1500 ton per day Cement Production Line /cement plant / cement making machinery

Active lime kiln system Process Description

Qualified limestone stored in silos, the lifting and transported into the pre heater top of the silo, pre heater top hopper, the bottom two materials position control feeding quantity, and then through the next feeding tube will be evenly distributed to the pre heater limestone calvary indoors.

Limestone pre heater kiln flue gas is 1150°C or so, about 30% of the decomposition, the hydraulic plunger push the rotary kiln, rotary kiln sintered limestone decomposed into CAO and CO2. Generated after decomposition of limestone into the cooler, the cooler was bubbled into the cold air cooled to 100 °C at the discharge. The hot-swappable 600°C hot air into the kiln and gas combustion. Exhaust fan in blended with cold air entering through the bag house, and then the exhaust fan into the chimney.

The vibration of cooler lime feeder, chain bucket conveyor, bucket elevator, belt conveyor into lime finished products. Limekiln price according to customer requirements whether screening processes.

Energy saving active lime kiln:

Technical characteristics:

1)       The installation of vertical pre heater kiln, kiln flue gas waste heat to make a direct transfer to the limestone flue gas temperature can be reduced to below 280°C, electively recovered exhaust heat taken away, which also reduces the load for subsequent removal.

2)       By a conventional rotary aspect ratio is reduced to 20-25 to 14-15. Shortening the length of the kiln surface not only reduces the heat loss to the surrounding, the device also reduces the footprint.

3)       Using the vertical kiln cooler cooling the materials to replace the original cooling tube, avoiding the lime sensible hear loss, failing from the hot lime kiln, with the drum into the secondary air heat exchanger, lime is cooled, the air absorbs heat into the rotary kiln temperature combustion .

4)       Cooler and kiln hood with integrated vertical design, small footprint, sealing, avoid hot exhaust fugitive emissions.

5)       The combustion air into the primary air and secondary air,. Directly involved in the primary air combustion, secondary air for the cooling air. Primary air and secondary air supply, respectively, by a single fan. This design of secondary air temperature to rise to as high as 600°C, as combustion air, in order to save fuel provided favorable conditions.

6)       To the rotary kiln combustion system using a dedicated heating, in addition to using coal as a fuel can also be used alone outside the low calorific value gas(such as furnace gas, calcium carbide exhaust, semi-coke gas) as fuel burning, you can also use a variety of fuels while the supply of use,. By adjusting the air calcination temperature, gas flow adjustment.

7)       Measures to improve environmental protection. Calcination exhaust using pulse jet bag filter dust, to meet the national emission standards. Point in the vertical blanking cooler also uses a bag house dust.

8)       High level of automation. Calcining system regulating the operation of equipment, control and alarm centralized control by PLC in the main control room, and a screen display of the control points and the necessary interlock monitor the production process for the operating parameters for automatic recording, and ready to print.

Key equipment

Energy saving active lime rotary kiln system mainly include vertical pre heater, transport chute, rotary kiln, combustion devices, vertical cooler, pulse jet bag filter and other equipment, the entire system and reliable equipment operation, degree of automation and labor high productivity, product quality is good.

1)       Vertical pre heater:1. pre day for different size of lime pre heater production of different sizes using the applicable square, circular, polygonal vertical pre heater, pusher pre heating area to determine the size according to the number. Tuiout coverage area and reasonable 2. using beams with low pressure drop pre heater flue gas reduces the resistance loss, reduce exhaust device power consumption. High-temperature heat from the kiln to smoke, directly across the materials layer, heat exchange with the gravel thoroughly, pre heat temperatures up to 800-900°C, part of the stones have been disassembled, preheat decomposition while effectively reducing the temperature of exhaust 3. pre heater kiln with hydraulic pusher to feed, equipment and reli 4.ble operation 4. pre heater at the top of the silo has a material position control ensures highly stable material layer pre heater 5. pre heater addition to the top with hanging outside brick the remaining parts are made of refractory castable, brick less masonry simple 6.less pre heater sports equipment maintenance is small.

