2.7 Limestone System

Asiakirjan nimi - Name of Document Tunniste - Identification Rev.
PROCESS DESCRIPTION CFBT-582-1 1

2.7 LIMESTONE
Osasto - Department Kohde - Subject Sivu - Page
Power Generation RAPP PB3 PROJECT 1 (34)

Systems CFB MULTIFUEL BOILER
TABLE OF CONTENTS
2.7 LIMESTONE SYSTEM.................................................................................. 3
2.7.1 Purpose of the system ................................................................................ 3
2.7.2 General description of the system............................................................. 4
2.7.3 Closer description of the equipment ......................................................... 7
2.7.4 Design criteria............................................................................................ 16
2.7.5 Equipment specification ........................................................................... 17
2.7.5.1 Limestone receiving hopper ........................................................................ 17

2.7.5.2 Limestone hopper vibratory feeder .............................................................. 17
2.7.5.3 Limestone intake belt................................................................................... 18
2.7.5.4 Magnet ........................................................................................................ 18
2.7.5.5 Limestone mill feed hopper ......................................................................... 19
2.7.5.6 Limestone mill vibratory feeder.................................................................... 19
2.7.5.7 Limestone mill and separator ...................................................................... 20
2.7.5.8 Limestone mill fan........................................................................................ 22
2.7.5.9 Limestone drying unit burner ....................................................................... 23
2.7.5.10 Limestone air heater fan.............................................................................. 24
2.7.5.11 Limestone cyclone....................................................................................... 24
2.7.5.12 Limestone cyclone rotary feeder.................................................................. 25
2.7.5.13 Limestone bag filter ..................................................................................... 25
1 2005 - 08 - 30 T. Anttonen
0 2005 - 03 - 09 T. Anttonen
Muut. Pvm Laatinut Pvm Tarkastanut Pvm Hyväksynyt
Rev. Date Prepared by Date Reviewed by Date Approved by
KLY-1 1997-05 P:\582-RAPP-PB3\int\Kayttoonotto\koulutus\Training Manuals\Folder 1\2.7 Limestone system(1).doc

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project
or purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005

2.7 LIMESTONE

2.7.5.14 Limestone bucket elevator........................................................................... 27

2.7.5.15 Limestone feeding silo................................................................................. 27
2.7.5.16 Limestone feeding screw............................................................................. 29
2.7.5.17 Limestone rotary feeder............................................................................... 30
2.7.5.18 Limestone injection piping ........................................................................... 31
2.7.5.19 Limestone injection air blower ..................................................................... 32

2.7 LIMESTONE

2.7 LIMESTONE SYSTEM
Flowsheets: T582-00030 Limestone drying

T582-00031 Limestone feeding
2.7.1 Purpose of the system
The purpose of the limestone system is to supply to the boiler

limestone needed for sulphur removal from the flue gas. Big and
moist limestone particles are first crushed and dried in a
separate limestone prehandling factory.

2.7 LIMESTONE

2.7.2 General description of the system
Limestone is delivered to the intake hopper (283T018), and a

vibratory feeder (283C032) discharges onto the inclined belt
conveyor (283C033), which discharges into the mill feed hopper
(283T027). The feed is extracted from the feed hopper by a
vibratory feeder (283C035), automatically keeping the mill at
constant load.
In the mill (283E099) plows throw the material between the

rollers and the die ring for grinding. The rollers are forced
against the die ring by centrifugal action, creating great grinding
pressure and automatically compensating for wear.

