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Parallel Flow
Regenerative
Lime Kiln
Throughout this paper, the word lime is used interchangeably to mean high calcium lime or dolomitic lime.
The calcination or burning of limestone and dolomite is a simple chemical process. When heated the carbonate decomposes
according to its respective equation.
rature of 100C may only be achieved with limestone containing less than 88% CaCO3. However, lime produced from such
low quality limestone has only a restricted field of application.
In practice limestones with much higher carbonate content are
processed resulting in higher waste gas temperature which is
the consequence of excess available heat in the preheating
zone.
The question now is: How can the surplus heat available in the
calcining zone of the kiln be utilised to minimise heat consumption and how do the modern kiln types match this aspect.
An almost perfect solution for this problem is offered by the
Maerz Parallel Flow Regenerative Lime Kiln (PFR-Kiln).
3. The PFR-Kiln
Two main types of vertical shaft kilns exist. The single shaft
counter flow heating kiln and the multiple shaft parallel flow
heating kiln. The standard PFR-Kiln is a two-shaft kiln defined
by alternating burning and non-burning shaft operation. There
are two key characteristics of the PFR-Kiln: 1) the parallel flow
of hot gases and stone in the burning zone, and 2) the regenerative preheating of all combustion air in the process. The
kiln is ideally suited to produce soft-burnt, high reactive lime
and dolomitic lime because of the conditions created by the
parallel flow of the stone and the combustion gases in the burning shaft. Additionally, the regenerative process provides the
lowest heat consumption of all modern kilns available today.
The difference in the temperature profile of conventional single shaft kilns and PFR-Kilns is depicted in Fig. 1. The curves
show the temperatures of the material, of the air and of the
combustion gases flowing through the kiln.
Fig. 1 compares parallel flow heating with counter flow heating. In single shaft kilns usually counter flow heating is applied, a typical temperature profile is shown in Fig. 1a. The
green line shows the temperature of the material. The blue line
shows the temperature of the cooling air and the red line the
temperature of the combustion gas and kiln off-gas. As the
amount of cooling air is not sufficient for complete combustion of the fuel additional air has to be introduced via the lateral burners. As in this type of kiln the fuel is introduced at the
lower end of the burning zone (where the material is already
calcined) the temperature in this area is significantly higher
than required for production of high reactive lime.
In parallel flow kilns the fuel is introduced at the upper end of
the burning zone and the combustion gases travel parallel to
the material. Fig. 1b shows a typical temperature profile where
the green line represents the material, the blue line in the preheating zone the combustion air, the blue line in the cooling
zone the cooling air and the red line the combustion gas and
kiln off-gas. As the fuel is injected at the upper end of the burning zone where the material can absorb most of the heat rele-
ased by the fuel the temperature in the burning zone is typically 950C in average. Because of this, parallel flow heating is
the best solution for the production of soft-burnt, reactive lime
and dolomitic lime.
The simplest design is to lengthwise place two shafts with rectangular cross section side by side in such a manner that the
kiln gases can flow directly from one shaft to the other (Fig.
3a). A disadvantage of this design occurs at larger kiln capacities (and consequently larger shaft cross sections) where the
hot gases have the tendency to concentrate on the crossoverchannel side of the shafts and the gas distribution is not uniform. Therefore at larger capacities, kilns of circular cross section are proposed. These kilns have circular connecting channels, as illustrated in Fig. 3b. The off-gases exit the burning
shaft and enter the non-burning shaft radially around the complete shaft perimeter thereby guaranteeing an absolute even
heat distribution which is a key factor for a high quality of the
burnt lime.
From the combustion air blowers an air duct leads to the top
of the kiln, from the cooling air blowers a similar duct leads to
the discharge device. The combustion air is fed to the kiln
above the stone charge, and the cooling air enters the lime
charge through the discharge devices.
