WE’RE ON FIRE FOR THE MOST EFFICIENT LIME KILNS. · PDF filelime bricks. THE PFR KILN....
Transcript of WE’RE ON FIRE FOR THE MOST EFFICIENT LIME KILNS. · PDF filelime bricks. THE PFR KILN....
E V E RY Y E A R , M O R E T H A N 3 0 0 M I L-
L I O N T O N S O F L I M E A N D D O L O M I T E
A R E B E I N G C A L C I N E D. M O S T LY I N
M A E R Z K I L N S .
For over 3000 years, burnt lime has been a basic
material in the construction business. Today, it is
also an important component for the chemical indus-
try, agriculture and especially for the steel industry.
Maerz kilns calcine the largest share of the amount
needed worldwide – more than kilns from any other
manufacturer. There are good reasons for the suc-
cess that Maerz kilns enjoy: Highest efficiency.
Lowest energy consumption. Broad range of kiln
types. Individual solutions depending on location,
raw material and available fuel. Maerz’ portfolio
comprises all modern kiln types.
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T H E H P S K I L N .
F O R H A R D - B U R N T L I M E , T H E L O W-
R E A C T I V E Q U I C K L I M E .
The HPS kiln from Maerz functions on the principle
of counter flow. Combustion gases flow from bottom
to top traversing the feedstock; while fuel is only
added towards the end of the burning zone. Upon
completion of the combustion process higher energy
input can be used to raise the peak temperature in
the burning zone: Thus, the CaO crystallites fuse
and reduce the specific surface of burnt lime. This
process produces low reactive lime, which is ideal,
e.g., for the production of aerated concrete and sand
lime bricks.
T H E P F R K I L N .
F O R S O F T- B U R N T L I M E , T H E H I G H -
R E A C T I V E Q U I C K L I M E .
The PFR kiln from Maerz is ideal for the production
of soft-burnt lime. The lime is calcined in a parallel
flow. The feedstock and the combustion gases move
in the same direction from top to bottom. The energy
needed for the calcination is supplied at the begin-
ning of the calcination process. This ensures that
the peak temperature in the burning zone is low
enough so that the resulting CaO crystallites do not
fuse. The specific surface of burnt lime thus remains
intact. This burnt lime is highly reactive and ideal,
e.g., for the steel industry.
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Typical Temperature Profile in a Single Shaft Kiln
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TYPCIAL TEMPERATURE PROFILE OF A MAERZ PFR KILN. TYPICAL TEMPERATURE PROFILE OF A MAERZ HPS KILN.
Temperature in °C
Tim
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Feedstock Exhaust gases Air
Feedstock Exhaust gases Air
com
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THE PFR K ILNS FROM MAER Z.
EFF IC IENT PRODUC T ION OF L ARGE
QUANT I T IES OF BURNT L IME .
A PFR kiln (parallel flow regenerative shaft kiln) con-
sists of two vertical shafts and a connecting cross-
over channel. Both shafts work with each other.
While one calcines the product, the other preheats
the stone. In the burning shaft the lime is calcined
in parallel flow. The hot combustion gases are then
transferred through the crossover channel to the
non-burning shaft where they preheat the limestone
in counter flow in the upper area of the shaft. The
flow direction of the gases is reversed at regular
intervals. This allows the regenerative preheating of
the stone to take place (the stone in the preheating
zone of the kiln acts as heat exchanger) and thus
for the maximum use of the heat contained in the
kiln gas.
The principle of calcination in parallel flow is ideal
for the production of high-reactive quicklime. A PFR
kiln from Maerz processes up to 800 tons of burnt
lime per day. Gaseous, liquid or pulverised solid fuels
as well as different combinations of these may be
used. Depending on the required output and grain
size of the limestone to be processed, Maerz designs
rectangular, circular or Finelime PFR kilns.
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®
T H E R E C TA N G U L A R P F R K I L N F R O M
M A E R Z . F O R U P T O 4 0 0 T O N S O F
B U R N T L I M E P E R D AY.
The most cost-efficient and simple design of a PFR
kiln: two burning shafts with a rectangular or hexa-
gonal cross section are placed next to each other.
Through a direct crossover channel the combustion
gases flow from one shaft to the other. The rect-
angular cross section simplifies the fabrication of the
kiln by imposing fewer challenges on the steel con-
struction and the refractory material. This simple
and cost-efficient PFR kiln is usually used for outputs
of up to 400 tons of burnt lime per day. Since 1966,
Maerz has installed more than 200 rectangular PFR
kilns worldwide.