2.7 LIMESTONE

Hot air is drawn into the mill (283E099), to dry the material being
ground and to carry the powder from the mill to the separator
(283E099), which allows only the correct particles size to pass.
The ground product is blown to the (limestone) cyclone
(283E124), where it is separated from the air stream and
discharged to the bucket elevator (283C038), which feeds the
limestone storage (or feeding) silo (283T019).
Air from the cyclone (283E124) passes through the mill fan
(283K017) and returns to the mill (283E099). Part of the air is
vented through a bag filter (283E097), and this is replaced by
hot air from the heater (283E126). The heater firing rate is
automatically controlled to keep the product moisture constant.
Collected dust from the filter (283E097) is also discharged to the

bucket elevator (283C038) and furthermore conveyed to the
limestone storage (or feeding) silo (283T019).
From limestone silo (283T019) material falls through the hand

operated slide gate to the variable frequency controlled dosing
screw feeder (283C039). Above screw feeder there is an
intermediate hopper. On the intermediate hopper there is a low
level detector which controls the fluidising valves (3pcs) near the
discharge chute of the silo. If low level detector gives alarm
fluidising is started as long as the material level is under low
level.
On the screw feeder pocket there are three screw feeders

(283C039) which discharge material to the rotary feeder
(283E101). Rotary feeder rotor is divided to three separate
blocks so that each screw feeds material to its own section.

2.7 LIMESTONE

After rotary feeder (283E101) there are three separate

pneumatic feeding lines, one for each section of the rotary valve,
where the material is falling from the rotary feeder. Pneumatic
line pressure is controlled by the magnetic valves. Limestone
feeding capacity is controlled by the speed regulated screw
feeders (283C039).
Furthermore pneumatic feeding is divided to six feeding points at

furnace front wall. Feeding openings are located close to the fuel
feeding points. The pneumatic conveying air comes from a
separate high pressure blower (283K014).

2.7 LIMESTONE

Amount of dosed limestone is adjusted according to fuel sulphur

content and boiler load and fine tuning is carried out based on
flue gas SO2-measurement. B B
2.7.3 Closer description of the equipment
Limestone mill and separator (283E099)
Limestone is fed to the mill by the vibratory feeder, and the feed
rate is automatically controlled to keep the mill motor load steady
at the required level.
The plows pick up the stone and throw into the path of the
rollers, into the gap between the rolls and the die ring.
The rollers are pivoted on the trunnion shafts and try to swing
outwards under the centrifugal action when the mill is turning.
The stone is crushed between the outward force of the rolls and
the resisting force exerted by the die ring.
This force varies with the mill speed, and optimum conditions are
achieved when the mill speed is set to maintain a minimum
thickness of stone between the rolls and ring, maximising
crushing efficiency and minimising metal-to-metal contact. This
optimum speed is determined during commissioning to suit the
nature of the stone, the throughput of the mill, and the fineness
of the product required.

2.7 LIMESTONE

Figure 1 Section through Bradley Mill
Hot air enters the mill through the vanes in the base below the
die ring, to dry the stone and sweep fine particles out of the mill
to the separator above. The combination of the plow action and
the air flow create a fluid bed in the mill base to sweep fine
particles away as soon as they are formed, minimising the
production of excessive fines, and maximising efficiency.

2.7 LIMESTONE

The air temperature leaving the mill is measured and used to

control the burner, so automatically adjusting the fuel
consumption to match the changes in feed moisture content.
Typical exit temperatures range from 60°C to 90°C depending
upon the product moisture required.
The separator is a simple static classifier, mounted on anti-

vibration supports above the mill. It has no rotating parts.
Figure 2 Adjusting the Separator

2.7 LIMESTONE

By adjusting the height of the separator cone the size of

particles able to leave the mill can be adjusted. Raising the cone
will give a finer product, lowering it will make a coarser product.
Oversize particles fall back into the mill for more grinding. There
is a scalping ring at the top of the separator cone which can be
used to give some further adjustment of the product size, if
lowered it will deflect larger particles back to the mill.
Limestone bag filter (283E097)
The dusty air enters the housing, and passes through the filter
bags. The bags retain the dust particles on their outside surface,
and clean air travels through the venturis into the upper plenum
chamber to the exhaust. A gauge indicates the differential
pressure across the bags in millimeters of water, and is a good
indication of collector performance.
The filter housing is dust tight and divided by the bag plate into a
lower section, enclosing the filter bags, and an upper plenum
housing the blow tubes.
The bags are 122 mm diameter snap ring type, and fit over the
galvanized cages, which have integral venturis. Each bag has a
snap ring at the top which seals to the bag plate.
Blow tubes are located above each row of filter bags, and the
blow holes are directly aligned with the throat of each venture in
the corresponding rows. Each blow tube has a diaphragm valve
at the inlet to admit the high pressure cleaning air.