The blowers are installed in a room designed to minimise the
sound emissions (Fig. 6). All blowers are provided with inlet
and outlet silencers. During the reversal period all air flow to
the kiln must be stopped and the kiln de-pressurised. Bypass
valves are provided so that the blowers can remain in operation
during this time.
5.4 Firing Equipment
The main requirement to produce a high, uniform quality product, i.e. quicklime or burnt dolomite, is to achieve a uniform
distribution of the fuel over the entire shaft cross sectional
area. This is accomplished by installing vertically suspended
burner lances inside the stone charge as shown in Figure 7.
The burner lances are in direct contact with hot gas and hot
stone therefore cooling air is required to cool the lances and to
prevent dust from entering into the lances in the non-burning
shaft during the exhaust gas cycle. Positive pressure, Rootstype blowers supply air to cool and purge the lances thereby
maximising lance life.
5.4.2 Fuel Oil
Vertical burner lances similar to those used for gas firing,
however, consisting of two concentric pipes are used for oil
firing (Figure 9).
Cooling air passes through the space between the inner and
outer pipes. Steam or compressed air is used to atomise the
fuel oil and to purge the lances to avoid clogging and/or
coking at the lance tip. Individual dosing pumps or control valves assure constant and even oil flow to each burner lance.
5.4.3 Coal
In many areas, coal, lignite or petcoke are less expensive and
more readily available than natural gas and fuel oil. A system
similar to the gaseous fuel design was developed to allow pulverised lignite, coal and petcoke be injected through the burner lances. Air is used as the carrier gas and lance cooling
medium. Figure 10 shows the basic scheme of the Maerz
Pulverised Solid Fuel firing system (PSF). Since its introduction
in 1980 the PSF system has been proven in more than 40
installations.
Pulverised fuel is stored in a bin to allow batch discharge of the
fuel into the weigh hopper beneath. The outlet cone of the storage bin is equipped with fluidising devices operated with compressed air or inert gas such as nitrogen or carbon dioxide. The
required weight of coal for one burning cycle is fed from the
bin into the weigh hopper during reversal periods when the
flow of coal and combustion air to the kiln is stopped. The bottom of the weigh hopper is designed with evenly spaced outlets around the circumference of the hopper leading to rotary
valve feeders that discharge into conveying pipes.
Contrary to the firing systems for gaseous and liquid fuels the
system for solid fuels operates in two steps. In the first step the
required amount of coal for one burning cycle is fed into the
weigh hopper. In the second step the coal is conveyed from the
weigh hopper via rotary dosing valves to the burner lances.
waste (specifically sawdust and grinding dust from the furniture industry) is injected through the burner lances. The particle
size should be less than 3 mm before being fed to the kiln.
5.4.7 Waste Oil
The recycling of waste oil, primarily used lubricants, has become an important and necessary routine in our industrialised
world. There are several Maerz lime kilns using converted oil
as fuel. Many waste fuels contain elevated levels of impurities
that can result in the production of toxic gases or the discharge of heavy metals. Special attention must be paid to environmental issues and the use of waste fuels may be restricted by
environmental regulations.
5.4.8 Simultaneous Use of Fuels
Besides the use of single fuels as described above the Maerz
PFR-Kiln may also be operated using two fuels simultaneously
in order to optimise overall fuel costs. Typical combinations of
fuels are coal dust and natural gas, fuel oil and natural gas as
well as coal dust and fuel oil.
It is also common practice to design the kiln for a single fuel
in the first stage and only later upgrade the firing system for
the use of two types of fuel.
5.5 Hydraulic Equipment
The kiln operation requires the alternating burning and nonburning shaft procedure. The kiln must be opened, closed, sealed, pressurised, fired, and de-pressurised. These actions require the use of hydraulically operated, movable parts. These
moveable parts include:
reversal traps for combustion air and off-gas
shaft closing traps
discharge tables
discharge traps
traps at the weigh hopper
relief valves in the air ducts
reversal valves for fuel and purging media
stone level indicators.
