_ . ,.

-.

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EPA Export 25-07-2013:16:43:21

The M&RZ@ Padlel FlOw Regenerative Lime Kiln

1. Limestone, Lime and Dolomite tive heat transferto the core.A temperatureof 900 C hasto
be reachedin the coreat leastfor a shortperiodof time since
Lime is one of the key elements in life. This natural raw mate- the atmosphere insidethe materialis pureCO,.Thestonesur-
rial is involved in the production of the majority of modem face mustbe heatedto greaterthan 900 C to maintainthe
products. The production of iron and steel, gold, silver, copper requiredtemperaturegradient and overcomethe insulating
and plastics as well as many chemical products and foodstuffs, effect of the calcinedmaterialon the stonesurface.Whenpro-
just to mention a few, requires lime and, to a lesser extent, ducing soft-burnt lime the surfacetemperaturemust not
dolomite. The most important fields of application for lime and exceed1100to 1150C asotherwisere-crystallisation of the
dolomitic lime are: CaOwill occurandresultin lowerreactivity and thusreduced
lron and steel slakingpropertiesof the burnt product.
Non-ferrous metals
Building industry A certainretentionor residencetimeisrequiredto transferheat
Pulp and paper from the combustiongasesto the surfaceof the stoneand
Chemical industry then from the surfaceto the coreof the stone.Largerstones
PCC - Precipitated calcium carbonate requirelongertimeto calcinatethan smallerones.In principal,
Sugar calciningat highertemperatures reducesthe retentiontime
Glass needed.However,too high temperatures will adverselyaffect
Flue gas desulphurisation the reactivity of the product.The relationbetweenburning
Agriculture temperatureand retentiontime requiredfor different stone

.
se
Soil stabilisation sizesis shownin the followingtable.
ru
he
Water treatment
ot
ny
fo y.

Sewage treatment. Stonesize Calciningtemperature Approx.residence

time
d nl
ra
re o

b-4 [Cl (hours]

ui es
eq os

World wide more than 120 milliontonsper year of lime and 50 1200 0.7
r r rp
ne pu

dolomiticlimeareproduced.Theiron andsteelindustryisthe 1000 2.1

ow ion

primaryconsumer with an annualdemandof approx.40 mil- 100 1200 2.9

ht ct
ig pe

lion tons. 1000 8.3

yr ns
op r i
f c Fo

High quality limestonecontains97 to 99%CaCO,.It requires Throughoutthispaper,the wordlimeis usedinterchangeab-

ly to meanhighcalciumlime or dolomiticlime.
to

approximately1.75 tons of limestoneto produceone ton of

en
ns

lime.Highqualitydolomitecontains40 to 43% MgCO,and57

Co

to 60% CaCO,.It requiresapproximately2 tons of dolomitic

stoneto produceoneton of dolomiticlime. 2. Lime Production EauiDment

Thecalcinationor burningof limestoneanddolomiteis a sim- Two typesof kilnsareprimarilyusedto calcinelimestoneand

ple chemicalprocess. Whenheatedthe carbonatedecomposes dolomitein todayslimeindustry:
accordingto its respectiveequation. l Rotarykilns,and
l Verticalshaftkilns.
CaCO,t approx.3180kJ [760kcal)= CaOt CO,
CaMg(CO,),t approx.3050kJ (725kcal)= CaO.MgOt 2 CO, Rotarykilns,with or without preheater,usuallyprocessgrain
sizesbetween6 and 50 mm.The heatbalanceof this type of
Thedecomposition temperature dependson the partialpressu- kilnsis characterised by ratherhigh losses
with the off-gases
re of the carbondioxidepresentin the processatmosphere. In andthroughthe kiln shell.Typicalfiguresfor off-gaslosses are
a combustiongasatmosphereof normalpressureand 25% in the rangeof 20 to 25%andfor kiln shelllosses15to 200/o
CO,,the dissociation of limestonecommences at 810 "C. In an of the total heat requirement.Only approx.60% of the fuel
atmosphere of 100% CO,,the initial dissociationtemperature energyintroducedinto preheatertype kilnsis usedfor the cal-
wouldbe 900 C.Dolomitedecomposes in two stagesstarting ciningprocess itself.
at approx.550C for the MgCO,portion andapprox.810 C
for CaCO,. For all typesof verticalsingleshaftkilnsthereis an imbalance
betweenthe heatavailablefrom theburningzoneandthe heat
In orderto fully calcinethe stoneandto haveno residualcore, requiredin the preheatingzone.Evenwith an idealcalcination
heatsuppliedto the stonesurfacemustpenetratevia conduc- process (havinganexcessair factor of 1.0)a wastegastempe-

EPA Export 25-07-2013:16:43:22

 Co
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EPA Export 25-07-2013:16:43:22

 Co
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EPA Export 25-07-2013:16:43:22

 Co
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EPA Export 25-07-2013:16:43:22

 Co
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EPA Export 25-07-2013:16:43:22

 Co
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EPA Export 25-07-2013:16:43:22

 Co
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EPA Export 25-07-2013:16:43:22

 Co
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EPA Export 25-07-2013:16:43:22