2.7 LIMESTONE

Figure 3 Limestone bag filter

2.7 LIMESTONE

The timer opens the solenoid pilot valve for a short time, which
releases the pressure on the diaphragm valve so that it opens
and lets a pulse of high pressure cleaning air flow from the
header pipe to the blow tube.
The pulse discharges through the blow holes into the venturis to
induce a reverse air flow for cleaning all the bags in the row.
After a pre-set interval this sequence is repeated for the next
row of bags, and ultimately the whole unit is cleaned.
Only a fraction of the total area is cleaned at one instant,

continuous flow is assured, and the dust loading on the bags
stabilizes.
The discharge hopper has a screw conveyor and rotary valve for
continuous discharge of the dust collected.
Limestone drying unit burner (283E126)
The burner consists of a perforated cone located within a

cylindrical housing. A sonic fuel oil nozzle mounts centrally in a
flame-retention head at the peak of the cone, which is encircled
by a manifold. A diffuser is mounted at the downstream end of
the cone and an outlet ring covers the last row of air apertures.
This diffuser directs the fuel-air mix toward the inside wall of the
cone. The “air curtain” effect developed across the last row of
apertures combined with the negative pressure area developed
at the base of the cone, serve to contain the flame and pull it
back into a short heart-shaped pattern.

2.7 LIMESTONE

Figure 4 Limestone drying unit burner
The burner parts are corrosion and heat resistant 330 stainless
steel with welded construction throughout. The diffuser support
rods are allowed to move freely through locater holes to
compensate for thermal expansion.
The air temperature upstream of the burner must not exceed

200ºC, and the downstream temperature must not exceed
500ºC. The wingcone operates most efficiently with a 2,5mbar
pressure drop across the burner; it will perform satisfactorily with
pressure drops from 2 to 4mbar.
Ignition is by gas pilot. Oil is supplied to the sonic nozzle through

the oil inlet. It is atomized for combustion in an intense sonic
field generated by the action of the atomising air on the nozzle
resonator. The atomized oil is mixed with combustion air
introduced through louvers in the burner head-plate. As this
combustible mixture burns, it forms a cone-shaped pattern just
forward of the nozzle. The louvers in the head-plate impart a
swirling vortex to assure complete, even combustion.

2.7 LIMESTONE

As the fuel rate is increased, the oil flame burns further out
within the cone. Combustion air is supplied in the correct
proportions at various firing rates by the graduated rows of air
apertures in the cone. At low input the oil flame is blue, shading
to intense yellow-white as the firing rate is increased. A 20:1
turndown ratio can be achieved by modulating the atomising air.
Figure 5 Limestone drying unit burner, operation principle

2.7 LIMESTONE

Figure 6 Schematic picture of the limestone prehandling

2.7 LIMESTONE

2.7.4 Design criteria
Limestone
Requirement for limestone is the following:

Particle size before crushing:
100 % mm < 25
Reactivity TGA index based on Kvaerner

Power analysis method % >50
Limestone properties according to report

dated February 09, 2001 and laboratory test
in Finland 19.06.2003:
CaCO3 B B % 96,6 – 97,1
MgCO3 B B % 1,5 - 3,0
Assumed maximum moisture content % 3
Limestone prehandling factory
Equipment is capable to handle 40t/h limestone when having

properties as explained above. The expected maximum end
moisture of the limestone is 0,5%.
The expected limestone size distribution after the prehandling is:

99 % mm <2
50 % mm < 0,2
20 % mm < 0,045

2.7 LIMESTONE

2.7.5 Equipment specification
2.7.5.1 Limestone receiving hopper
Equipment number 283T018

Number pcs 1
Manufacturer RAPP (Bradley Pulverizer
Company design)
Volume m3 P
P
20
Dimensions m 4x3
Feed height m 5
Material steel
Equipment
− weather cover
− supports to ground
2.7.5.2 Limestone hopper vibratory feeder
Equipment number 283C032

