Henan Hongke Heavy Machinery Co., Ltd. is pleased to report on the successful deployment of a Φ 3.3×60m rotary kiln lime production line at a customer site in Heshun County, Shanxi Province, China. The system is designed for a capacity of 300 tons per day and represents a proven, efficient solution for medium-to-large-scale lime calcination in a key industrial region.
Project Background: Meeting Shanxi's Industrial Lime Demand
Shanxi Province is a major industrial base in northern China, with substantial metallurgical, calcium carbide, and building materials sectors. These industries all depend on a reliable supply of high-quality active lime for fluxing, chemical reactions, and construction applications . Heshun County, with its accessible limestone resources and proximity to major industrial centers, has become a strategic location for lime production.
Our customer, a well-established industrial operator in Heshun County, identified the need to expand their lime production capacity to serve growing regional demand. Their existing production methods were inefficient and could not consistently produce lime meeting the reactivity specifications required by downstream steel and chemical customers. They needed a modern, reliable rotary kiln solution that could deliver 300 tons per day of high-quality quicklime while reducing operating costs and meeting environmental standards.
The Challenge: Capacity, Quality, and Efficiency
Before choosing Henan Hongke Machinery, the customer faced several key challenges:
| Challenge | Impact |
|---|---|
| Limited production capacity | Could not meet growing demand from local steel and carbide plants |
| Inconsistent product quality | Lime reactivity varied widely, affecting customer processes |
| High fuel consumption | Operating costs were cutting into margins |
| Environmental compliance | Dust emissions needed to meet stricter national standards |
| Labor-intensive operation | Manual controls required constant operator attention |
The customer required a modern rotary kiln system that would address all these issues while fitting within their existing site footprint and investment budget. The Φ 3.3×60m configuration was selected as the optimal balance of capacity, efficiency, and capital cost for their 300 TPD target .
Our Solution: Φ 3.3×60m Rotary Kiln System
Henan Hongke Heavy Machinery engineered a complete lime production system centered around a Φ 3.3×60m rotary kiln – a well-established configuration for 300 TPD applications. According to industry specifications, the Φ 3.3×55m model supports capacities of approximately 300–400 TPD, making the Φ 3.3×60m variant an ideal choice for this application .
Key Equipment Specifications
| Parameter | Value |
|---|---|
| Kiln diameter | 3.3 meters |
| Kiln length | 60 meters |
| Capacity (design) | 300 tons per day |
| Operating temperature | 950–1,250°C |
| Kiln inclination | 3.5–4% |
| Rotation speed | 0.3–1.8 rpm (variable frequency drive) |
| Drive system | Heavy-duty gear drive with auxiliary motor |
| Sealing system | Advanced labyrinth seals with air purge |
Complete System Configuration
The delivered system includes the following integrated components, all engineered and manufactured by Henan Hongke Machinery:
1. Vertical Preheater
The preheater recovers thermal energy from kiln exhaust gases to preheat limestone feed to approximately 800–900°C before it enters the kiln, achieving 25–35% pre-calcination . This reduces fuel consumption by up to 30% compared to non-preheater configurations and significantly improves overall system thermal efficiency . The preheater is designed with multiple chambers for uniform material distribution and efficient heat exchange.
2. Φ 3.3×60m Rotary Kiln
The core calcination unit features a high-quality carbon steel shell with high-alumina refractory lining. The slightly inclined, slowly rotating cylinder ensures uniform heat distribution and complete calcination of limestone at temperatures between 1,100°C and 1,250°C . The 60-meter length provides extended residence time—critical for achieving complete calcination and maintaining product quality under variable feed conditions. The open calcination design allows effective removal of impurities during the burning process.
3. Vertical Cooler
The cooler rapidly quenches hot lime product from approximately 1,100°C to below 80–100°C, preserving the lime's reactivity (activity degree) . Rapid cooling is essential for maintaining the high reactivity required for metallurgical and chemical applications. The hot cooling air is recovered and recycled to the kiln as secondary combustion air, further improving thermal efficiency .
4. Multi-channel Burner
Provides precise flame control and fuel flexibility, capable of operating on pulverized coal, natural gas, or mixed fuels.
5. Dust Collection System
The system incorporates multi-stage dust collection – typically a cyclone pre-separator followed by a bag filter – to ensure outlet dust concentrations consistently below 30–50 mg/Nm³, meeting national environmental standards .
6. Automation & Control
PLC or DCS-based centralized control monitors temperature profiles, feed rates, kiln rotation speed, and emissions in real time . This ensures consistent product quality and minimizes operator intervention.
Why This Kiln Works for Shanxi Conditions
| Feature | Advantage |
|---|---|
| Extended 60m length | Provides sufficient residence time for complete calcination even with variable feed |
| Preheater integration | Reduces fuel consumption, lowers operating costs by ~30% |
| Rapid cooler | Preserves lime reactivity for high-value metallurgical applications |
| Advanced sealing | Minimizes heat loss and dust emissions, improves thermal efficiency |
| Automated controls | Consistent quality, reduced labor requirements |
| Fuel flexibility | Can operate on coal, gas, or mixed fuels |
Customer Benefits
Once fully operational, this 300 TPD lime production line delivers:
| Benefit | Impact |
|---|---|
| Consistent high-quality product | Active lime meeting metallurgical specifications with reactivity ≥ 320ml |
| Lower operating costs | Preheater technology reduces energy consumption by approximately 30% |
| Increased production capacity | 300 TPD meets growing regional demand |
| Environmental compliance | Dust emissions controlled to meet national standards |
| Reduced labor requirements | Automated controls minimize operator intervention |
| Enhanced competitiveness | Higher quality product at lower operating cost |
About Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd. (Henan Hongke Machinery) has been manufacturing industrial processing equipment since 2006. Our product portfolio includes:
Rotary Kilns – for lime, dolomite, metallurgy, and mineral calcination
Rotary Dryers – for sludge, biomass, and industrial materials
Ball Mills – for ore, slag, cement, and chemical grinding
Crushers – for primary and secondary size reduction
We provide custom engineering, full manufacturing, installation guidance, commissioning support, and after-sales service for customers worldwide.
Summary
The Φ 3.3×60m lime rotary kiln project in Heshun County, Shanxi, demonstrates Henan Hongke Heavy Machinery's ability to deliver efficient, reliable lime production solutions for medium-to-large-scale operations. By integrating preheater technology, advanced sealing, extended kiln length, and automated controls, the system delivers consistent product quality with optimized fuel consumption and reliable 24/7 operation.
For lime calcination, mineral processing, or other thermal treatment applications, contact Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd.
Rotary Kilns | Rotary Dryers | Ball Mills | Crushers – Engineered for Real-World Results