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15~300tph Double Chamber Lime Kiln Heat Accumulating Type Kiln¹

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Product Description Product DescriptionOverview1. Project Outline1.1 Basic Conditions1.2.1 Geological & meteorological conditions, and power supply modeDescriptionUOMParametersAltitude above MSLMeter498Ambient temperature0C43 (max), 16(min)Relative humidity%20 - 45 Mean wind speedkm/hr60Seismic zone II, least to moderateHT AC power supply 11 kV and 3.3 kV.LT AC power supply 415 V, 3 phase 50 Hz.AC controlling & signaling voltage 100 VoltsControl voltages 110 VAC & 24V DC Type of safety IP 651.2.2 Specifications of raw materials(size and chemical composition) Chemical compositionBagalkoteRajasthanMalaysiaDubaiCaO48 % min52 % min53 % min53 % minSiO22.5 % max1 % max0.5 % max0.5 % maxMgO5 % max1 % max1 % max1 % maxR2O3(Al2O3+ Fe2O3)2 % max1 % max0.5 % max0.5 % maxSize of lime stone: within 30 to 60mm, O/S (overlarge size) and U/S (ultra small size) are no more than 10%.Volume density: 1.6 to 1.8Humidity: 2.00% max.1.2.3 FuelDual Fuel: Pulverized Coal and BF Gas (730 KCal/NM3)1) Pulverized Coal Properties Coal fineness: - 0.075 mm ≥80 %. Pulverized coal moisture content: < 1%.Ash Content: ≤ 14%.GCV: ≥ 7000 KCal / Kg VM: ≤ 22%. Sulphur: ≤ 0.651.2.4 Finish product specification:CaO: - 90 to 92 % SiO2:- 1.00% max MgO: - 1.5 % max. Fe2O3 + Al2O3:- 1.00% max LOI:- 3 % maxReactivity: - 400 ml min of 4N HCl.Size:-10 mm ~30 mm for EOF (140T/D) & 10mm- 50mm for LRF (25T/D) Packing: - 1 Ton. HDPE Jumbo bag facilities.1.3 Production Capacity and Products Performance1.3.1 Production capacityType of lime kiln: parallel flow regenerative annular double hearth lime kilnQ'TY of lime kiln: 1 setDaily capacity: 300T/DWorking days in one year: 340 daysAnnual capacity: 100,000 tons1.3.2 Product performance of lime stoneActivity: ≥ 360 ml (4N.HCL), max. 420 mlRaw burning rate: ≤5%Content of CaO: ≥ 90 %1.4 Main Job Content of the Project1) storage, screening and transportation of raw material2) Hopper and charging hoist system3) lime kiln proper4) lime transportation, screening and storage system5) air blower room and air transportation system6) gas pressurizing system7) pulverized coal injection system8) dust collection system for flue gas of lime kiln9) transportation, screening and dust collection system for lime stone and quicklime,10) hydraulic station and piping2 Technical proposal2.1 Foundation of Proposal Development1) to produce active lime with BFG or pulverized coal2) calorific value of BFG: ≥730×4.18KJ/Nm3(low):Q≥730×4.18KJ/Nm33) calorific value of pulverized coal: ≥7000×4.18KJ/kg (low):Q≥7000×4.18KJ/kg4) capacity: 300t/d2.2 Design Content2.2.1 Guidelines for process designThis design focuses on reliable technology, advanced process and compact design of the workshop, to be economical, environmentally friendly, safe, energy saving and highly efficient project.2.2.2 Scope of designThe scope of design includes the whole set of process technology and equipment from receiving lime stone raw materials which meet the requirement of the process to producing qualified lime products for metallurgy. Namely, they are lifting transportation equipment for all lines, process mechanical equipment, process thermal equipment, hydraulic control equipment, electrical control equipment, computer control equipment, etc.The starting point of design is the lime stone receiving hoppers and the terminal is the storage bins for active lime.2.2.3 Scope of engineeringThe scope and content of engineering are lime stone charging system (raw material yard not included), parallel flow regenerative annular double hearth vertical kiln, hydraulic station, air blower room, gas pressurizing station, main control room, finished products warehouse, dust collection from flue gas, dust transfer and transportation system, etc.2.2.4 Scale of constructionA new 300T/D annular double hearth vertical kiln for active lime is to be built. It will meet the requirements of capacity, quality, continuity of following production, economy, and fluency of material