2)       Rotary kiln:1.adopt and adapt the size, diameter and length of the appropriate type of kiln 2.transmission equipment using speed motor drive kiln, and has an auxiliary motor, stable , and flexible adjustment 3.kiln has a spring sea structure, simple, reliable, and good sealing effect 4.spare a diesel driven power outage

3)       Vertical cooler: 1.cooler is divided into four zones, each can be controlled separately, cooling wind and direct contact with hot materials, the cooling effect is good , the ash temperature is not higher than the ambient temperature of about 50°C, secondary air can be pre heated to a temperature above 600°C, which will help calcined  2. cooler has no moving parts, less maintenance of equipment.

4)       Combustion devices : 1. use of coal as fuel, according to the size of the kiln type matching two- of four-channel PLC combustion device different, with combustion, flame lively and strong, good stiffness, not to hurt the skin kiln, maintainability strong, post-maintenance costs low, key components of high temperature ceramic components, stable and reliable performance, system investments and other small features 2. gas from the gas burner combustion system , the control valve and other components . regulation of gas through the pipeline to the valve, into the rotary kiln burner, with a secondary air combustion. Gas flow adjustment and flexible. Gas burner by a plurality of hollow sleeve and a spiral deflector body composition, combustion air and gas channel formed in the burner swirl of DC, the gas and air mixture more uniform combustion effect is more ideal, but also by controlling the flow of how much wind so that the burner flame shape self-regulation based on production. Combustion system is also equipped with automatic purge relief, emergency shut-off and other measures, safe and reliable .

Precalcining active lime rotary kiln technology and equipment

1. the raw material conveying system

limestone ,dolomite mining crusher and the sent to the factory, to the raw materials from the pit forklift upgrade to the raw materials by screening libraries, metered size 10-50mm lifting equipment by a qualified limestone pre heater top bin. Feed size is 10-50mm, resorted to the finished size is 5-40mm more than 90%.

2.Active lime calcining system

Lime calcining system is composed of a vertical pre heater, rotary kiln, cooler components.

1.   Vertical pre heater: vertical pre heater body is made, storage silos, feeding tubes, hydraulic pusher device and other components. Pre heater with multilateral and round inner wall using sub-storage device, so that the rapid warning of limestone heated gradually to avoid bursting produce large amounts of powder, limestone kiln decomposition rate reached 30%-40%, exhaust gas temperature of 230C-average 260C, thereby reducing system heat loss.

2.   Rotary : rotary kiln from the cylinder, the support device, variable speed drives, gear wheel device, kiln and kiln seals, kiln hood components. Kiln levels were 3.5% and tilted . equipment with two sets of support device roller bearings for the water cooled oil-lubricated plain bearings spoon, and can self-aligning spherical bush. Comes close to the ring gear at hydraulic gear wheel . VVVF motor drive kiln, and has the supporting transmission drive kiln, kiln with spring-pieces seal. VVVF motor drive combined pre heater kiln decomposition rate, effective control of calcination time and temperature, reaching students burned and burnt indicator.

Burner using coal, gas burner firing four channels. Flexible adjustment, easy to operate freely, the ejection velocity of each duct can be adjusted during operation, adjustable different kilns any case require flame kiln callcination temperature is easy to control .

3.  Vertical cooler: vertical cooler is a cooler body, fixed screen, cooling wind device, electric vibrator unloading machine and so on. Vertical cooler cooling the material is divided into several areas, each of the feed speed can be individually controlled material temperature, cooling air in the cooler and heat lime direct contact with the cooling effect, the temperature is low ash, the ash temperature higher than ambient temperature of about 40C, cooling air through the cooling lime, the temperature can be pre heated to 600C or more, as part of the secondary combustion air using rotary kiln, one for drying coal. Coolers have no mobbing parts, simple structure, the cooling effect is good ,less equipment maintenance.