The non-compressible feature of hydraulic oils has the advantage of producing strong moving force with small construction
elements. Operation is safe, reliable and requires minimum service. The hydraulic system consists of a power unit (as shown
in Fig. 11) comprising an oil reservoir, pumps and filters, as
well as cylinders and control valve stands.
5.6 Electric, Measuring and Control Equipment
5.6.1 Motor Control Centre
The Motor Control Centre (MCC) generally is of conventional
relay technology design. The main switches, current, voltage
and protection elements as well as the transformer for control
voltage are all installed in the entry section. The other sections
house the control, switch and protection elements for the individual drives as well as the frequency converters for the blower
drives.
The last section of the cabinet comprises all electric apparatus
that must be emergency operated in case of power failure. The
provision and scope of the emergency section depends on the
type of fuel used and customer requirements.
For each drive the operation modes Local - Off - Auto may
be selected with a key-operated switch on local control panels
on the kiln or at the control panel depending on customer
request. Furthermore the individual drives may also be equipped with local isolators.
5.6.2 Control Panel and Remote I/O Stations
The control panel houses the following instruments:
PLC
Input/Output module cards
(if not located in remote I/O stations)
Control power supply
Interface relays
Transmitters (if not located in remote I/O stations)
Uninterruptible Power Supply (UPS) for the PLC
Data bus interfaces for the visualisation station and
remote I/Os.
All digital and analogue signals from the field or the power
cabinet are transmitted to the system via PLC input/output
module cards installed in the control panel or the remote I/O
stations. Measuring signals for temperatures and pressures are
transmitted as analogue signals. Signals from limit switches
and other position indicator devices are digitally transmitted.
5.6.3 Operator Control Station
The control station consists of a visualisation industrial PC with
monitor, keyboard and printers. All kiln operation commands
such as kiln start, conveyor start, etc. can be given via the PC.
In Fig. 12 a graphic display of the kiln and its operating parameters is shown.
Process data and limit value inputs are handled via the visualisation PC. Also historical data may be charted from the stations database.
The operator interface system is programmed to provide the
following information:
Indication of system operating conditions
in a process flow chart
Input/output of process data and measured values
Output of alarm messages
Output of short term trends
Storage of data on hard disk for long term trends
Output of production reports
Print function of all charts/graphs/pictures and reports.
5.6.4 Process Parameters Calculation Module
All process parameters are calculated in a program module
according to the input data. The kiln operator can for example
make the following selections:
Production rate (t/d)
Amount of stone per cycle (kg)
Heat consumption (kJ/kg lime)
Excess combustion air factor (-)
Cooling air volume (m3n/kg lime)
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From these data the following process parameters are calculated among others:
Number of cycles per day (cycles/d)
Combustion or burning time (sec)
Fuel quantity per cycle (kg or m3n)
Fuel flow (kg or m3n/hr)
Combustion air flow (m3n/hr)
Cooling air flow (m3n/hr).
5.6.5 Production Report Module
The following reports may be displayed:
Cycle report
Day report.
The cycle report provides specific data on date and time such
as stone charge weight in each shaft, fuel per cycle, heat consumption, crossover channel temperature and actual combustion air factor.
The day report is a summary of the cycle reports giving an
overview over the most important operating parameters.
5.6.6 Operation without Human Intervention
In a number of cases Maerz kilns are operated without continuous personnel interaction during night shifts and weekends.
6. Kiln Operation
6.1 Principles and Control Philosophy
The PFR-Kiln operates in cycles: during each 10 to 15 minute
cycle, fuel and combustion air are fed into one shaft - the burning shaft - while the other shaft serves as the preheating and
off-gas shaft - the non-burning shaft. During kiln reversal the
fuel flow is stopped and combustion and cooling air are vented to the open. In this phase the kiln is de-pressurised, stone
is charged into the kiln and calcined product is discharged from
the collecting hoppers underneath the discharge tables. When
the reversal period ends the shafts switch roles, the burning
shaft is now the non-burning shaft and the non-burning shaft
becomes the burning shaft.
