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Chemical Properties:
CaCO3: >97%, Fe2 O3: < 0,5%, SiO2: < 0,5%, MgCO3: <1%, Al2O3: <0,5%,
humudity:<1%
All performance parameters stated in this quotation are based on this typical analysis.
Signficiant changes of the lime stones chemical and/or physical properties may result in
accordingly adapted performance parameters.
Consumption Figures:
The kiln shafts are equipped with access doors for inspection and maintenance
All doors are equipped with a bulb iron in order to avoid opening of the door when the
kiln is pressurised. It is not allowed to open any access door before the kiln has been
shut down and is depressurised.
The upper part of the kiln is clad for weather and sound protection. The housing
consists of a bolted steel construction and sound insulation lining. The lower part of the
kiln is not enclosed. The major installations of the kiln are accessible via platforms and
their respective staircases.
1.6- Limestone Weighing Hopper before the skip (with load cells) (1Set)
The skip hopper has a volume of approx 3.5 m3 corresponding to approx. 4500 kg of
limestone.
The lime kiln is charged batch wise by means of a skip hoist. A pre-determined amount
of limestone is prepared in the skip hopper and charged into the skip bucket.
The amount of stone filled into the skip hopper must be limited to 4500 kg otherwise
there is the danger of overflow of the following charging system.
The hopper is over the skip bucket and placed onto weighing cells.
The skip (weighing) hopper trap is opened by means of a hydraulic cylinder and closed
by means of a counterweight and hydraulic pressure at the cylinder. In case of a total
power failure the trap closes by means of the counterweight only.
Volume: 3,5 m3
Capacity: 4500 kg of limestone
Number of weighing cells: 3
1 Skip run = Filling of the bucket, run up, emptying of the bucket, run down.
Design data
Skip capacity: 4.5 t per run
Skip bucket volume approx.: 3.0 m3
Speed of the skip bucket: approx. 20 m/min
The skip winch shall be supplied completely pre mounted on a frame, including:
- 1 double wire rope drum
- 1 gear
- 1 electric motor, approx. motor power 3 * 400 VAC, 50 Hz. 37 kW incl. VVVF
- 2 dynamic brakes for power failure.
1 Skip rope
The following safety equipment shall be delivered together with the skip:
- Capacity: 4.5 t
- Volume: 3.0 m3
1.8- Limestone Weighing Hopper on top of the kiln (with load cells) (1Set)
The silo on kiln is mounted on the stone hopper platform and placed onto weighing
cells.
Volume: 7.5 m3
Capacity: 11200 kg of limestone
Number of weighing cells: 3
The reversible belt conveyor distributes the limestone to the rotating buckets.
To discharging the limestone into the shaft the rotating bucket will be lowered
hydraulically.
The shaft closing trap serves for a safe closing of the shaft. Before charging the kiln the
trap lowers hydraulically to open the shaft
The shaft closing traps are located above the kiln shafts.
The traps open and close the shaft and are moved due to hydraulic cylinders.
Tightness is achieved by means of special silicon rubber seals.
The level indicators are installed directly on top of the shafts and are used for
measuring the filling level of the shafts. The level indicators are equipped with hydraulic
rotary drives and probe weights, which continually monitor the stone level.
The reversal traps allow supply of the burning shaft with combustion air, or the waste
gas coming from the regenerative shaft to exit the kiln. For this purpose they are
changing their position by means of hydraulic cylinders.
The filter/ chimney trap can be used to feed the waste gas to the filter or, if necessary,
directly to the chimney.
The filter/ chimney trap are installed above the reversal traps on the stone hopper
platform.
The positions "waste gas to chimney" or "waste gas to filter are set by a hydraulic
cylinder.
If the waste gas filter fails, the kiln is stopped and the exhaust air is conducted to the
emergency chimney by switching the filter/ chimney trap.
The inward and outward movement of the table causes the lime to fall off of the outer
edge of the table.
The discharge tables are located below the kiln shafts and are used to discharge the
burnt lime.
The discharge tables consist of four steel plate segments connected crosswise to each
other. The segments are made up of two steel plates and an intermediate ceramic fibre
plate, which pre- vents the plates from warping due to differences in temperature.
Each pair of segments rests on four rollers, which allows for easy movement and makes
maintenance unnecessary.
Each of the connected two segments is shifted back and forth by hydraulic cylinders,
which causes the lime to fall off of the outer edge of the table.
This type of discharge device ensures a steady vertical movement of the lime in the
shafts.
Two beams are mounted crosswise above the discharge table to cover the gaps
between the segments and to support a conical displacement body used to cover the
center opening
The discharge traps are located underneath the lime collecting hoppers of the shafts.
The traps discharge the burnt lime collected in the conical discharge hoppers installed
underneath the shafts during the burning period. For this purpose, the traps are opened
and closed by means of hydraulic cylinders.