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T H E C I R C U L A R P F R K I L N F R O M
M A E R Z . F O R U P T O 8 0 0 T O N S O F
B U R N T L I M E P E R D AY.
For the production of larger capacities of burnt lime
per day (300 to 800 tons) Maerz recommends PFR
kilns with a circular design. These kilns have a circu-
lar shaft cross section and circular ring channels for
gas flow. In these channels the combustion gases of
the burning shaft are collected before flowing through
the crossover channel to the non-burning shaft. In
the non-burning shaft the hot gases in turn flow
through the circular ring channels along the whole
circumference of the shaft. The circular shaft cross
section and the gas distribution along the whole cir-
cumference of the shafts ensure an even heat distri-
bution in large kilns – indispensable for high lime
quality. Since 1966, Maerz has installed more than
300 circular PFR kilns worldwide.
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T H E F I N E L I M E K I L N F R O M M A E R Z .
S O Y O U C A N M A K E B E T T E R U S E O F
Y O U R L I M E S T O N E D E P O S I T S .
Limestone that is calcined in conventional shaft kilns
usually has a grain size of more than 40 millimetres.
Smaller-grained stones, not more than 6 to 50 milli-
metres in size, are often calcined in rotary kilns –
which, however, feature very high heat consumption.
To solve this problem, Maerz developed a highly
specialised PFR kiln: the Finelime® kiln.
How does it work? The special geometry of this kiln
and the special charging of the feed material guar-
antee ideal heat distribution, even when processing
small-grained stone.
The principle of the PFR kiln, i.e., the calcination of
lime in one shaft and the preheating of the stone
with the hot kiln gas in the other shaft, is also used
in the Finelime® kiln. Thus its heat consumption is
significantly lower compared to rotary kilns. Since
1989, when it was first introduced onto the market,
Maerz has installed approximately 60 Finelime® kilns
worldwide.
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®
T E C H N I C A L D ATA .
R E C TA N G U L A R P F R K I L N . C I R C U L A R P F R K I L N .
F I N E L I M E K I L N .
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KILN TYPESRECTANGULAR
PFR KILNCIRCULAR PFR KILN
FINELIME® KILN
KILN TYPE E1 – E6 R1 – R5 F1 – F3
CAPACITY(tons per day)
100 – 400 300 – 800 200 – 400
GRAIN SIZE(mm)
30 – 120 30 – 160 15 – 40
HEAT SUPPLY(kJ/ kg)
(kcal / kg)3390 – 3650810 – 870
3390 – 3650810 – 870
3310 – 3560790 – 850
MAIN PRODUCTHigh-reactive
quicklimeHigh-reactive
quicklimeHigh-reactive
quicklime
®
T H E H P S K I L N F R O M M A E R Z .
F O R T H E C A L C I N AT I O N O F L O W-
R E A C T I V E Q U I C K L I M E .
Low-reactive burnt lime is used for the production
of sand lime bricks, aerated concrete bricks and
aerated concrete blocks. Previously, no modern
shaft kiln was really well adapted to the production
of low-reactive burnt lime. This is why Maerz de-
signed, constructed and patented a new single-shaft
kiln, the HPS kiln (high-performance shaft kiln). It
consistently delivers low-reactive burnt lime with
the best quality and the highest energy efficiency.
Maerz HPS kilns feature:
• Use of cooled burner lances, which protrude
into the hot bed of material and are
adjustable.
• Precisely adjustable operating temperature
resulting in individual specific product
reactivity.
• Highest specific heat load in correlation to
shaft diameter and thus highly compact design.
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H P S K I L N S: T E C H N I C A L D ATA .
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HPS KILN
KILN TYPE H1 – H5
CAPACITY(tons per day)
100 – 300
GRAIN SIZE(mm)
10 – 80
HEAT SUPPLY(kJ/ kg)
(kcal / kg)4100 – 4610980 – 1100
MAIN PRODUCTLow-reactive
quicklime
S P E C I A L P R O D U C T S F R O M M A E R Z .
PFR and HPS kilns are not everything. Maerz also
offers other kiln types for specific purposes. For
instance the annular shaft kiln for all applications
requiring a continuous stream of exhaust gases and
a high CO² content in the exhaust gas. We can also
process fine-grained limestone or sand in our
suspension calciner POLCAL®. And last but not least
we have developed a technology for preheater rotary
kilns, which enables the use of cheap fuels with high
sulphur content without raising the sulphur level in
burnt lime. Ask us if you are looking for a special
solution.
