Customer: GHCL
Project: Lime kiln package for Soda Ash plant
Location: Mandvi, Gujarat
Document: Lime kiln specification (Single fraction feed)
Date: 28.02.2024
S. No. Description Units Specification Vendor’s Inputs
A GENERAL GHCL Eberhardt/CJM
1 Kiln Type Vertical Shaft Kiln KR 8.0
3 X 450 TPD
2 Total CaO(active) t/d 1070
Burnt lime
3 Number of Kilns nos Vendor to specify 3 nos as above
B PROCESS PARAMETERS
6 min/ charging
4 Operation time considered Min/cycle
cycle
450 TPD Burnt
5 Capacity of each kiln in terms of CaO(active) tpd 350 or higher capacity
lime max.
6 Per day Limestone consumption (Indian / Imported) tpd Vendor to specify Later
7 Per day fuel consumption (for Indian / Imported Limestone) tpd Vendor to specify Later
8 Limestone size (main size) mm ~40 - 120 80-120
9 Limestone size (Periferal) mm ~20 - 40 80-120
10 Fuel size (main size) mm ~30 - 60 40-80
11 Fuel size (Periferal) mm ~15 - 30 40-80
12 Cooling sea water temperature °C 34 deg. C
13 Cooling sea Water pressure barg 2.2
14 Instrument air (free of oil and water) operating barg 3.5
15 Voltage kV 0.415 (+/- 3%)
16 Frequency Hz 50
17 Altitude above mean sea level m ~5
Ambient temperature
18 Lowest temperature °C 8
Maximum temperature 45
C Lime Stone composition Considered (Domestic)
Noted, Spec as
19 CaCO3 (Average / Design) min wt% 94
given by GHCL
Noted, Spec as
20 MgCO3 (Average / Design) max wt% 2.4
given by GHCL
Noted, Spec as
21 SiO2(Average / Design) max wt% 2
given by GHCL
Noted, Spec as
22 R2O3 (Average / Design) Fe2O3/Al2O3 max wt% 0.8
given by GHCL
Noted, Spec as
23 Adhering Moisture wt% 0.8
given by GHCL
Noted, Spec as
24 Crushing Strength kg/cm2 1500
given by GHCL
25 Bulk density (Loose) t/m3
26 Sieve analysis of Domestic Limestone (Before sieving which is not included in vendors scope)
% Fraction, mm Average of Sample readings
110 7.46
100 11.19
50 61.91
30 12.26
-30 7.2
D Lime Stone composition Considered (Imported)
Noted, Spec as
27 CaCO3 ( Design) wt% 97.5
given by GHCL
Noted, Spec as
28 MgCO3 (Design) wt% 1
given by GHCL
Noted, Spec as
29 SiO2( Design) wt% 0.5
given by GHCL
Noted, Spec as
30 R2O3 (Average / Design) Fe2O3/Al2O3 wt% 0.3
given by GHCL
Noted, Spec as
31 Adhering Moisture wt% 0.5
given by GHCL
Noted, Spec as
32 Crushing Strength kg/cm2 1600
given by GHCL
Noted, Spec as
33 Bulk density (Loose ) Kg/m³ 1.62 mt/m3 ( Typical value )
given by GHCL
34 Sieve analysis of Imported Limestone (Before sieving which is not included in vendors scope)
% Fraction, mm Average of 10 readings
110 0.04
100 0.74
50 82.25
25 7.85
-25 9.12
Coke Composition
E
Quality of available Metallurgical Coke (solid fuel)
Noted, Spec as
35 Fixed Carbon (Average /Design) Wt % 82-83 %
given by GHCL
Noted, Spec as
36 Ash (Average /Design) Wt % 10.85 - 11.58
given by GHCL
Noted, Spec as
37 Sulphur content (max.) Wt % 0.6
given by GHCL
Noted, Spec as
38 Volatile Matter (Average /Design) Wt % Below 2 %
given by GHCL
Noted, Spec as
39 Moisture (Average /Design) Wt % 3-5 %
given by GHCL
Noted, Spec as
40 Net calorific value kcal/Kg 6661 - 6817
given by GHCL
Noted, Spec as
41 Bulk density t/M3 0.63
given by GHCL
Noted, Spec as
42 Size: ( used in Lime Kilns ) mm 30 - 60
given by GHCL
43 Hardness according to abrasion strength process : DIN 51717
Actual
Parameters Specifications
(Typical value)
M 16 5 % Max. 2.18%
M 40 70 % Min. 80.20%
M 10 10 % Max. 6%
CSR ( Coke strength after reaction ) 63 - 66 62.35
CRI ( Coke reactivity index ) 24 - 26 25.2
Anthracite Composition
F
Quality of available Anthracite (solid fuel)
44 Net calorific value kcal/Kg 6923 - 7026
45 Sulphur content (max.) Wt % 0.3 Max.
46 Ash content (max.) Wt % 4.31 - 4.85
47 Size: ( used in Lime Kilns ) mm 30 - 60
48 Bulk weight t/M3 1.1
49 Hardness according to abrasion strength process : DIN 51717
PARAMATER SAMPLE NO.1 SAMPLE NO. 2
M40 : % Weight of Coal retained on
44.88% 36.80%
40 mm sieve
M10 : % Weight of the coal passed
26.92% 26.34%
through 10 mm sieve
Weight of Coal retained on 10 mm
sieve and passed through 40 mm 28.20% 36.86%
sieve ( I.e.-40 mm + 10 mm )
G Kiln Gas Composition (Domestic Lime stone)
50 CO2 vol% Dry Basis Vendor to specify 40 +/- 1%
51 O2 (Max) vol% Dry Basis <1 %
52 CO (Max) vol% Dry Basis <1 %
H Kiln Gas Composition Imported Lime Stone
53 CO2 vol% Dry Basis Vendor to specify 40 +/-1%
54 O2 (Max) vol% Dry Basis <1 %
55 CO (Max) vol% Dry Basis <1 %
I PROCESS PARAMETER
56 For Domestic Limestone (Base case-94% CaCO3)
57 Heat Consumption kcal/Kg of lime Vendor to specify 800
58 Power Consumption (Only for Lime Kiln) KWh/Ton of Lime Vendor to specify 10.8
59 Residual CO2 content in the lime % < 6.6 6 +/-1.5%
60 Active CaO in lime Wt % > 65 70 +/-5%
61 CaO(inactive) and other inert impurities % < 15
62 Coke consumption Kg/MT Vendor to specify later
63 Dust content at the outlet of cleaning system mg/Nm³ 15
64 Kiln gas volume Nm³/hr Vendor to specify Later
65 Kiln Gas Outlet temperature Deg C Vendor to specify 90-180
66 Kiln Pressure Drop mmWG Vendor to specify
67 Lime Temperature Deg C Vendor to specify 80-120
68 Combustion air Nm³/hr Vendor to specify
69 For Imported Limestone (97.5% CaCO3)
70 Heat Consumption kcal/Kg of lime Vendor to specify 900
71 Power Consumption (Only for Lime Kiln) KWh/Ton of Lime Vendor to specify 11.8
72 Residual CO2 content in the lime % Vendor to specify 6 +/-1.5%
73 Active CaO in lime Wt % Vendor to specify 80 +/-5%
74 Coke consumption Kg/MT Vendor to specify later
75 Dust content at the outlet of cleaning system mg/Nm³ 15
