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LIME

Hydrating
Process

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Lime Technologies

Contents

Page

LIMESTONE ... TO HYDRATED LIME

THE HYDRATION PROCESS

THE HYDRATORS MODELS

THE CIM-ZEROPOLL FILTER

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THE CIM-MICROSEP SEPARATOR

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THE CONTROL SYSTEM

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WORLDWIDE ASSISTANCE

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E
LIM
QUICK

To

Lime
Hydrated

Besides quicklime, hydrated lime is the second major


product of the lime industry.
Hydrated lime (calcium hydroxide) is produced by
reacting quicklime with water in controlled conditions.

CaO + H2O = Ca(OH)2 + HEAT


Hydrated lime is a natural market for quicklime
producers. In fact the hydrated lime is much easier to
handle and is chemically purer.
Cimprogetti has a full range of equipment and plants to
meet every requirement in lime hydration. In particular,
new uses have required new product characteristics,
e.g. enhanced particles fineness for use in flue gas
desulphurization.

The

Process

Hydration
No later than sixty year ago, hydrated lime was
produced by filling a big pit with quicklime and water.
Times impose now closer and closer control over
hydrated lime fineness and specific surface. The highly
exothermic reaction between lime and water must be
carefully controlled in order to drive it towards the
desired product quality and fineness.
The main body of the machine consists of two or three
superimposed chambers, called stages. In the first
stage, the quicklime receives the hydration water from
the water feed rack and is subject to a strong mixing
action. At the end of the first stage the lime falls into the
second stage where the hydrating reaction is mostly or
wholly completed.
During the transformation of the calcium oxide into
hydrate the apparent specific weight of the material is
basically reduced to a half. For this reason, the second
stage volume is twice as big as the one of the first stage.
The third stage (whenever provided) is designed to
further homogenise the finished product, or to allow an
extra retention time to complete reaction for those
quicklime qualities featuring medium or low reactivity.
An adjustable weir allows the lighter hydrated material
to overflow to the discharge, while most of the overburned lime (when in lumps) with a slower reaction
speed and a higher specific weight may be retained for a
longer period enabling the final reaction to take place.
The unburned material (when in lumps) may also be
collected on the bottom of this stage from where it is
periodically removed.

The
Models

Hydrators

Many of the end uses of quicklime require mixing it with


water, that is why it is important to be able to do that
under strictly controlled conditions.
Cimprogetti has developped the following Cim-Hydrax
series, the latest achievement in lime hydration
technology:
Cim-Hydrax (1-2-1)
Cim-Hydrax-TG (2-2-1)
Cim-Hydrax-4G (2-2-2)
Cim-Hydrablock (2-2)
The basic principles which first led to the design of our
Cim-Hydrax hydrators series are mainly the following:
a compact machine capable of converting a given
raw material into high quality finished products with
continuous operation;
sturdy construction, easy to operate with minimum
maintenance required;
high flexibility in terms of turn-down ratio;
wide range of acceptable raw material qualities;
wide range of feasible finished products;
possibility of an automated, unmanned control.

capacity

raw material size


quality
BET (natural)
BET (with additives)

1 to 40 tph

dust to 40 mm

up to 25
up to 40

Note:
Data and performances may change
in function of available raw materials.

hydrator

Cim-HYDRAX (1-2-1)
The Cim-Hydrax hydrator has a first stage with one shaft
allowing to use large quicklime lumps.
This equipment is Cimprogetti traditional hydrator
operating throughout the world for over 40 years.
Its ability to handle lime in large lumps may contribute to
an improvement of the resulting hydrated lime thanks to
the possibility to settle down and remove the larger
unburnt / overburnt granules.
The Cim-Hydrax standard design can be summarised in
:
able to handle quicklime in lumps up to 40 mm;
retention time approx. 15 / 20 minutes;
design for lower quality lime, as it may still be
produced in the older lime kilns.

hydrator

Cim-HYDRAX-TG (2-2-1)
The Cim-Hydrax-TG hydrator is a three-stage machine
with specially designed hi-efficiency paddles to mix
continuously the reacting lime and the water.
Paddles have different design in the various hydrator
stages for the optimum matching of their specific
operational performances.
The Cim-Hydrax-TG series features a first stage with
two high-speed shafts, equipped with an advanced
multi-point water injection system for the most accurate
control of the initial phase of the slaking process.
The specially designed water sprayers assure the best
coverage and water distribution over the first stage thus
improving the reaction efficiency.
The second stage with double counter rotating shafts,
strongly mix the material, favoring the completion of
reaction in the large volume of this second chamber
which is approximately the double of the first one.
The third stage, with its specially designed paddles and
in conjunction with a new improved overflow weir, is
vigorously ventilating the hydrated lime in order to
minimize any possible light agglomeration so that the
hydrate coming out of the Cim-Hydrax hydrator is
already of enhanced fineness.

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hydrator

Cim-HYDRAX-4G (2-2-2)
Cim-Hydrax-4G (2-2-2) is the further evolution of the
TG series, developped to produce enhanced fineness of
raw hydrate, in order to allow its use for FGD
applications without other downstream treatments, or
high quality high reactive lime for industrial uses.

hydrator

Cim-HYDRABLOCK (2-2)
Design characteristics:
factory pre-assembled and pre-tested;
ready for automatic in-line operation with FGD
scrubbing system;
for high reactive lime;
st
nd
high speed 1 & 2 stage;
multi-point water injection.