Number pcs 1
Manufacturer Bradley Pulverizer Co
Model ROTEX SFH32
Capacity (max) t/h 60
Drive kW 0,5
Accessories
− thyristor in local panel

2.7 LIMESTONE

2.7.5.3 Limestone intake belt

Number pcs 1
Manufacturer Universal Conveyor
Size (length x wide) m 29,1 x 0,6
Speed m/s 0,75
Drive kW 5,5
Materials:
− 2 ply nylon
− 3 mm rubber face
− 1,5 mm rubber reverse
Accessories
− dust covers
− supports to ground
− foundation bolts
2.7.5.4 Magnet
Equipment number 283E095

Number pcs 1
Manufacturer Master Magnets
Type 6 PSM 4 (permanent
magnet)
Motor kW 2
Accessories
− suspension chains
− draw plate to remove tramp iron

2.7 LIMESTONE

2.7.5.5 Limestone mill feed hopper

Number pcs 1
Company design)
Dimensions m 5x3
Feed height m 8,5
Material steel
Equipment
− weather cover
− isolating slide gate at exit
Level probes
U U
Type Magnetrol VSH-S2BA-00

Size 235 insertion lenght
Quantity 3 off
2.7.5.6 Limestone mill vibratory feeder

Number pcs 1
Model ROTEX SFH38
Drive 0,9 kW with variable amplitude from
automatic thyristor drive
Accessories
− local panel houses controls to keep mill amps contstant

2.7 LIMESTONE

2.7.5.7 Limestone mill and separator
Figure 7 Grinding chamber of the limestone mill
Limestone mill
U U

Number pcs 1
Manufacturer’s type BM20
Pendulum 3 roller
Capacity t/h 40
Materials
− cast iron base
− cast steel gearbox, grinding chamber and roll carrier
− wear resistant cast alloy die ring and rollheads

2.7 LIMESTONE

Accessories
− four large spanners (special tools)
Drive
U U
Type Bradley supply belt drive

and pulleys with slide rails
Motor (supplied by RAPP) kW 250 (6 pole)
Limestone mill lubrication pump

U U
Equipment number 283P030

Manufacturer Coulthard
Type D, CODE 1162 (Lubricator for
gearbox with low pressure switch)
Motor kW 0,18
Limestone mill purge air fan

U U
Equipment number 283K018

Manufacturer Alldays & Peacock
Type 1425QT/LS (Air fan for mill rolls)
3
Flow at design point m /hP P 400
Motor kW 3
The airswept mill system grinds, classifies and dries material

simultaneously. Pulverized material from the grinding zone is
carried by air stream to a separator, mounted directly above the
mill. Product-size material is carried to the collection cyclone
while oversize particles are rejected and recycled for further
grinding.

2.7 LIMESTONE

Limestone separator
U U

Number pcs 1
Type IC20 (Inverted cone
separator)
Adjustment hand winch to raise or lower
inner cone
Capacity t/h 40
Material steel
Accessories
− antivibration mountings
− isolating rubber sleeve at base
2.7.5.8 Limestone mill fan

Number pcs 1
Type 1200BA75 (centrifugal)
Capacity m3/h P P 50000
Material steel
Drive Vee belt drive, guard and
base frame with slide rails
Motor (supplied by RAPP) kW 250 (4 pole)
Accessories
− rubber sleeve on inlet (anti-vibration)

2.7 LIMESTONE

2.7.5.9 Limestone drying unit burner

Number pcs 1
Manufacturer NU-WAY
Type Wingcone (fully modulating diesel
burner, sideplate mounted in duct
packaged heater)
Maximum capacity kW 1500
Maximum oil flow (5,5 barg) l/h 170
3
Atomising air flow (3 barg) m /hP P 36
Flame lenght m 1,2
Pilot propane / cycle (60 mbarg) l 20
Materials
− cast iron manifold
− stainless steel diffuser plate and end wings
− mil steel housing
Accessories
− panel with controls and temperature indicator direct mounted on
duct
− flame monitoring
− ignition system
Burner is automatically adjusted to keep mill exit temperature

constant.