Counterweights close the traps in the event of a power failure or a failure of the
hydraulic power unit. The traps can be locked in their upper position by means of a
mechanical locking device (e.g. for maintenance purposes).
2 vibrating feeder for discharging of burnt lime at kiln bottom with following
characteristics:
? length: approx. 1'500 mm
? width: approx. 650 mm
? capacity: approx. 0 - 50 t/hr
? quicklime size: 0 - 80 mm
Air shock blowers for cleaning the kiln cross over channel including:
22 air shock blowers with pressure vessel 100 l, with main and pilot valve,
22 pressure switches for the control of the air shock blowers
The compressed air is released by rapidly opening cylinders through connecting pipes
and heat resistant nozzles.
2- Refractories For HYM Kiln (1 Set)
The lime kiln is operated at high temperatures. Burning zone temperatures, at times,
reach up to 1'100 C. This is why the kiln shafts are completely lined with refractory
materials.
The pre-heating and cooling zones of the kiln are lined with an abrasion-resistant
material and backed by insulating firebricks. The wear lining in the burning zone
consists of magnesite and high- alumina bricks, backed by a lining made of light fire
clay and insulating bricks as well as a ceramic fibre mat. The work lining has a thickness
of 250 mm, while the total thickness of the wall is about 500 mm.
The arrangement of the bricks is simple as shown in the figure be- low. No burner
bridges or devices that may affect the stone/lime while it passes through the kiln have
been installed
- cooling zone
- burning zone
- preheating zone
- magnesite bricks
- magnesite mortar
- insulating bricks
- insulating plates
- slag wool
- fireclay mortar
Gunning mass for corrosion and noise protection to be installed in the top sections of
the two shafts. Thickness of the protection approx. 100mm.
3. Refractories Lining
Main components
Manually operated shut-off valve,
Flow measuring device,
Control valve for natural gas
Safety Shut-off valves ,
Double block shut-off valves for shaft 1,
Double block shut-off valves for shaft 2,
Double block shut-off valves for start-up burner,
Electrical Equipment
The gas reversal and safety rack is designed fail safe. That means that in case of de-
energising the pilot solenoid valves the fuel shut-off valves will close automatically by
spring force. The venting valves between the main shut-off valves will open
automatically by spring force.
In normal kiln operation the manually operated shut-off valve, must be open.
The double block valves open and close cyclically in order to feed fuel gas to the burner
lances at the burning shaft.
The valves control the required gas flow.
These control valves can be set to either automatic or manual mode by the kiln
operator.
The gas flow is measured by means of a vortex meter. The PLC converts the measured
flow using the pressure measuring instrument, and the temperature measuring
instrument, , to a flow expressed as normal flow (0C/1013 mbar base).
Fuel is fed to the burning shaft only during the fuel feeding time FFT.
A filter unit is arranged behind the main shut off valve (50 my).
4.1- Burner lances for natural gas (66 Pcs.) and equipments.(1 Set)
The burner lances are suspended from steel structures covered by protection boxes.
The length of the burner lances depends on the range of stone size to be burnt in the
lime kiln. The horizontal position of each single burner lance is well determined to
achieve an optimal distribution of fuel over the cross section of the shaft.
The burner lances can be changed from the outside of the kiln.
Fuel gas which is supplied by the gas reversal and safety rack arrives at the reversal
valves at a pressure of maximal 4.0 barg.
For each single burner lance two non return valves have been provided. One for fuel
gas and one for lance cooling air. For uniform fuel gas distribution through all lances,
orifices are installed, directly before entering the lance body.
Fuel gas is supplied to the burner lances only during the fuel feed time. During burn out
time and the kiln reversal the reversal valves are automatically closed.
Lance cooling air is provided by means of ring ducts at both kiln shafts. Similar as
above for fuel gas each burner lance is connected to that ring duct. The total amount of
lance cooling air is uniformly distributed by means orifice plates installed close to the
burner lance connection unit .
The inside diameter of the orifice plates must be adjusted to achieve a pressure approx.
400 mbarg at full kiln capacity.
Blowers are sized for 25 % spare capacity, stand by blowers for combustion / lime
cooling air and lance cooling air.
Roots type blowers for the supply of combustion, cooling and lance cooling air.
? All the blowers will be supplied completely pre- mounted on frames including each:
- Suction filter
- Inlet silencer
- Blower body
- Coupling or V-Belt
- Motor
- Outlet silencer
- Check valve
- Safety relief valve
- Bellow expansion joint
- Ant vibration mounts
The combustion air relief trap releases the kiln pressure while it is being opened. When
set to its open position, the trap provides exit to the outside. In doing so, the trap
relieves the kiln and releases the combustion air supplied by the combustion air
blowers. For this purpose, the trap is opened and closed by a hydraulic cylinder.
The cooling air relief trap relieves the lower part of the kiln while its being opened.
