Parallel Flow Regenerative (PFR) Lime Shaft Kilns

Comparison of lime kiln types

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 (see Fig. 3) defined by
alternating burning and non-burning shaft operation.
There are two distinguishing features of the PFR-Kiln:
1) the parallel flow of hot gases and stone in the burning zone, and
2) the regenerative preheating of combustion air in the process.
This type of kiln is ideally suited to produce soft burned, 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, where the curves show the
temperatures of the material, of the air and of the combustion gases
flowing through the kiln.
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 the temperature of the
cooling air and the red line the temperature of the combustion gas
and kiln exhaust gas. As the amount of cooling air is not sufficient
for complete combustion of the fuel additional air has to be introduced via 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 the production of high reactive lime.

Fig. 1a: Temperature Profile in a Counter Flow Kiln

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 temperature, the blue lines in the preheating and cooling zone the relevant air temperatures and the red
line the combustion gas and kiln exhaust gas temperatures. As the
fuel is injected at the upper end of the burning zone where the material can absorb most of the heat released by the fuel the temperature
in the burning zone is typically as low as 950 C on average. Because
of this, parallel flow heating is the best solution for the production
of soft burned, reactive lime and dolomitic lime as required in most
applications.
The second important characteristic of the PFR-Kiln is the
regenerative preheating of the combustion air. In kilns with counter
flow heating the combustion air is preheated in the cooling zone by
the sensible heat contained in the calcined lime. The amount of
preheating is limited, however, by the enthalpy of the lime. In the
counter flow heating process there is a surplus of usable sensible
heat contained in the exhaust gas that is not recovered prior to being
exhausted. As a consequence some single shaft kiln designs have
incorporated recuperators in an effort to recover this waste heat, but
such heat exchangers are susceptible to operating problems caused
by dust contained in the hot exhaust gases.
In the parallel flow regenerative kiln the combustion air is
preheated in an optimal way. The regenerative process requires two
connected kiln shafts. Each shaft is subject to two distinct modes of
operation, burning and non-burning. One shaft operates in the

Fig. 1b: Temperature Profile in a PFR-Kiln

non-burning shaft through the crossover

burning mode and simultaneously the second
channel, travelling up in counter flow to the
shaft operates in the non-burning or exhaust
stone. The exhaust gases transfer heat to the
mode. Each shaft spends an equal amount of
stone bed in the non-burning shaft and even
time in both the burning and non-burning
calcine it to a small degree. The exhaust
modes of operation. In the burning mode a
gases then regenerate the stone bed in the
shaft is characterised by the parallel flow of
preheating zone in preparation for the next
combustion gases and raw stone whereas in
burning cycle on that particular shaft.
non-burning mode a shaft is characterised by
Each shaft cycles through the burning and
the counter-current flow of exhaust gases
non-burning mode at intervals of approxiand raw stone. The combustion gases exit the
mately 12 minutes. The changeover from
burning shaft through a crossover channel
burning to non-burning is called reversal
into the non-burning shaft. The alternating
period. Calcined product is discharged from
burning/non-burning shaft sequence serves
both shafts continuously throughout the
as a regenerative preheating process. Heat is
burning cycle by discharge tables into a
transferred to the raw stone from the exhaust
pressurised hopper. Cooling air is congases during the non-burning mode and
tinuously introduced at the bottom of both
then reclaimed by the combustion air from
shafts to reduce the temperature of the
the raw stone during the burning mode. The
Fig. 2: Operating Principle of a MAERZ Kiln
product prior to being discharged into the
preheating zone acts as a regenerator with
lime storage hopper. During reversal periods, when the kiln is
the stone charge as checkers. This kind of regenerator is completely
depressurised, the product is discharged from the storage hopper
insensitive to dust-laden or corroding gases and, at the same time,
onto vibrating feeders and conveyor belts.
shows excellent heat transfer characteristics.
The regenerative preheating of the combustion air makes the
thermal efficiency of the kiln practically independent from the excess
Thermal efficiency and heat consumption
combustion air factor. This considerably simplifies the setting of the
The excellent thermal design of the PFR-Kiln can be satisfactorily
correct flame length required to achieve the desired degree of lime
proven by means of the heat balance. The sum of effective heat,
reactivity. A larger quantity of excess air produces a shorter flame
i.e. the heat required for dissociation, and of the various heat losses
and less excess air produces a longer flame. The length of the flame
provides the thermal requirement of the kiln.
is one of the key factors to control the reactivity of burned lime.
The heat losses consist of:
Generally shorter and hotter flames reduce the reactivity of the
the loss through the kiln walls equal to approx. 170 kJ
burned product.
(40 kcal)/kg of lime,
the sensible heat of the discharged burned lime equal to
approx. 80 kJ (20 kcal)/kg of lime at a discharge
Operating principle of the PFR-Kiln
temperature of 100 C, and
Fig. 2 shows the basic operating principle of the PFR-Kiln and
the sensible heat contained in the exhaust gases equal to approx.
illustrates the two phases of gas flow. Two shafts, designated 1 and 2,
290 kJ (70 kcal)/kg of lime at a discharge temperature of 100 C.
contain the material to be calcined. The stone charging system, the
reversal traps for fuel, combustion air, and exhaust gas, and the lime
Considering the above figures for heat losses of the kiln and when
discharge system have been omitted from this diagram. The shafts
producing lime with 96% CaO the total thermal requirement is approx.
are either alternately or simultaneously charged with stone
3520 kJ (840 kcal)/kg or 3.02 million Btu per ton of burned lime.
depending on kiln capacity. Lime is discharged continuously at the
bottom of both shafts.
Fuel is supplied to only one of the two shafts. In Fig. 2 it is supplied to shaft 1 this being designated the burning shaft and shaft 2
is designated the non-burning shaft. The fuel is introduced through
multiple lance tubes that vertically extend to the bottom of the
preheating zone. The lower end of the lance tubes marks the limit
between the burning zone and the preheating zone. Fuel is injected
through these lances and evenly distributed over the cross sectional
area of the shaft.
Combustion air is introduced under pressure at the top of the preheating zone above the stone bed. The complete kiln system is
pressurised. The combustion air is preheated by the stone in the
regenerator (preheating zone) prior to mixing with the fuel. The
air/fuel flame is in direct contact with the calcining material as it
passes through the burning zone from top to bottom (parallel flow
heating). The exhaust gases leave the burning shaft and enter the
Fig. 3: MAERZ PFR Lime Shaft Kiln
2