2.7 LIMESTONE

2.7.5.10 Limestone air heater fan

Number pcs 1
Manufacturer Fans & Blowers
Manufacturer’s type 23/15 R180
Flow at design point m3/h P
P
1745
Motor kW 2,2 (2 pole)
2.7.5.11 Limestone cyclone

Number pcs 1
Company design)
Type Standard mill cyclone
Dimensions, diameter mm 3600
Efficiency % 90 – 92
Material steel
Accessories
− fixing bolts to steelwork
− support to ground level

2.7 LIMESTONE

2.7.5.12 Limestone cyclone rotary feeder

Number pcs 1
Manufacturer Rotolok
Type 450 (rotary airlock)
Size, diameter mm 450
Drive Geared motor with chain
set and guard
Motor kW 1,5
The airlock has cast iron body, end covers and gland followers.
The closed rotor has replaceable abrasion resistant tips. The
bearings are sealed for life, and the gland packing is PTFE.
2.7.5.13 Limestone bag filter

Number pcs 1
Manufacturer Pennaire
Type B132R-10-0.05NR TRL-S
(Reverse jet, top bag
removal, tubular bags)
Capacity m3/h 15000
Filter bag area m2 150
Controls Timer for compressed air
pulses
Consumption, pressurized air m3/h 15
Materials steel
− bags polyester needle felt cloth
− casing steel

2.7 LIMESTONE

Accessories
− fixing bolts to steelwork
− access platform for valves
− ladder to filter top
Limestone filter fan

U U

Number pcs 1
Flow at design point m3/h P
P
15300
Type Belt drive
Motor kW 15
Limestone filter rotary feeder and screw

U U

Number pcs 1
Manufacturer Solitec (screw) and
Rotolok (rotary feeder)
Type 200 (Combined drive with chainset)
Screw diameter mm 200
Screw lenght mm 4000
Chain drive 1” SIMPLEX
Motor kW 2,2
The screw is made of mild steel. The shafts are coupled together
and supported by a hanger bearing. The drive end bearing is
flanged, the tail end bearing is pedestal mounted, both with lip
seals. The screw is chain driven by a geared motor, which also
drives the rotary feeder.

2.7 LIMESTONE

The rotary feeder has cast iron body, end covers and gland
followers. The closed rotor has replaceable abrasion resistant
tips. The bearings are sealed for life, and the gland packing is
PTFE.
2.7.5.14 Limestone bucket elevator

Number pcs 1
Manufacturer Raumaster Oy
Belt speed m/s 1,4
Motor kW 11
Materials
- frame carbon steel
- bucket carbon steel + Hardox 400
Accessories
− feed chute from cyclone and filter
− discharge chute to silo
2.7.5.15 Limestone feeding silo

Number pcs 1
Manufacturer RAPP (Raumaster design)
Gross volume m3 P
P
300
Diameter m 6,5
Height (total) m 16

2.7 LIMESTONE

Equipment:
− legs and support steel construction
− fluidizing air ring
− filter A = 10 m², pneumatic cleaning
− standard service doors
Hand operated slide gate (below the silo)

U U
Opening size mm 400 x 400

Materials:
− frame carbon steel
− slide gate stainless steel
Pneumatic cleaning system removes limestone dust which

appears when feeding the limestone silo. Pneumatic cleaning
system (motor 1,5 kW + cleaning) is started at the same time
when starting the conveyor which is feeding the silo. Cleaning
system has a control system of its own which controls the
magnetic valves of cleaning. The motor of the cleaning system is
stopped with 5 minutes delay after the silo feeding conveyor is
stopped. The cleaning is stopped with 2 minutes delay after the
motor of the cleaning system is stopped.
Intermediate hopper (above the feeding screw)

