needed to burn the higher quantity of limestone.
In reference to a given cross section, the higher production rate causes a significant increase of the operating pressure.

Thanks to a simple & effective design, all the Process Valves (Air-Fume Valves, Stone Charging Valves, Lime Discharging Valves) of the kiln have been designed to operate at higher nominal pressure (up to 500 mbar).
Kiln Shell are dimensioned to safely withstand higher operating pressures as well, assuring highest robustness & reliability and Making Synthesis kiln & its key components fully compliant to be operated in High Pressure (HP) mode.

Synthesis_HP Plus Point

The new HP modus operandi can be applied in new QualiCal Synthesis Kiln, as well as retrofitting existing lime kiln, obtaining clear and effective results that concern:

Increased Nominal Production

Since the HP mode has been implemented in the QualiCal Synthesis lime kiln, the first evident goal was obtaining a greater throughput, that means more ton of lime at the end of the day. The increase in nominal production is attested to be in a range between 5 to 10% !

A Synthesis Kiln designed for 400tpd stably operating above the nominal capacity

Decreased Specific Consumption

The second indirect, but really important effect, is the correlated reduction of specific heat consumption [kcal/kg lime]: from a standard value around 850 kcal/kg, a Synthesis HP guarantee approx. 5–10% fuel saving reaching a new target around 800 kcal/kg (!).

Infact, a very important fact to be taken into consideration, while operating PFR lime kiln, is that the greater it is the operating pressure, while producing at higher range, the better is the heat distribution and the contribution to the calcination process an all the kiln crossover section. This lead to a clear virtuous effect for which is it possible to increase production and gain in reduction of heat consumption obtaining also a more uniform quality lime.

Production increase with consequent Consumption Decrease

Last but not least the HP solution is perfect to deal with

Fine lime production

QualiCal proposes the HP High Pressure Synthesis Kiln operation
to deal with higher pressure drop generated by the reduction of the free volume between the stones in case of usage of fine lime raw material

Synthesis_HP maximize the kiln capacity production, even in case of fine lime Production Experience by optimizing the kiln operating pressure to reach an uniform heat distribution.

FINE LIME production with Synthesis_HP kiln version

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