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Henan Hongke Heavy Machinery Co., Ltd. designed, manufactured, and commissioned a complete active lime rotary kiln production line in De'an County, Jiangxi Province. The line produces 8,000 tons of high-quality active lime per year, fully meeting the client's requirements for product quality, energy efficiency, and environmental compliance.
De'an County in northern Jiangxi is rich in limestone reserves with convenient transportation, making it an ideal location for lime production. This project demonstrates Henan Hongke Machinery's ability to deliver customized, cost-effective lime production solutions across diverse regions.
System Configuration
The production line adopts the proven vertical preheater + rotary kiln + vertical cooler configuration — the most energy-efficient layout for active lime production.
Vertical Preheater
Hot flue gases (1,000–1,150°C) from the kiln tail preheat limestone to ~900°C inside the preheater, achieving 20–30% pre-decomposition before the material enters the kiln. This cuts fuel consumption by up to 40% compared to systems without a preheater. Hydraulic push rods discharge preheated material into the kiln at precisely controlled intervals.
Rotary Kiln
The core equipment — a slightly inclined, slowly rotating cylindrical furnace lined with refractory bricks. Key specs:
| Parameter | Specification |
|---|---|
| Inclination | 3.5% |
| Rotation speed | 0.36–3.57 r/min (VFD) |
| Support stations | 3 sets of support rollers |
| Combustion temperature | 1,200–1,350°C |
| Seal type | Spring-plate (kiln head & tail) |
The kiln completes calcination of CaCO₃ into CaO and CO₂ at 1,100–1,350°C. A multi-channel burner supports coal powder, natural gas, or mixed fuels with independently adjustable air channels.
Vertical Cooler
Rapidly cools hot lime from ~1,200°C to below 100°C. The fast quenching preserves high reactivity (activity degree: 340–400 ml). No moving parts — relies on gravity and forced air. Recovered hot air (~600°C) is recycled back to the kiln as secondary combustion air.
Exhaust Gas Treatment
A multi-stage system ensures full environmental compliance:
Multi-tube cooler — reduces exhaust temperature from ~280°C to below 200°C
Pulse jet bag filter — PTFE membrane bags, dust removal efficiency >99.9%
Outlet dust concentration: <30 mg/Nm³
Automation
A DCS control system with PLC controllers provides centralized monitoring and control from a single room — covering kiln temperature, preheater levels, cooler output, exhaust composition, and fuel-air ratios. Built-in expert algorithms auto-adjust key parameters for consistent product quality with minimal operator involvement.
Key Advantages
| Advantage | Detail |
|---|---|
| High product quality | Low over-burning rate (<8%), high activity (340–400 ml), low sulfur content |
| Wide raw material range | Processes 10–50 mm limestone directly, utilizing fines that shaft kilns cannot |
| Energy efficient | Specific heat consumption ~5,000–5,225 kJ/kg CaO |
| Eco-friendly | Outlet dust <30 mg/Nm³, fully enclosed process |
| Highly automated | DCS central control, low labor requirement |
| Fast delivery | 6–7 months from design to full production |
Henan Hongke Machinery — Full Project Scope
Henan Hongke Heavy Machinery Co., Ltd. handled every phase of this project:
Customized process design and plant layout
Equipment manufacturing under strict quality control
On-site installation supervision by experienced engineers
Commissioning, parameter optimization, and trial production
Operator training (operation, maintenance, safety)
All equipment factory-tested for 24 hours before shipment
About Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd. is a professional rotary kiln manufacturer and complete lime production line supplier based in Henan, China. The company provides lime rotary kiln lines with capacities from 150 to 1,500+ tons/day, serving clients in China, Southeast Asia, Africa, Central Asia, and the Middle East.
Product range: Active lime rotary kiln lines, vertical preheaters & coolers, coal powder systems, exhaust gas treatment, DCS automation, and turnkey project services.
Contact Us
Looking for a lime rotary kiln production line? Henan Hongke Machinery offers free consultation, customized design, and competitive pricing for any scale.
Contact us today to discuss your project requirements.