U U
Volume (about) l 120

Material stainless steel
Level switch Drexelbrook

2.7 LIMESTONE

2.7.5.16 Limestone feeding screw

Number pcs 1 (3 separate screws)
3
Capacity (total) m /h 2,6 ... 25 P
P
Screw rotation speed rpm 4,5 ... 45

Screw flight diameter mm 3 x 219
Screw length m 3 x 1,2
Motors kW x 2,2 with thermistors (3 pcs)
− variable frequency drive (supplied by RAPP)
Accessories:
− ventilation pipeline connection DN80 in the discharge chute and in
intermediate hopper
− pipeline to the upper part of the limestone silo
Figure 8 Limestone feeding screw

2.7 LIMESTONE

2.7.5.17 Limestone rotary feeder

Number pcs 1 (3 separate sections)
Manufacturer’s type ALF 30/60 P
Capacity (total) m3/h P
P
25
Rotation speed rpm 24
Motor kW 5,5
Zero speed swith manufacturer Telemecanique
Materials:
− inner lining of cells stainless steel
− inner surface of frame hard crome plating
− other parts carbon steel
The rotary feeder divides limestone flow into three outlets.

2.7 LIMESTONE

2.7.5.18 Limestone injection piping
Manufacturer Kvaerner Power Oy

Pipe from the feeding air blower DN400
Piping from rotary feeder 3 x DN250
Piping to boiler 6 x DN150
Injection nozzle location Furnace front wall
Injection nozzle height m 2,5 from furnace bottom
Nozzle inclination 30° downwards

2.7 LIMESTONE

2.7.5.19 Limestone injection air blower

Manufacturer Oy Ekstrom Flow Ab /
Dresser
Number of blowers 1
Model XLP408
Type Three-bladed roots blower
Motor (supplied by RAPP) kW 355
Performance at maximum pressure difference

U U
Differential pressure kPa 73

Air flow Nm3/s P
P
2,6
Temperature increase °C 80
Rotary blower speed rpm 1924
Accessories:
− pressure relief valve
− acoustic enclosure (about 4m x 2,2m x 3,6m)
− suction side silencer
− ventilation air fan for the acoustic enclosure (fan motor rated
power 0,55 kW – 0,75 kW, manufacturer WEG, CMG or equal)
− flexible connection (either a stainless steel bellows type with mild
steel flanges or a silicon tube type with mild steel flanges)
Figure 5 shows Limestone injection air blower curve and figures

6 and 7 the structure of the blower.

2.7 LIMESTONE

PERFORMANCE BASED ON
DRESSER ROOTS AIR, INLET PRESSURE = 1013
HOLMES OPERATION PRESSURE PERFORMANCE MBAR INLET TEMPERATURE =
PO BOX B7 TURNBRIDGE FRAME XLP 408 20 0C
HUDDERSFIELD HD1 6RB MAX. PRESSURE RISE = 800 MBAR
MAX. SPEED = 2000 RPM
200 MBAR
400 MBAR
14000.0
600 MBAR
800 MBAR
ACTUAL INLET FLOW - M3/H
12000.0
10000.0
8000.0
6000.0
4000.0
2000.0
500 1000 1500 2000 2500
150.000
TEMP. RISE - 0C
100.000
800 MBAR
600 MBAR
50.000
400 MBAR
200 MBAR
0.000
500 1000 1500 2000 2500
400.000
800 MBAR
350.000
300.000
600 MBAR
POWER - KW
250.000
200.000 400 MBAR
150.000
100.000 200 MBAR
50.000
0.000
500 1000 1500 2000 2500
SPEED - RPM
Figure 9 Limestone injection air blower curve

2.7 LIMESTONE

Figure 10 Limestone injection air blower (type XLP)
Figure 11 Three-bladed rotor of the blower

2.7 Limestone System

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Asiakirjan nimi - Name of Document Tunniste - Identification Rev.

PROCESS DESCRIPTION CFBT-582-1 1

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 1 (34)