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1. Background
In a shaft kiln there are three zones in which distinct operations involving heat transfer
take place.
They are:--
a) The preheating zone, in which the limestone is dried and heated to
calcination temperature.
b) The calcination zone, in which the stone dissociates.
c) The cooling zone, in which the quicklime is cooled.
The quality of the lime is most influenced by the conditions in the calcination zone.
Here, heat must be supplied at a temperature above the calcination temperature; which
consequently results in a sufficiency of heat in the combustion gases and dissociated
carbon dioxide to adequately heat the stone in the preheating zone. Unless the required
product is a hard burnt lime, or dead burnt lime, the rate of heating in the calcination
zone must be carefully controlled to ensure that there are no 'hot spots' or cool
channels. Most of the design variations of shaft kilns are attempts to address this aspect
of the kiln performance.
The available shaft kiln technologies fall into following four types.
a. Single shaft
b. Double shaft (recuperative)
c. Annular
d. Inclined
The following pages give brief descriptions of typical kilns of each type, and a summary
table of their operating characteristics is given at the end of this file.
3. Single Shaft Kilns
These are the most common forms of kiln in use. The vintage and number of
manufacturers are large:--
The mixed feed kiln is the most basic and oldest shaft kiln design, in which alternate
layers of stone and fuel are laid on to the top of the preheating zone, and are then
drawn down through the kiln as material is discharged at the bottom. Mixed feed kilns
are still widely used in the ammonia soda process, and in regions of the world where the
infrastructure and technical support are limited. The designs range from very basic
small open top, hand loaded kilns relying on natural chimney draught to induce air
through the bed, to large automatic feed and discharge, forced draft units. The latter are
highly efficient, whereas the former are not.
A significant advantage of this type of kiln is that it can be operated to produce
consistently low lime reactivity. Higher reactivity is usually only obtained at the expense
of a higher level of residual CaCO3, which is not the case with more modern kiln
designs. They are typically fired on a low volatile coal (anthracite) or metallurgical coke,
o
both of which have high ignition temperatures (~800 C). Higher volatile solid fuels, such
as wood, tend to release the volatile components of the fuel in the preheating zone,
which results in the excessive emission of smoke and a loss of some of the calorific
value of the fuel.
West kilns
These kilns are designed for two basic outputs, 50 and 100 tons/day lime, although
more recent experience with these units has shown that they are capable of
considerably increased output with suitable modification. They were originally designed
for oil firing, using four, five or six 'carburetors' equally spaced around the kiln at the
base of the calcining zone, the idea being to flash vaporize the oil on the hot walls of the
carburetor chamber. This was achieved by injecting a solid rotating jet of oil which
partially combusted with about 15% stoichiometric air, before entering the burning
zone, where it meets the cooling zone air and some recycled flue gas. An original
schematic is shown in Fig 1. The original oil-firing concept was later abandoned for
simple rotating oil injection onto the stone bed, and they have also been successfully
operated using natural gas as the fuel.
Esjornsson
This kiln is of Swedish design in which the preheating zone is hexagonal, tapering into a
rectangular burning zone of approximately 3.0m by 1.2m, and then opening out into a
square cooling/discharge zone. A separate gasification unit is used to provide the heat
to the calcining zone. Water sprays cool the gasified fuel before being injected into the
calcining zone at two levels.
These kilns were originally designed by Union Carbide as mixed-feed, coke-fired units
They were first converted in 1952 to gas or oil fired using water cooled burner beams at
two levels and are now marketed by Fercalx. The ability to inject fuel at a large number
of discrete points within the bed in the calcining zone enables a more even heat
distribution to be achieved, although mechanical failure, distortion and the higher heat
usage due to the beam cooling tend to outweigh this potential advantage.
Azbe
There are a large number of Azbe kilns in the USA, and other parts of the world, and
there are a number of variations as the technology has developed. Typically, these kilns
are of curved rectangular cross section, with a multiple level refractory burner beam for
fuel, air and flue gases at the base of the burning zone on the longer kiln axis.
Westofen
This kiln design is similar to the West kiln using flue gas recycle and side firing at the
base of the burning zone. Figure 2 shows a schematic of the design.
This kiln design of Japanese origin is based on fixed bed preheater technology as
developed in the Davis preheater, or the Kraus-Maffai preheater.
4. Double Shaft Kilns
Double shaft kilns have been in use since the 1960's, and were developed to overcome
the problems of increased bed resistance to gas flow with smaller sized stone. They
employ the technique of regenerative flow, whereby two, or more, shafts are fired singly
in a cyclic sequence, the flue gases exhausting through the non-fired shaft(s), thereby
effecting heat recovery. They generally have very good specific fuel consumption, but
are more costly in electrical requirements due to the need for air blowers, rather than
fans. There follows a resume of the currently available double shaft kilns.
Maerz
The Maerz kiln design is probably accepted as the most successful double shaft kiln.
Fuel is burnt in the upper end of the burning zone in one cylindrical shaft, and the hot
gases flow co-currently with the charge in that shaft, and then via a connecting duct to
the other shaft, where they flow counter-currently to the charge. The second shaft thus
acts as a recuperator. After a given time, the roles of the shafts are reversed. It is
claimed that since the flow of gases and stone are in the same direction in the burning
zone, the risk of overheating the lime is reduced, and a softer burnt, more reactive lime
results. The kiln designs come in two forms, a standard and a finelime kiln.
The finelime kiln, which is a later development of the standard design, has a smaller
rated capacity for any given geometric size relative to the standard kiln, and contains
more refractory. Fig 3 shows a schematic of the kiln system.
There are two types of inclined kilns, which have been developed to cater for small
stone.
Double Inclined
The double incline kiln was developed by Warmestelle, Steine und Erde Gmbh, and is
now made by Beckenbach. The principal is to lengthen the burning zone, producing a
milder flame, with more even heat distribution and transfer without the need for flue gas
recycle. The kiln cross-section is rectangular, widening for two firing chambers.
Considerable care is needed in selection of the refractory lining, due to the complex
geometry. Waste gas and dust losses tend to be high, but the material residence time is
typically about half of a conventional shaft kiln. Fig 6 shows a schematic of the kiln
system.