Henan Hongke Heavy Machinery Co., Ltd. has delivered a 10,000-ton-per-year active lime rotary kiln production line to a customer in Shandong Province, China. The line processes limestone into high-reactivity quicklime for local metallurgical and chemical applications.
This article covers the full project: customer background, the original problem, equipment configuration, delivery timeline, commissioning results, and customer feedback.
1. Customer Background
Location: Shandong Province, China
Industry: Metallurgical lime / building materials
Shandong is a major industrial province in eastern China, with a strong metallurgical, chemical, and building materials sector. The region's steel mills, chemical plants, and construction material producers require a steady supply of active lime (quicklime) for fluxing, chemical reactions, and environmental treatment.
Our customer operates a lime production facility in Shandong. They supply local industrial customers. Their existing production setup could not meet demand consistently, particularly in terms of lime reactivity and fuel efficiency.
The target capacity for this project was 10,000 tons per year.
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 industrial customers |
| Inconsistent lime reactivity | Downstream process efficiency affected |
| High fuel consumption | Operating cost per ton above competitive levels |
| Dust emissions | Difficulty meeting Shandong's strict environmental standards |
| Manual operation | High labor requirements, variable product quality |
| Maintenance downtime | Frequent stoppages for kiln repairs |
The customer needed a purpose-built 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) Environmental compliance for Shandong
Shandong enforces strict emission limits for industrial kilns (particulates <10 mg/m³, SO₂ <50 mg/m³, NOx <100 mg/m³ under DB37/2373-2018) . We designed the dust collection and gas treatment system to meet these requirements.
e) Factory inspection and reference review
The customer reviewed our manufacturing facility and similar lime kiln projects before signing.
f) Long-term support commitment
The customer wanted a supplier who would remain available for process optimization and spare parts after handover.
4. Equipment Configuration
The line is built around a rotary kiln, with a vertical preheater and vertical cooler.
| Parameter | Specification |
|---|---|
| Design capacity | 10,000 TPY active lime |
| Kiln type | Rotary kiln with refractory lining |
| Preheater type | Vertical, multi-chamber |
| Cooler type | Vertical |
| Calcination temperature | Up to 1,300°C |
| Fuel | Pulverized coal / gas (dual-fuel capable) |
| Drive system | Heavy-duty gear drive with main and auxiliary motors |
| Sealing | Labyrinth seals with air purge |
| Control | PLC-based with temperature, speed, and emission monitoring |
Scope of supply:
| System | Function |
|---|---|
| Vertical preheater | Preheats limestone using kiln exhaust gas; partial calcination before kiln entry |
| Rotary kiln | Main calcination unit; limestone decomposes to CaO + CO₂ |
| Vertical cooler | Cools lime; recovers hot air as secondary combustion air |
| Multi-channel burner | Heat input and flame control |
| Dust collection | Cyclone + bag filter; meets Shandong emission limits |
| 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 Shandong | Completed |
| On-site installation | Completed |
| Commissioning and hot testing | Completed |
| Handover to customer | Completed |
6. Commissioning Results
| Performance Metric | Result |
|---|---|
| Production capacity | 10,000 TPY achieved and sustained |
| Lime reactivity | Meeting target for local industrial applications |
| Residual CO₂ | Within specification |
| Calcination temperature | Stable across operating shifts |
| Fuel consumption | Within expected range for the process |
| Dust emissions | Within Shandong regulatory limits |
| 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 customers. The engineering team was responsive during installation and commissioning. We're satisfied with the equipment and the support." — Production Manager, Shandong lime producer
8. What This Means for the Customer
| Benefit | Practical Value |
|---|---|
| 10,000 TPY capacity | Meets contract volumes for local industrial customers |
| Consistent lime reactivity | Stable downstream process performance |
| Lower fuel consumption | Reduced cost per ton of lime |
| Environmental compliance | Meets Shandong emission requirements |
| Reliable operation | Fewer unplanned stoppages |
| Full-scope supplier | Single point of responsibility |
9. Building Long-Term Partnerships
Our commitment to the Shandong 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.
Let's Talk About Your Lime Project
If you are planning an active lime production line, expanding capacity, or optimizing lime quality and fuel consumption, we can discuss kiln sizing, preheater and cooler configuration, and expected performance based on your limestone data.
Contact Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd.
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