transportation.2.2.5 Product quality and heat consumption index2.2.5.1 Product quality Activity: ≥360ml (4NHCl)Content of CaO: ≥90 %2.2.5.2 Heat consumption indexHeat consumption 1 ≤ 1050×4.18KJ/kg lime (calorific value of BFG ≥ 730×4.18KJ/Nm3)Heat consumption 2 ≤ 950×4.18KJ/kg lime (calorific value of pulverized coal ≥ 7000×4.18KJ/Nm3)2.2.6 External conditions for the project2.2.6.1 Raw materialThe raw material is the purchased qualified lime stones. If they are landed during transportation and storage, they should be put on concrete lands and should not contact the earth. They should not mix with other minerals during transportation to avoid impurities entering the lime stones.--particle size of raw materialThe particle size of raw material within 30 to 60mm is qualified. These materials should be screened or washed to remove impurities. The proportion of particle size is in a matter of linear distribution. Particle size smaller than 30mm (the minimum no smaller than 20 mm) and larger than 60mm (the max. no larger than 70mm) occupies less than 10% of the total, not including impure stones and earth.Considering the quality requirement from the client, we thought materials from the following three can be selected as qualified materials.Table 3-1 List of Physicochemical Index of Lime StoneChemical compositionRajasthanMalaysiaDubai CaO52 % min53 % min53 % minSiO21 % max0.5 % max0.5 % maxMgO1 % max1 % max1 % maxR2O3(Al2O3+ Fe2O3)1 % max0.5 % max0.5 % maxMgO1 % max1 % max1 % maxR2O3(Al2O3+ Fe2O3)1 % max0.5 % max0.5 % max2.3.6.2 FuelBFG1) calorific value: BFG ≥730kcal/Nm32) water contained: saturated vapor3) dust content <10mg/Nm34) inlet pressure of pressurizing machine: 6 to 8 KPa (stable)5) inlet temperature of pressurizing machine: ambient temperature6) BFG flow rate at inlet: 20700 Nm3/h(with 15% surplus)Pulverized CoalPulverized Coal Properties Coal fineness 0.075 mm ≥80 % Pulverized coal moisture content: < 1%.Ash Content: ≤ 14%.GCV: ≥ 7000 KCal / Kg VM: ≤ 22%. Sulphur: ≤ 0.652.3.6.3 power supplyTo ensure the production of active lime, there should be two lines of power supply.Voltage: 415V/110V, fluctuation: ±10%Frequency: 50 Hz, fluctuation: ±1HzInstalled capacity: 2000 KW2.3.6.4 water supplyThe water for the production is to cool equipment and the pressure is within 0.3 to 0.4Mpa.PH of water: 7~9Max. temp. of supplied water in summer: ≯30oCTemp. at outlet: <50oCsuspended matter: <15mg/LTotal hardness: <150ppmSupplement quantity (lucid circulating): <10t/h2.3.6.5 compressed air (N2)a,N2used for purging BFG pipelinespressure: 0.2MPapurity: 99.9%max. time period: 200m3/timepurging time: 15~30 minutes/timeb,reverse blowing bag for dust collectionconsumption amount: about 6 m3/minworking pressure: 0.5MPa~0.7MPac,compressed air (exchanged with N2)--compressed air (or N2)for instrumentationTo control instrumentation actuating mechanism, the compressed air is cleaned after oil and water are removed and being dried. If N2 source is available, try to use N2 as far as possible.consumption amount: 2 m3/minworking pressure: 0.4MPa~0.6MPapurifying requirement: <15mg/m3oil content: <15ppmdew point: <-15oCSafety stock: in case of emergency, it should reserve 2m3 lasting for 3 seconds to be used for turning down BFG rapid cut-off valve.2.4 Main Content of the Projectscreening and transportation of raw materialHopper and charging hoist systemlime kiln proper4) air blower room and air transportation system5) BFG pressurizing machine room and transportation system6) storage, transportation and injection system of pulverized coal,,7) dust collection system for flue gas of lime kiln8) control and operating rooms for lime kiln,9) LT power distribution system10) hydraulic station and piping system11) transportation, screening and dust collection system for lime stone and quicklime,12) 5 Nos. of lime products (3 for block ash products, 1 for scrape and 1 for powder ash )2.5 Main Index of Lime Kiln1) production capacity of lime: 300T/D, 100,000T/A2) consumption of lime stones: 540T/D, 183,600T/A3) fuel consumption: BFG 18000 Nm3/h(Qlow=730KCal/Nm3) Pulverized coal 1696 kg/h(Qlow=7000KCal/kg)4) water