The high thermal efficiency of the Maerz PFR-Kiln requires the
accurate control of multiple operating parameters such as:
Weight of charged stone
Stone level in the kiln shafts
Combustion and cooling air flow rate
Fuel flow rate, i.e. heat input
Temperature and pressure inside the kiln
Discharge speed of calcined product.
The batch process of charging stone allows accurate weighing
of each charge added to the preheating zone of the shafts.
Level control is usually done by either a mechanical level probe
connected to an electronic instrument or by gamma ray instrumentation.
Continuous measuring of ambient air temperature and pressure allows the setting of a constant amount of air under local
conditions thereby eliminating the influence of outside air
temperature and barometric pressure fluctuations. Constant air
flow is maintained with variable speed blower motors.
15
An important objective for kiln operation is to control the temperature in the calcining zone in a consistent, uniform manner.
Temperature within 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 pyrometer 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 calcine a wide range of top to bottom stone size because of its
sophisticated charging system. The ideal range is 2:1, but operation using 4:1 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
size may be as high as 180 mm provided the burning zone as
well as the feeding and discharge equipment have been adequately designed for it.
6.3 Quality of the Stone
As for all types of vertical shaft kilns the use of hard, nondecrepitating, high purity limestone is an ideal condition for
trouble-free operation of the PFR-Kiln. Nevertheless, due to
the fact that the shafts of the PFR-Kiln are virtually a pipe
without any devices which could obstruct the free flow of
limestone and lime the movement of the material column is
slow and uniform minimising abrasion and formation of fines.
This means that also soft limestone can be calcined in the PFRKiln.
In case the limestone has a tendency to decrepitate during the
calcining process an increased percentage of fines will be generated. The installation of so called air cannons in the crossover
channel area where dust particles could stick to the refractory
lining facilitates the calcination of soft and decrepitating
stone.
High quality limestone and dolomite with consistent chemical
properties is often not available or is scarce. Varying contents
of carbonates and impurities can result in the production of
overburnt or underburnt product with inconsistent values for
residual CO2 and loss on ignition. For such cases a fully automatic temperature control system of the Maerz PFR-Kiln may
be implemented to adjust the heat input to maintain uniform
quality of the calcined product.
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3 to 4 years
6 to 8 years
9 to 12 years
Environmental issues
The installation of modern bag house filters reduces dust
emissions to meet the environmental regulations set by local
authorities. Better control of the combustion process results
in lower CO and NOx emissions.
10. References
11. Summary
Since 1966 more than 350 Maerz PFR-Kilns have been built
around the world (Fig. 19). Of these, approx. 150 kilns are gas
fired, approx. 130 kilns fuel oil fired, approx. 20 kilns solid fuel
fired and approx. 50 kilns are fired with a combination of gaseous, liquid and solid fuels.
Since its introduction into lime industry in the late fifties the
Maerz PFR-Kiln has become a piece of standard equipment in
the lime and dolomite industry. Its unbeatable thermal efficiency together with the flexibility in operation with virtually
all types of fuel and raw material have made him an excellent
choice whenever the installation of new calcining equipment is
an issue.
approx. 80
approx. 90
approx. 110
approx. 40
approx. 30
Bibliography
R.S. Boynton, Chemistry and Technology of Lime and Limestone,
John Wiley & Sons, 1980
J.A.H. Oates, Lime and Limestone, Wiley VCH, 1998
E. Schiele / L.W. Berens, Kalk, Verlag Stahleisen, 1972
Maerz Ofenbau AG
Richard Wagner-Strasse 28
CH-8027 Zurich
Switzerland
2002 - Maerz Ofenbau AG, Zurich, Switzerland: www.maerz.com; Dtp: aku2 kury-kugler, Seeboden, Austria: www.aku2.at; Drawings: W. Kury, Seeboden, Austria: www.aku2.at; Printed in Austria by Krntner Druckerei, Klagenfurt: www.kaerntner-druckerei.at
Phone +41-1-287 27 27
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