When set to its open position, i.e. when the exit to the outside is open, the trap vents
the cooling air produced by the blowers outside. For this purpose, the trap is opened
and closed by a hydraulic cylinder.
2 cooling air flow control traps DN 250 with servo drive. 220 VAC, single phase.
5.3.1 - 2 Units Air Blowers at 35 C: each at 4575 m?/h, 600 mbar (one as a stand-by)
2 AC Motor 110 kW, 1500 rpm
5.6- Stand-by Air Blower for Cooling air and combustion air and lance cooling air
(with motor and frequency converter) (1 Pcs.)
1 Units Air Blowers at 35 C : each at 7250 m?/h, 400 mbar
1 AC Motor 132 kW, 250-1500 rpm (Frequency converter)
6- Hydraulic System
Complete hydraulic equipment to operate all movable parts of the kiln, such as the kiln
traps in the charging device for limestone, the discharging device for burnt lime air and
waste gas reversal valves, relief valves for combustion and cooling air, etc.
The hydraulic power pack will be supplied completely pre-mounted on a frame including
the following main equipment:
Instrumentation
All solenoid valves necessary to operate the hydraulic cylinders are installed on several
blocks built into covers. The hydraulic blocks will be installed on different levels of the
kiln nearby the hydraulic cylinders in order to keep the pipe work as short as possible.
The number of hydraulic valve stands will be determined during the detail design stage.
7- Jet Pulse Bag Filter For Kiln (Waste gas dust cleaning system)
A suction type bag house filter is installed to reduce the dust content of the waste
gases leaving the kiln to a level compatible with environmental requirements.
The waste gas filter collects the dust in the exhaust air.
The fan draws the exhaust air through the waste gas filter. The filter bags are cleaned
with compressed air.
The filter dust is collected in a conical hopper underneath the body of the bag house
filter. A screw conveyor discharges the filter dust to a rotary valve in to a dust silo.
If the temperature of the exhaust gas is too high, quench air is fed in to avoid filter
damages.
If the waste gas filter fails, the kiln is stopped and the exhaust air is conducted to the
emergency chimney by switching the filter/ chimney trap.
The unit runs PLC controlled. No manipulation by the operator is required. Settings can
be made in the visualization system.
Typical figures for emissions from natural gas fired HYM kiln,
Motors: 220 VAC Solenoid valves: 220 VAC PLC inputs/outputs: 24 VDC
8.1.1 The main incoming section comprising:
For each motor or motor group one local control panel is provided, equipped with:
Motor operation:
The switchboard will include all frequency converters (blowers, filter fan and skip) of
the HYM Kiln.
The VVVF electrical switchboard have to be tested and parameterized in the workshop
before delivery to plant site. All required data from / to PLC S7-400 will be sent by L2
Bus (Speed set point / feedback signal, output current, start/stop signals, on, off ,fault,
etc. ).
The powers of the motors indicated in the list are preliminary, and may be subject of
revision during the detail design.
All local control panels equipped with AUTO / LOCAL mode selector, emergency stop
and start push button. LCP will be connected to MCC.
8.4 Control system (PLC) for the lime kiln and kiln auxiliary equipment
1 lot of I/ O modules ( analogue and digital ) inserted into central and expansion racks
as well as in the remote I/O stations.
The S7 400 as well as the remote I/Os in the Filed will be supplied on the following
basis of I/O signals:
required 20% spare total installed quantity
All relevant Siemens L2 DP and Industrial Ethernet cables according to the following
description:
Simatic L2 DP Bus cables complete with relevant connectors in order to connect the
PLC S7 400 Cabinet with frequency converters and the remote I/O Stations.
Simatic Industrial Ethernet bus cables complete with relevant connectors in order to
connect the PLC S7 400 Cabinet with the MMIs (Man machine Interface) stations. The
topology of this BUS will be ring type in order to increase the availability of the entire
system in case of a break of an cable.
- Temperature sensors
- Pressure Transmitters
- Level sensors
- Scales for dolomite stone
- Flow measuring devices
- Flame safety guard
- Kiln Trap limit switches
All sensors where possible will be connected to the AI-modules in the remote I/O
stations or transmitters installed in the PLC cabinet if necessary.
The number and type of measuring sensors included the scope of supply are shown in
the Instrument list.
Supplier may be changed and replaced by equivalent - if necessary - during the final
design.
8.8 Electric Cables (Field cabling) and cable trays (by Client)
Complete cabling of the kiln and its ancillary equipment including local motor isolator if
required and all necessary mounting material such as cable trays. Quantity as
required.
9.6.4 Supply of drawings for refractory lining 8 months from Due Date
9.6.6 All technical documentation except manuals 12 months from Due Date
9.6.7 Materials and Equipment 8 months from Due Date
Ex-Works delivery starts 4 months from Due Date
Ex-Works delivery completed 12 months from Due Date
9.6.8 Manuals 10 months from Due Date
9.6.9 Commissioning approx. 14 - 16 months from Due