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The Importance of Following A Good Production Process: Extraction

The document discusses the important process of lime production. It begins with extracting limestone from quarries then grinding and classifying it by size. The limestone then undergoes calcination at high temperatures to produce calcium oxide. The calcium oxide is further classified, ground, and sometimes hydrated to produce products like slaked lime. Rigorous quality control is performed during production to ensure consistent high quality. The production process allows the company to offer differentiated lime products to various industrial customers for over 50 years.

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Abdisa Gemechu
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47 views

The Importance of Following A Good Production Process: Extraction

The document discusses the important process of lime production. It begins with extracting limestone from quarries then grinding and classifying it by size. The limestone then undergoes calcination at high temperatures to produce calcium oxide. The calcium oxide is further classified, ground, and sometimes hydrated to produce products like slaked lime. Rigorous quality control is performed during production to ensure consistent high quality. The production process allows the company to offer differentiated lime products to various industrial customers for over 50 years.

Uploaded by

Abdisa Gemechu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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The importance of following a good production process

The production process starts at the quarry, where we get our raw material from, the limestone
(calcium carbonate).

Extraction

Limestone gets extracted through controlled blasts. Afterwards it is grinded and then classified
by size. Whereas sizes between 20 and 80 millimetres are used for manufacturing lime, the
smallest sizes are used for obtaining calcareous aggregates.

Calcination

Once the stones are classified we move on to the calcination process hereof. The unslaked lime
(quicklime) is obtained though the calcination of lime stones, with a content of calcium
carbonate (CaCO3) higher than 95% and at a temperature of between 900-1.100° C according to
the following reaction:

CO3 Ca + Q –> CaO + CO2


Thanks to its calcination process the calcium oxide we manufacture has certain features, which
differentiates it from the rest of limes in the market. With a high level of reactivity it is ideal for
certain industrial processes.

Classification, grinding and micronization

Once calcium oxide is obtained, it is classified by sizes and qualities, depending on its later use.
The product can be sent in bulk, in dump trucks, in pressurized tank trucks and in big bags and in
bags.

Hydration

To part of this calcium oxide, after grinding it, in a controlled way, water is added, converting it
into calcium hydroxide (slaked lime), which reaction is:

Ca O + H2O –> Ca (OH)2

This product is presented in bags as well as in bulk, in pressurized tanks and in big-bags. Its size
is smaller than 200 microns.
In an intermediate phase, the calcium hydroxide is saturated with water, forming a ready to use
lime milk delivered in 1.000 litres containers.

Quality Control

To be able to be present for almost 50 years in the industry, it is necessary to offer quality
products. With that purpose, CALES DE PACHS has highly technified installations and in the
production process there is a rigorous quality control system, which guarantees the features of
the different lime products we produce.

The product is controlled and analysed in our laboratory during the different stages of
production. A systematic analysis of the drill hole debris at the different stages of the quarry is
done. We constantly track the purity of calcium carbonate possessed by the extracted lime stone.

The Production Department does a basic follow-up of the richness in calcium oxide being
produced by the calcination kilns, doing quick analysis which get reassessed on a daily basis in
our Quality Control Laboratory, which also does daily controls on reactivity, fineness, useful
lime and volume stability of our slaked lime.

Active Lime Production Line


Capacity:50-800（t/d）

Main Materials:Limestone

Main Equipment:vertical preheater,lime kiln,bag filter


Lime Activity:≥360mL

Active lime is produced from limestone, dolomite, chalk and other minerals with high calcium
carbonate content by the calcination process under the temperature of 1000-1100 ° C. There are
various processes for the active lime production, mainly including: Advanced 'Preheater-
Rotary kiln-Vertical cooler' energy-saving process, Traditional 'long rotary lime kiln'
process, Mixed buring vertical kiln process, Gas-fired or oil-fired vertical kiln process. The
selection of the active lime process is effected by many factors, such as : the activity
requirement, the fuel, the limestone sizes, production capacity, environmental-protection
requirement. 


Send e-mail [email protected]

Whatsapp : +86 18037866379

Our Advantage

  Saving energy

  Vertical preheater is equipped at the kiln inlet. It will use


the hot air from rotary kiln to preheat the raw material which also can partially decomposed
inside the preheater. This will increase the 40% of output capacity and 30% of thermal
efficiency. Vertical cooler is equipped at the kiln outlet. It will use the high temperature from the
calcined material to heating the secondary air to 600℃. Kiln outlet adopts integration design for
vertical cooler and kiln outlet hood, and it needs less construction land and good sealing.

