Henan Hongke Heavy Machinery Co., Ltd. has delivered a 1,000-ton-per-day active lime rotary kiln production line to a customer in Changzhi, Shanxi Province, China. The line processes limestone into high-reactivity quicklime for the steel and chemical industries.
This article covers the full project: customer background, the original problem, equipment configuration, delivery timeline, commissioning results, and customer feedback.
1. Customer Background
Location: Changzhi, Shanxi Province, China
Industry: Metallurgical lime / building materials
Changzhi is a major industrial city in southeastern Shanxi, with a strong metallurgical and chemical sector. The region’s steel and calcium carbide industries require a consistent supply of high-reactivity active lime (quicklime) for fluxing and chemical reactions.
Our customer operates a lime production facility in Changzhi. They supply local steel mills and chemical plants. Their existing production capacity could not meet growing demand, and the quality of lime produced from older kilns was inconsistent—particularly in reactivity and residual CO₂.
2. The Original Problem
Before approaching Henan Hongke Machinery, the customer faced several practical constraints:
| Problem | Impact |
|---|---|
| Capacity shortfall | Unable to meet contract volumes from local steel mills |
| Inconsistent lime reactivity | Downstream steelmaking efficiency affected |
| High fuel consumption | Operating cost per ton of lime above competitive levels |
| Dust emissions | Difficulty meeting tightening environmental standards |
| Manual operation | High labor requirements, variable product quality |
| Maintenance downtime | Frequent stoppages for kiln repairs |
The customer needed a purpose-built, high-capacity lime production line—not a rebuild or upgrade of existing equipment.
3. Why the Customer Chose Henan Hongke Machinery
After evaluating several suppliers, the customer selected us for specific, practical reasons:
a) Process discussion, not just equipment quotation
Active lime production depends on the interaction of limestone properties, preheating temperature, kiln calcination profile, cooling rate, and combustion control. We discussed these parameters during technical exchange—not just dimensions and price.
b) Design matched to their limestone
Limestone from different quarries behaves differently. We reviewed the customer’s limestone characteristics (particle size, CaO content, impurities) before finalizing the kiln configuration and process parameters.
c) Complete line responsibility
We supplied the full scope: vertical preheater, rotary kiln, vertical cooler, burner system, dust collection, conveying equipment, and PLC controls. The customer did not have to coordinate multiple suppliers.
d) Proven reference in large-capacity lime production
The 1,000 TPD configuration is a well-established design in the industry, with corresponding kiln specifications of approximately Φ4.0×60m and preheater dimensions of Φ10.5×8.5m .
e) Factory inspection and reference review
The customer reviewed our manufacturing facility and similar lime kiln projects before signing.
4. Equipment Configuration
The delivered line is built around a Φ4.0×60m rotary kiln, with a vertical preheater and vertical cooler.
| Parameter | Specification |
|---|---|
| Design capacity | 1,000 TPD active lime |
| Kiln diameter | 4.0 m |
| Kiln length | 60.0 m |
| Kiln slope | 3.5% |
| Rotation speed | Variable frequency drive |
| Calcination temperature | Up to 1,350°C |
| Preheater type | Vertical, multi-chamber |
| Cooler type | Vertical, fixed grate |
| Fuel | Pulverized coal / gas (dual-fuel capable) |
| Control | PLC-based with temperature, speed, and emission monitoring |
Scope of supply:
| System | Function |
|---|---|
| Vertical preheater | Preheats limestone to ~900°C using kiln exhaust gas; partial calcination (~25–30%) before kiln entry |
| Φ4.0×60m rotary kiln | Main calcination unit; limestone decomposes to CaO + CO₂ at 1,100–1,350°C |
| Vertical cooler | Cools lime to <100°C; recovers hot air as secondary combustion air (600–700°C) |
| Multi-channel burner | Heat input and flame control |
| Dust collection | Cyclone + bag filter; outlet dust concentration <50 mg/Nm³ |
| Conveying system | Material transfer between stages |
| PLC control system | Process monitoring, data logging, interlock protection |
5. Delivery Timeline
| Stage | Status |
|---|---|
| Technical exchange and process design | Completed |
| Limestone testing and parameter definition | Completed |
| Manufacturing at Henan Hongke facility | Completed |
| Factory assembly and no-load testing | Completed |
| Shipment to Changzhi, Shanxi | Completed |
| On-site installation | Completed |
| Commissioning and hot testing | Completed |
| Handover to customer | Completed |
6. Commissioning Results
| Performance Metric | Result |
|---|---|
| Production capacity | 1,000 TPD achieved and sustained |
| Lime reactivity | Meeting target for steelmaking applications |
| Residual CO₂ | Within specification |
| Calcination temperature | Stable across operating shifts |
| Fuel consumption | Within expected range for the process |
| Dust emissions | Outlet concentration below regulatory limit |
| Operational stability | Continuous operation achieved |
7. Customer Feedback
“The line has been running steadily since commissioning. Capacity meets our contract needs, and the lime quality is consistent—reactivity is where it needs to be for our steel customers. The engineering team was responsive during installation and commissioning. We’re satisfied with the equipment and the support.” — Production Manager, Changzhi lime producer
8. What This Means for the Customer
| Benefit | Practical Value |
|---|---|
| 1,000 TPD capacity | Meets contract volumes for local steel mills |
| Consistent lime reactivity | Stable steelmaking performance downstream |
| Lower fuel consumption | Reduced cost per ton of lime |
| Environmental compliance | Meets local emission requirements |
| Reliable operation | Fewer unplanned stoppages |
| Full-scope supplier | Single point of responsibility |
9. Building Long-Term Partnerships
Our commitment to the Changzhi customer does not end at handover. We continue to provide:
Technical support on process optimization
Spare parts availability for critical components
Maintenance guidance and preventive maintenance planning
Support for future capacity expansion or process adjustment
About Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd. (Henan Hongke Machinery) has been designing and manufacturing industrial processing equipment since 2006. Our product portfolio includes:
Rotary Kilns – for lime, dolomite, cement, metallurgy, and mineral calcination
Rotary Dryers – for sludge, sand, gypsum, biomass, and industrial materials
Ball Mills – for ore, slag, cement, and chemical grinding
Crushers – for primary and secondary size reduction
We focus on one-stop solutions for mining and materials processing—complete systems, not just individual machines.