3.Coal preparation system

   Coal preparation system is active lime kiln fired an important part. There are two systems, one is wind swept coal mill and pipe mill bag filter composed of coal preparation system , which is easy to operate, clean environment and so on.

Its production process is as follow:

Fragmentation < 25mm coal, by the process is supplied to the belt bucket elevator, and the enter the raw coal silo by a belt through the lower coal storage disc electromagnetic vibrating feeder or feed mill , the mill is a set of grinding, drying in one device, while in the grinding pass into the hot air from the kiln system or secondary combustion chamber to the hot flue gas for drying. Out from the mill containing coal gas, in exhaust pumping force, to powder gas separation. Out of the powder gases, after collection purified by the exhaust fan discharge portion of the waste drums into the mill recycling, another portion of the waste discharge into the atmosphere through the chimney, collected by the dust collector into the kiln down before unloading coal cilos. As required by the silo by a blower into the kiln burner, burner combustion air blower through the combustion air supply for the calcination of limestone used.

4.Product delivery ststem

Finished lime cooler by the bucket chain conveyor to the elevator, the elevator to the top of the silo, after sieving size of 5mm or more qualified products into the belt conveyor into finished products warehouse, less than 5mm pink powder sent silos, finished products warehouse and powder positions both fitted with electric discharge valve. Here is the main function of the finished product warehouse measured from the buffer role, finished steel carbide plant should be used to reduce chalking.

5.flue gas treatment system

high temperature flue gas produced by combustion rotary kiln, pre heater and limestone in the heat exchange after the temperature dropped to below 260C, the multi-tube cooler and then into the hot bag ouse dust after the high temperature exhaust fan through the chimney into the atmosphere, the atmosphere of the flue gas dust concentration is less than 30mg/nm3.

To meet the modern active lime rotary kiln production process requirements, to ensure reliable operation of process equipment, stable process parameters, to ensure product quality, energy conservation, improve the operating rate of the production line. Line using advanced technology and control the entire process, the PLC control based on the increase DCS control, the main production line for centralized monitoring, operation and decentralized control, control rotary kiln operating system to improve product quality and reduce consumption, electric equipment to improve the reliability and maintainability, in order to achieve control, monitoring, operation modernization.

6.Product quality: CaO>93,MgO<4.5,SiO2<1.0,P<0.01 S<0.025 Loss on ignition<3, degree of activity<350ml-380ml, raw burning<1.5% ,over-burning<1.5%

Lime kiln set of technologies whose mian features are:

1. The system is stable, small amount of maintenance, high functioning, production efficiency, yield, product quality and stability, excellent performance.
2. The use of exhaust system energy saving 1.efficient heat exchanger 2.stepless setting of the contacts sealed, dust collector 3.world leader in heat consumption
3. The host equipment, energy efficient 1.vertical pre heater, cooler pressure loss, high heat exchange efficiency can be forced to accompany 2.kiln firing
4. The application of new refractory materials 1.resistant, high temperature insulation bricks 2.good strength refractory composite materials
5. Utilization of resources able to use high 1.abandoned Arabica grade limestone can be used 2.able to make full use of the abandoned steel mill low calorific value gas
6. Key equipment of good quality, excellent performance 1.host device all by our company according to the professional requirements of burnt lime design and manufacture of high-performance 2.equipment using national standards, drawing on international manufacturing system, quality assurance
7. 1.the high degree of automation in the S7-400H redundant system, DCS system, remote 1/0 control 2.entire line 2-3 persons operation

After-Sales Service

1)  Pre-sale service:Freely provide project designing, process designing, choosing suitable equipment for you.

2)  Medium-sales service: Accompany you to complete the acceptance of the equipment,draft the construction scheme and

detailed process, and complete process of export crusher

3)  After-sales service: We sent engineer to the scene to guide installation, debugging and training operators.