  Environmental protection
 Good dust collecting treatment at kiln inlet. The cyclone
dust collector and pulse bag filter can control the dust emission is lower than China standard.
High level of automation requires less workers, the adjusting of production system operation,
control and alarm are controlled at control room by PLC.

Production Technology

We will select the most workable and efficient and economical solution based o the clients' specific
requirement and conditions.

Energy Saving Rotary Lime Kiln Process

Rotary kiln is one kind of furnace which is widely used for calcined active lime production in the world. It is
also widely used in many industries such as construction materials, metallurgy, chemical and environmental
protection. The energy-saving rotary lime kiln has the advanced structure and stable operation. It adopts the
vertical preheater with low pressure loss  which can  effectively improve  the  preheating effects. The raw
materials’  decomposition rate in the  vertical preheater can reach to 30% before entering into the rotary kiln.
It is also suitable for different fuels including pulverized solid fuel, liquid fuel and gas fuel. The final lime
products have high activity. This kind of rotary kiln already have been widely used in the steel industry and
chemical industry.

Traditional Rotary Lime Kiln Process

The long rotary lime kiln has the characteristics of simple structure and stable operation. It increases the
length of the rotary kiln cylinder to improve the preheating effect, and after preheating, the limestone is
entering into the calcination zone for decomposition; The limestone feeding size can be 10 ~20 mm, 20~40
mm. It can use various fuels including pulverized solid fuel, liquid fuel and gas fuel. The final lime or dolime
product has relatively higher activity. This kind of rotary kiln is suitable for middle & small production lines,
and is suitable for the lime production with limestone with small sizes or lower heat strength.

Mixed Burning Vertical Lime Kiln Process

The qualified raw materials and solid fuels are mixed uniformly according to a certain proportion and then
sent to the vertical kiln through a single bucket elevator for calcination. After calcination, the final lime
products are discharged from the bottom of the vertical kiln through a discharge device to the conveyor, and
the conveyor sends the final lime products to the storage silo. The hot flue gas generated by calcination will
firstly go into the dust collecting system, and then the clean flue gas will be emitted through chimney to the
atmosphere.

PROCESS FLOW CHART 


Configuration

Capacity 200t/d 225t/d 250t/d 300t/d 400t/d 500t/d 600t/d 800t/d


Preheat Dodecag Dodecag
Shape Hexagon Hexagon Octagon Octagon Octagon Decagon
er on on
Qty. Of
6 6 8 8 8 10 12 12
 Top Silo
Qty. Of 6 6 8 8 8 10 12 12
Hydraulic
Pusher
Preheating
Capacity 600 600 800 800 800 1000 1600 1600
(t)
Φ2.8×42 Φ3.0×50 Φ3.2×50 Φ3.3×55 Φ3.6×55 Φ3.8×58 Φ4.3×56
Size Φ4×60m
m m m m m m m
Slope 3.50% 3.50% 3.50% 3.50% 3.50% 3.50% 3.50% 3.50%
Rotating
Speed
0.3-1.8 0.3-1.8 0.3-1.8 0.3-1.8 0.3-1.8 0.3-1.8 0.3-1.8 0.3-1.8
Rotary
(r/min)
Kiln
Calcinatio
n
Temperatu
1350 1350 1350 1350 1350 1350 1350 1350
re

(℃)
Type Vertical Vertical Vertical Vertical Vertical Vertical Vertical Vertical
Qty Of
Temperatu
3 3 3 3 3 3 3 3
re Control
Area
Qty. Of
4+1 4+1 4+1 4+1 4+1 4+1 4+1 4+1
Cooler Wind
Tower
Size(m) 3.6×3.6 3.6×3.6 3.6×3.6 3.6×3.6 4.1×4.1 4.1×4.1 4.1×4.1 4.7×4.7
Output
Temperatu
re ≤120 ≤120 ≤120 ≤120 ≤120 ≤120 ≤120 ≤120

(℃)
Product Thermal
5500 5400 5400 5400 5400 5400 5400 5000
Loss(kcal/kg)
Coke oven gas, mixed gas, natural gas, coal powder, low heating value coal
Available Fuel
gas

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