No more second guessing, we share three must-follow tips on how to start a lime manufacturing plant to ensure success from day one.
Want more information about lime calcination? As a professional solution provider of lime manufacturing plants, we are familiar with related equipment, spare parts, layout design, processing technology, and other configurations.
A lime manufacturing plant is designed for calcining limestone, also called lime calcination plant, lime processing plant, or lime production line. The entire lime manufacturing plant covers the lime kiln, lime calcination process, lime production equipment, etc.
Why do we start the business of lime manufacturing plant? Lime is a widely used intermediate material, extensively employed in cement manufacturing plant. It also finds broad applications in organic chemistry, manufacturing, and various other industries. For instance, it is used in decorative agents, castor oil, alcohol production, and more. The lime industry has achieved significant economic benefits through these applications. As a result, it is foreseeable that the market demand for the lime industry will continue to exhibit a steady growth trend in the future.
Lime manufacturing process
The lime manufacturing process is the first thing to learn, all lime manufacturing plant design is based on this, it can be divided into raw material preparation, lime calcination system, conveyor system, dust collector system, etc.
Raw Material Storage and Transportation System
Limestone with a particle size of 10 to 50mm is transported to the factory area and stacked in the material yard using a loader. The qualified materials with appropriate particle size are loaded into the receiving hopper by the loader. From the receiving hopper, a feeder provides controlled feeding, delivering the limestone to a steep-angle conveyor, which transports it to the screening tower. After screening, the limestone with the desired particle size is measured and conveyed by the steep-angle conveyor to the top storage bin of the preheater. The undersized powder from the screening process is sent to the storage yard via a conveyor and periodically removed by a forklift.
Calcination System
The lime calcination process consists of a vertical preheater, a rotary lime kiln (or vertical lime kiln), and a vertical cooler. With a production capacity of 100 to 1200t/d, the material is fed into the preheater’s top storage bin via a discharge chute. Simultaneously, the high-temperature flue gas introduced by the rotary kiln heats the material to over 1000°C, causing partial decomposition of the limestone. Hydraulic push rods sequentially push the material into the tail section of the rotary kiln, where high-temperature calcination occurs. Afterward, the material is discharged into the cooler, cooled to below the environment temperature +60°C by cold air blown by fans, and then discharged from the cooler. The air blown into the cooler also serves as secondary air for combustion in the rotary kiln.
Finished Product Conveying System
After being discharged from the cooler, the finished lime is conveyed using a chain conveyor, bucket elevator, and belt conveyor to various finished lime storage areas. Underneath the lime storage silos, discharge valves are used to load lime into trucks and tankers for transportation. Different-sized storage silos are set up based on customer storage requirements. Circular storage silos are used for finished products, with two silos for 5~50mm-sized products and one silo for <5mm-sized products. Each silo has a capacity of approximately 800t.
Flue Gas Treatment System
The high-temperature flue gas generated by the rotary kiln combustion exchanges heat with limestone inside the preheater, reducing its temperature to below 250°C. The gas then undergoes primary dust collection in a cyclone separator to capture larger dust particles. Subsequently, it enters a bag filter for further dust removal, and after this treatment, the gas is expelled into the atmosphere using a high-temperature fan. The dust concentration in the emitted gas is kept below 30mg/m3. A cold air control system is installed at the inlet of the dust collector to protect it.
Lime production equipment
Lime production equipment is another necessary part we must consider. Common lime production equipment includes crushers, lime kilns, preheaters, coolers, conveyors, dust collectors, etc. One thing to be clear, all lime production equipment configurations should be set according to the scale of the lime manufacturing plant.
Raw material preparation equipment
Calcination equipment
Auxiliary equipment
Lime manufacturing plant cost
When lime kiln plant manufacturers create equipment quotations, they consider a variety of factors based on the user’s requirements for raw material particle size, fuel selection, daily production demands, equipment models, manufacturer investments, desired profits, and more. These factors are comprehensively evaluated to provide a market quotation. As buyers consider their options, there are several key aspects to keep in mind to ensure they get value for their money:
- Quality of Lime Kiln Production Line: The quality of the lime kiln has a direct correlation with its price. High-quality rotary kilns often involve higher costs in terms of materials, processes, and labor inputs, leading to a higher price point.
- User Requirements: The price of the lime kiln production line is also influenced by the user’s specific requirements. Equipment with higher production capacities and stricter raw material particle size demands will typically command higher prices.
- Manufacturer’s Profit: Lime kiln production lines are developed to generate profits. Manufacturers aim to earn profits from the production and sale of lime kilns. Consequently, the manufacturer’s equipment sales and their own profit margin will affect the quotation they provide.