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Hydrator

The

Pilot

Very effective testing campaignes at clients plants sites


are possible.
The results of the tests are effectively used for the
design and supply of the industrial scale hydrator which
is best matching the client objectives.
Technical features:
production:
dimensions:

up to 130 kg/h
L3800x660xH3850 mm

(including feeding & discharge screw conveyor and bag filter)

electric board dim.: 800x600x2100 mm


installed power:
5 kW
total weight:
1600 kg (including eletric board)
Client should provide a quicklime feeding hopper above
screw conveyor and a collection systema of hydrated
lime (e.g. a big bag), the electric power connection to the
board and water connection to hydrator.

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The

filter

Cim-Zeropoll
The Cim-Zeropoll is the dedicated bag
ting. It is based
filter for hydrators dedusting.
se-jet cleaning
on the well proven pulse-jet
epresents the
system. This device represents
most modern pollution control system
and it is responding in full up to the
ality standards
most stringent Air Quality
mission content
with the lowest dust emission
at the stack.
The bag filter is located on the top of the
hydrator as a result of extensive
studies and industrial experiences.
election and
The filtering area selection
e also the result
operatin parameters are
ng to determine
of several years of testing
o and the most
the right air to cloth ratio
suitable fabric for the bags, featuring
good value for money and extended
operation life.
The ID fan is controlled by a frequency
converter, to adapt the filter operation
to the variable flow of steam that the
e in different
f
hydrator may generate
operating conditions.
so be installed
The Cim-Zeropoll can also
on any hydrator of similarr design.

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The

Separator

Cim-Microsep
The Cim-Microsep separator is designed to ensure
ontrol of the endmaximum efficiency & quality control
product.
f
The separator is highly adaptable to different
fineness
ks to the wide range
requirements of the product, thanks
and combination of regulationss applicable to the
e and to the air flow.
rotation speed of the selection cage

Drive shaft

Pressure sensors in the circuit and selection cage


speed control assure a smooth and stable running of the
separator.

The raw material entering


through the feed inlets is
subject to centrifugal force,
which uniformly distributes
the material within the air
stream. The ascending air
flow pushes the material
towards the multi-blade
selecting cage. The fines are
then exhausted into the
system collector, while the
coarse material is discharged
by gravitational force through
a cone for further processing.

Material feed inlets

Fines / air
outlet

Separating cage

Material distribution plate

Air inlet
Coarse material
discharge

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HIGH-EFFICIENCY
SEPARATION TOWER
CIM-MICROBLOC
The Cim-Microbloc is an integrated tower, which
has been designed to join the highest
separation efficiency with a compact, standalone unit which houses all auxiliary
components for the separator process.
Flexible layout, simple plant arrangement, the
separation tower concept is very suitable for the
revamping of existing plants.
Main features:
The separation tower responds to the demand
for a cost effective upgrading of existing
hydration units:
Reduce to the minimum the downtime of the
plant during the upgrade works;
The tower is installed and put on-stream in a
few days as it requires minimal interfacing
works with the plant;
Installation is eased by the Cim-Microbloc
total mechanical and electrical shop preassembly.

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Separator
Plant configurations with the

Cim-Microsep

CIM-MICROCLON concept

Two separation circuits CIM-MICROSEP plus CIM-MICROCLON


for contemporary production of no.2 hydrate grades

Two sequential separation circuits enable the contemporary production of a 1st grade with higher
Ca(OH)2 content (called chemical grade) and of a 2nd grade (called building grade);
Higher production flexibility by adjusting the ratio of production of 1st grade vs. 2nd grade to
follow market demand.
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The

System

Control

Having always been sensitive to technical innovation


and striving to add value to its plants, Cimprogetti has
studied, designed and realized its own control system,
which is continuously updated on the basis of the
experience gained in the design and commissioning
kilns worldwide.
Designed for industrial environments, where the
security of data and personnel is a primary issue, the
control system manages all the problems relevant to the
regulation, control and tracking of data and functions of
plant operation while keeping its user friendly
characteristics.
Last but not least, remote data transfer and analysis of
the kiln operation, alarm management as well as on line
scheduled maintenance support, are only but a few of
the standard features of the Cimprogetti control
package.
Cimprogetti control system is the software of the lime
experts.

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Assistance
Worldwide
From our headquarters or directly on site, our
specialists are fully committed to support our
customers in all phases of a project...
be it a brand new installation,
or the modernization of existing units,
or simply to support plants operational
requirements,
or training operators on all phases of kilns
use and maintenance.

The CIM-ONLINE package has made possible


to visualize in remote operations and assist
customers from the headquarters in Italy.

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Cimprogetti s.p.a. - M-A. Grellier - 10.2013

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Environment Certification

Cimprogetti S.p.A.
Via Pasubio 5, ang. Via Einstein | 24044 Dalmine (Italy)
T: +39 0354550 111 | F: +39 0354550 335
E: inform@cimprogetti.com | www.cimprogetti.com

group

Industrieanlagenbau GmbH

Cap. soc. Euro 1.000.000 i.v. | r.e.a. 119273 | P.E.C. pec@pec.cimprogetti.com | c.f./ p. IVA / registro imprese di BG 00221170160 | S.p.A. a socio unico - soggetta a direz. e coord. di FMW Industrieanlagenbau GmbH (A)

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