consumption for production: about 10t/h (lucid circulation water)5) compressed air (N2): 6m3/min6) area covered and construction area:The area covered by the lime kiln proper is 10.3×13.6m2, BFG pressurizing machine room is 10×18m2, dust collector of flue gas2 and the transportation system 8.5×6m2.3 Process and Equipments3.1 Brief IntroductionA new 300T/D annular lime kiln will be built and the performance and index of final products lime are shown in list 3-1. (Note: activity index in the flowing list requires the CaO content in lime stone should be large than 52%, for lime stone with better quality, the requirement will be high.)List 3-1ItemIndexactivityCaO%SiO2%MgO%Fe2O3 + Al2O3%LOI,%Particular size(mm)data≥360ml(4N.HCL),with the improved quality, the max> will be 420ml90-92≤1≤1.5≤1≤30~503.2 Material Balance SheetTo fulfill the goal of 300 tons per day of finished product lime, the capacity and consumption amounts of lime and lime stone are shown in list 3-2. (Note: the calorific value of BFG is 730 Kcal/Nm3, the calorific value of pulverized coal is 7000Kcal/kg.)List3-2 Material Balance SheetNo.ItemEquipment operating system Q'TY of material(t)yeardayshifthour1Lime discharged340/3/810200030010012.52Lime created340/3/810404030610212.83Lime stone charged340/3/818360054018022.54Lime stone in stock before charging340/3/8187170550183235Consumption of BFG, Nm3340/3/8142560000432000144000180006Consumption of pulverized coal, t340/3/813432.32040.70413.5681.696Note:1. The consumption of BFG per day and shift are the average one for the reversing time is ignored.2. The quantity of lime stone is for the qualified one, scrapes are not considered.3. The LOI of lime stone is based on 43.5%4. The transportation loss of lime stone during transportation is based on 1%.5. Ash loss of lime calcinations is based on 2%.3.3 Brief Introduction of Process Flowchart3.3.1 raw materialThe daily capacity of lime is 300 tons and raw material lime stones needed is about 540tons. To reduce initial cost, the raw material yard of this project is original stone yard. The raw materials are placed into the storage hopper by forklift truck, and then transferred to raw material screening by conveyor belt according to quantity required. The waste material after being screened will be transferred to pointed locations by conveyor belt. The qualified material on the screening unit is transferred to charging hopper by conveyor belt and delivered weighing hopper by vibration feeder beneath. Material weighed will be unloaded onto charging trolley by sliding groove. The charging trolley is ready, when receiving signal from PLC, it will begin to charge material.3.3.2 process flowchart of hearth charging and discharging,3.3.2.1 chargingThe charging process is that the lime stone in the material warehouse on the top of the kiln is delivered into the top of the two kiln hearths by sliding groove. The sequential charging is realized by opening and closing the gate on the sliding grooves in turn. The volume of charging hopper is 6m3. Since the two kiln hearths are periodically charged, all the equipments mentioned above are working in an interrupted way.3.3.2.2 dischargingThe finished limes after being calcined and cooled in the kiln hearth will enter the storage bin at the bottom of the kiln and are ready to be discharged through 6 discharging platforms and 2 unloading valves.The finished limes in the storage bin on the kiln bottom are delivered to the vibration screening unit to be classified through vibration feeder on kiln bottom, belt machine, three-way distributor and bucket lifting machine. After being screened, the block ash is delivered to product storage bin. All the vibration equipments are sealed to prevent dust from flying.In the discharging system, the average flow rate is 12.5t/h. All the equipments shall boast suitable surplus enough for production capability.Dust collection equipments are installed in each transferring points.3.3.2.3 products storage binThe lime storage system is initially considered to be made up with 5 product storage bins, 3 for stock ash, 1 for powder ash and the other