 Co
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EPA Export 25-07-2013:16:43:23

 Co
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EPA Export 25-07-2013:16:43:23

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EPA Export 25-07-2013:16:43:23

 Co
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EPA Export 25-07-2013:16:43:23

 Co
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EPA Export 25-07-2013:16:43:23


perature in the calcining zone in a consistent, uniform manner.
Temperaturewithin this zone can vary due the stone grain size,
the chemical analysis of the stone, variations in the amount
and distribution of air flow, and variations of the heat value of
the fuel. Fuel input has to be controlled as a function of the
calcining temperature. As the temperature in the crossover
channel is an excellent indicator for the calcining temperature
an accurate measurement of this temperature by optical pyro-
meter is required.
6.2 Grain Size of the Stone
A narrow range of grain size is ideal for any kiln, but, due to
the crushing properties of stone, a widely varying grain size is
the typical situation in the quarry. The PFR-Kiln is able to cal-
tine a wide range of top to bottom stone size because of its
sophisticated charging system. The ideal range is 2:1, but ope-
ration using 4:l is still permissible. The top to bottom size
* range is not the only criteria though as the shape of the grain
also plays a role. The minimum stone size for the standard type
PFR-Kiln is approximately 25 mm with a typical maximum
stone size of 125 mm. Upon customer request the maximum
6.4 Excess Combustion Air
Excess air has a considerable influence on fuel consumption in
the typical counter flow shaft kiln. But this is not the case in
the parallel flow regenerative kiln where the excess air factor
has hardly any effect. The same amount of heat is recovered in
the stone of the non-burning shaft regardless of the introdu-
ced excess combustion air. Therefore the air volume can be
adjusted to produce a short or long flame and adapt the bur-
ning zone temperature to produce the desired product. Lime
cooling air does not take part in the combustion and dilutes
the combustion gases thereby making the CO, content in the
off-gas of PFR-Kilns lower than in a conventional single shaft
kiln.
7. Performance, Product Quality, Energy
Consumption, Maintenance
7.1 Kiln Capacity
The trend in todays market is to focus on large capacity kilns.
PFR-Kilns with a daily output of 600 tons have been in opera-
tion for years with up to 1000 tpd available. Small capacity

.
size may be as high as 180 mm provided the burning zone as

se
kilns are restricted by economic factors. The relation between
ru
well as the feeding and discharge equipment have been ade- he
the cost to install a large kiln and a small kiln is not linear. It
ot
quately designed for it.
ny
fo y.

is generally recognised and accepted that the investment costs

d nl
ra
re o

per ton of burnt lime are higher on small kilns than they are on
ui es

6.3 Quality of the Stone

eq os

a larger kiln. Even so, under certain conditions, PFR-Kilns with

r r rp

As for all types of vertical shaft kilns the use of hard, non-
ne pu

a daily output of 50-75 tons have been proven economical.

ow ion

decrepitating, high purity limestone is an ideal condition for

ht ct

trouble-free operation of the PFR-Kiln. Nevertheless, due to

ig pe

The output of a PFR-Kiln can be varied within a wide range: it

yr ns

the fact that the shafts of the PFR-Kiln are virtually a pipe
op r i

is quite possible to operate the kiln at only one half of the

f c Fo

without any devices which could obstruct the free flow of

nominal capacity without considerable influence on the speci-
limestone and lime the movement of the material column is
to

fic fuel and power consumption.

en

slow and uniform minimising abrasion and formation of fines.

ns
Co

This means that also soft limestone can be calcined in the PFR-
7.2 Product Quality
Kiln.
l In case the limestone has a tendency to decrepitate during the
7.2.1 Residual CO,
The PFR-Kiln allows the production of lime and dolomitic lime
calcining process an increased percentage of fines will be gene-
with residual CO, figures as low as 0.5%, in certain cases even
rated. The installation of so called air cannons in the crossover
lower. The steel industry, the biggest consumer of lime and
channel area where dust particles could stick to the refractory
dolomitic lime, generally asks for residual CO, contents of less
lining facilitates the calcination of soft and decrepitating
than 2%.
stone.
7.2.2 Reactivity
High quality limestone and dolomite with consistent chemical
The parallel flow of material and combustion gases during the
properties is often not available or is scarce. Varying contents
calcining process is the ideal condition to produce high reacti-
of carbonates and impurities can result in the production of
ve lime and dolomitic lime as required for most applications.
overbumt or underbumt product with inconsistent values for
For special applications such as the production of porous con-
residual CO, and loss on ignition. For such cases a folly auto-
Crete,lime with medium or low reactivity is required. By adap-
matic temperature control system of the Maerz PFR-Kiln may
ting operating parameters, such as excess air ratio and heat
be implemented to adjust the heat input to maintain uniform
input, medium burnt lime can be produced in the PFR-Kiln
quality of the calcined product.
with adequate quality of the raw stone. The production of hard
burnt lime, however, is in general not possible in this type of
kiln.

16 .

EPA Export 25-07-2013:16:43:23

 Co
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EPA Export 25-07-2013:16:43:23

 Co
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EPA Export 25-07-2013:16:43:23

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.
!

EPA Export 25-07-2013:16:43:23