E X P E R I E N C E A N D R E S E A R C H
F U E L E A C H O T H E R . F O R C O N S TA N T
I M P R O V E M E N T O F Q U A L I T Y.
Maerz has already built more than 600 lime kilns
worldwide. More than any other manufacturer. We
have gained a lot of experience from this, yet we
continue to drive our research and development.
With each kiln that we build we continue to refine
new technologies and to surpass ourselves.
Thanks to its sophisticated technology and wide
range of different kiln types, Maerz became the
leading supplier for the global lime kiln market. Each
kiln can be individually adapted to suit all the re-
quirements and conditions imposed by the location,
e.g. the altitude above sea level, the quality of the
lime-stone or the available fuel.
Maerz knows all about the different types of lime-
stone and dolomite. Globally. Before designing a new
plant, we carry out tests in our laboratories with the
stone to be calcined. Thus we can adapt each plant
perfectly to its purpose – and make it the ultimate
benchmark for all relevant criteria.
H I G H E S T E N E R G Y E F F I C I E N C Y.
W I T H E V E RY F U E L .
Maerz PFR kilns achieve the highest thermal effi-
ciency of any modern lime kiln: more than 80 per
cent. We not only promise you this figure. We achieve
it with fuels such as:
• natural gas
• heavy fuel oil
• pulverised coal
• liquefied gas
• off-gas from steel-making process
• wood dust
• waste oil
• as well as with a combination of various fuels.
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L O W E S T C O N S U M P T I O N O F F U E L A N D
E L E C T R I C A L E N E R G Y.
The typical heat consumption (based on the fuel’s
lower calorific value) lies between 3480 and 3850 kJ
(830–920 kcal) per kilogram or 2.99 to 3.32 MBtu
per short ton of lime, depending on the chemical
analysis and the grain size as well as the type of fuel
used. The consumption of electrical energy depends
on the grain size, the fuel and the kiln’s altitude
above sea level. The consumption amounts to 25 to
45 kWh per ton of lime.
E M I S S I O N L E V E L S T H AT A R E A L S O A N
A D VA N TA G E F O R T H E E N V I R O N M E N T.
In PFR kilns there is no open flame with a high tem-
perature. This is why hardly any nitrogen oxides are
produced. The flames in the kiln are entirely sur-
rounded by material with a lower temperature. The
stone directly absorbs the heat for the calcination
process. Thus the peak flame temperature is reduced
– along with the formation of nitrogen oxides. The
interaction of all components and the fine-tuning of
the lime plant also play their part in achieving low
emission levels.
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M A E R Z ’ C U S T O M E R S E R V I C E
O P E R AT E S J U S T A S I M P E C C A B LY A S
I T S K I L N S D O . G L O B A L LY.
Maerz supports its customers in different ways –
anytime, fast and everywhere. Also after the com-
missioning of a turnkey plant. These are the services
Maerz offers:
• Feasibility studies for your project
• Planning and engineering of lime kilns and
entire lime plants
• Turnkey assembly of lime kilns and entire lime
plants
• Support with assembly and commissioning
from our specialists
• Technical training of your employees for
operation and maintenance
• Supply of spare parts
• After sales service including consultation on
operation or maintenance issues
• Suggestions on how to modernise existing
plants, e.g. by retrofitting to adapt to different
fuels or by modernising the control system
B E T T E R S A F E T H A N S O R RY.
A reliable control system monitors and controls the
operation of the plant. It also operates unmanned.
Should a serious incident arise, the kiln will shut
down automatically. Constant control also means
prevention of breakdowns and thus more efficient
operation.
S M O O T H P R O J E C T H A N D L I N G
F R O M A T O Z .
Maerz meets all customer requirements and fulfils
all expectations – thanks to our experience, know-
how and a wide range of different kilns. And also
because we are Swiss. We keep our promises. We
deliver excellent quicklime quality and efficiency in
plant operation, on time and on budget.
Maerz Ofenbau AG – A company of ThyssenKrupp | Richard-Wagner-Strasse 28 | 8027 Zurich | Switzerland
Tel. +41 44 287 27 27 | Fax +41 44 201 36 34 | www.maerz.com
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Maerz Ofenbau AG – A company of ThyssenKrupp | Richard-Wagner-Strasse 28 | 8027 Zurich | SwitzerlandTel. +41 44 287 27 27 | Fax +41 44 201 36 34 | www.maerz.com