one is for scrape material. The volume of product storage bin is for 1 to 2 days' capacity.Continuous location detecting and dust collection facilities are installed in each storage bin.The stock ash and powder ash in each bin are loaded onto vehicles to be transported through discharging valves under the bins and unloading equipments of dust collection system.All the equipments in this system are all controlled on site.3.3.3 Main process equipmentsMain equipments in this process system include preparing storage bins, transition storage bins, measuring hopper, belt transporting facilities, drawer lifting machines, screening units, hoisting machines, trolleys, charging and discharging valves, etc. Among these, the unloading gate of the measuring hoppers and charging and discharging valves are all driven by a hydraulic system, others are by electrical.3.3.3.1 charging hoisting machineThe charging hoisting machine is pre-installed on the assemble platform, including:? 1 upper position reducer and 1 lower position reducing limit switch? 1 anti-loose rope equipment? 2 terminal upper position and lower position power limit switches3.3.3.2 charging hopper? Capacity: 5 tons? Volume: 6m3 Company ProfileCompany ProfileVisionWith decades of rapid development and accumulation, China has been perfect and mature on technology and management in various industrial areas, shaping a complete processing manufacturing industry with competitive price, well known for its excellent skill, high efficiency and hardworking team with qualification for personnel dispatching.At the time of economic globalization, it is our consistent target and objective to integrate and export all kinds of technology, management mode, engineering project and manpower as per the actual requirement of our client With our own abundant technical strength, superior integration capability of technology and resources, well experienced of project implementation and management as basis and platform;Let China go out to the world, and make the world know of China;ProfessionalProfessional technical and management team with abundant experience in the implementation of domestic and international projects;ResponsiveResponsively and meticulously, translating your needs into complete solutions;IntegrationIntegrating various technologies and resources in China and fulfilling complementary advantages, by relying on professional teams;MotivationMotivated to provide the optimal solution and quality products;ExceptionalExceptional, delivery and,implementation of projects to meet, your expectations;Our TeamProfessional technical teamPrime is staffed with professional import & export team skilled with the practice of import and export business, including sea freight packing, logistics organization, L/C review, cargo booking, and customs clearance, L/C negotiation, double authentication of shipment documents, etc.All above personnel are well experienced in the execution of projects in Southeast Asia and Middle East. Complete procurement mechanismOur professional team of procurement offers strict management of supplier 's qualification inspection and selection, complete system of supplier listing, rating and elimination, to ensure the supplier is qualified and capable of implementing the project and supplied with product of high quality, and maintain a healthy and good condition of credibility, contract settlement and capital flow management.Quality management systemOur complete quality management system , the process control covering from Scheme formulation , engineering technology, detailed design, to processing and manufacturing of equipment and material , ex-factory test and site erection and commissioning till it put into production, which through multi-level inspection, tour inspection, supervision and node control can ensure quality of the final product.Well experiencedExecutive team is abundant in experience of overseas project implementation with similar project working experiences, esp. experience in Southeast Asia, Middle East projects; ISO System Certification Partners

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