Active lime, LECA/ Oil Proppant plant

Rotary kiln / furnace for clinker, lime Active lime/Oil Proppant production line

An active lime production line is a set of equipment designed to produce high-quality lime from limestone, with the aim of meeting various industrial applications, such as in the production of steel, environmental desulfurization, and other processes. The process typically involves several stages, including limestone crushing, calcination, hydration, and finally, the production of active lime. Here is a general overview of the main steps involved in an active lime production line:

1. Limestone Quarrying:
- Raw limestone is extracted from quarries and transported to the lime plant. The limestone may undergo crushing and sizing processes to achieve the desired particle size.

2. Limestone Preheating:
- The raw limestone is typically preheated in a preheater or precalciner before entering the rotary kiln. This preheating step helps to reduce the energy consumption in the kiln by partially decarbonizing the limestone.

3. Loading into the Rotary Kiln:
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- The preheated limestone is loaded into the rotary kiln, a large, rotating cylindrical furnace. The kiln is inclined at a slight angle to facilitate the movement of materials through the kiln.

4. Calcination:
- In the rotary kiln, the limestone undergoes high-temperature calcination (typically in the range of 900 to 1,450 degrees Celsius). This process causes the limestone to undergo chemical and physical changes, converting it into lime (calcium oxide).

5. Cooling:
- After calcination, the lime moves through the cooling zone of the kiln, where it is cooled down. This cooling step is essential to stabilize the lime and prepare it for further processing.

6. Hydration:
- The quicklime produced in the kiln is then slaked with water in a hydration process to produce slaked lime (calcium hydroxide). This is typically done in a separate hydrator.

7. Separation of Unreacted Lime:
- The slaked lime is separated from any unreacted quicklime or impurities. This step ensures that the final product is of high quality.

8. Filtering and Drying:
- The separated slaked lime is filtered to remove excess water, and the resulting product is dried to achieve the desired moisture content.

9. Storage and Packaging:
- The final product, active lime (calcium oxide), is stored in silos or other storage facilities. It can then be packaged for sale or transported to end-users.

10. Environmental Considerations:
- Dust collection systems and other environmental control measures are often implemented to minimize emissions and ensure compliance with environmental regulations.

The design and configuration of an active lime production line can vary based on factors such as the type of limestone used, production capacity requirements, and specific industrial applications. Modern production lines often incorporate advanced technologies to optimize energy efficiency, minimize environmental impact, and ensure high-quality active lime production.