Post on 21-Oct-2015
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December 2013
Maerz news
Editorial
Dear Readers and Friends
Rising fuel costs and limited availability
of good limestone sources are challeng-
es being faced by the lime industry in
the entire world. Hence we as Maerz
focus on technologies for an economical
lime production - be it energy saving by
optimising the burning process or re-
source saving by making the utmost use
of a limestone quarry’s yield. Read
more about this in a presentation Maerz
recently gave to the mining industry in
Peru - a country with very restricted
access to high quality limestone.
A round-up of new orders Maerz re-
ceived, some reports on Maerz’s ongo-
ing turn-key projects as well as news on
our recently commissioned kilns keeps
you informed about what is going on in
the lime-world.
I wish you, your colleagues and your
families a few relaxing days over
Christmas and for the New Year loads
of energy and success stories.
Enjoy reading our Maerz News
Stephan Lechner
Managing Director
In this edition:
New Finelime® Kiln in Morocco Lafarge-Calcinor Maroc commissioned
its new Finelime® Kiln in Tlad Loulad 1
Lime for the Mining Industry -
An Economic Approach
On the economics of large scale lime plants 2
Latest Orders and References A list of Maerz’s recent orders and projects 6
Ground Breaking in Zambia
Handyman’s Paradise’s first Maerz Kiln
installation has begun 9
Site Report: Mexicana de Cobre
Erection of the second kiln well on track 11
Implemented Projects Maerz kilns have recently been commissioned at:
- Anhui Hwasu Corporation , China 8
- Xinjiang Zhongtai Chemical Co. Ltd., China 8
- PT Krakatau Steel (Persero) Tbk., Indonesia 10
- McDonald’s Lime Limited, New Zealand 10
- ZPW Trzuskawica SA., Kujawy, Poland 11
- Kalkfabrik Netstal AG, Switzerland 12
As reported in the “Maerz News” in
July 2011, Calcinor – LCM S.A.S
successfully commissioned a 200
tpd rectangular type Maerz PFR lime
shaft kiln at their Tlad Loulad Plant.
The kiln of the rectangular type pro-
duces 250 tpd of burnt lime per day,
processing limestone with a grain
size of 40 to 90 mm and using pul-
verised petcoke as fuel.
In 2011 the customer placed another
order with Maerz, this time for the
supply of engineering, license, know
-how, equipment and technical assis-
tance for a kiln of the F2S type.
This kiln is to produce 300 tons of
quicklime per day processing lime-
stone with a nominal grain size of 15
to 50 mm and also using pulverised
petcoke as fuel.
In September this year the contractu-
al guarantee test run was carried out
and the performance and quality
parameters as shown in the adjacent
table were achieved.
Based on the results of this test run
and after completing the training of
the customer’s operating and mainte-
nance personnel, the FAC (Final
Acceptance Certificate) was estab-
lished and the contract plant has
been accepted by LCM.
Implemented Project in Morocco
Calcinor S.A. / Lafarge-Calcinor Maroc S.A.S.
Lafarge-Calcinor Maroc ‘s Tlad Loulad lime plant with (from the left) the petcoke dust silo, the 200 tpd rectangular Maerz kiln and the new Maerz Finelime® Kiln .
Kiln capacity (tons/day) > 300
Limestone size (mm) 20 - 50
Heat consumption (kcal/kg) 810
Residual CO2-content (%) 2.5
Spices - a key to Moroccan cuisine ...
2
Lime for the Mining Industry - An Economic Approach
Increased capacities in the copper industry demand additional lime production facilities. High fuel costs
and limited availability of good quality limestone in the Andean region are the main drivers for employ-
ing modern shaft kiln technology instead of conventional rotary kilns to economically produce quick-
lime. Lime plants serving the mining industry - whether captive plants or "commercial" lime plants -
are usually characterised by large capacity kilns producing high reactive lime.
Introduction
Increased capacities in the copper
industry demand additional lime pro-
duction facilities. High fuel costs and
limited availability of good quality
limestone in the Andean region are
the main drivers for employing mod-
ern shaft kiln technology instead of
conventional rotary kilns to economi-
cally produce quicklime. Lime plants
serving the mining industry - wheth-
er captive plants or "commercial"
lime plants - are usually character-
ised by large capacity kilns produc-
ing high reactive lime.
Until recently rotary kilns were con-
sidered to be the first choice whenev-
er high lime production capacity was
an issue despite the comparatively
high fuel consumption. This situation
has completely changed due to the
sharp increase of fuel costs and the
recent development in modern shaft
kiln technology regarding the maxi-
mum capacity per kiln unit.
What is Lime?
Burnt lime or "quicklime" is the dis-
sociation product of Calcium Car-
bonate (limestone), which is pro-
duced by exposing the limestone to
heat. This process is also known as
"calcination".
The CaO in burnt lime is available
for chemical processes such as neu-
tralisation of tailings or control of the
pH value of a flotation liquid.
The main properties of burnt lime are
(a) residual CO2-content and (b) re-
activity:
The residual CO2-content describes
the completeness of the calcination
process, i.e. how much CaO is still
bound by CO2 thereby not being
available for other chemical process-
es. It is widely used in the industry
as quality parameter as it is easy to
measure in comparison to the deter-
mination of "available lime", which
directly measures the free CaO in
burnt lime.
The reactivity describes the reaction
speed of the CaO with other sub-
stances. It is mainly influenced by
the specific surface of the burnt lime:
the larger the specific surface, the
higher the reactivity is. A large spe-
cific surface is maintained by expos-
ing the limestone to just enough heat
in order to complete the calcining
process. If the burnt lime is heated
up further, the CaO crystallites start
fusing thereby reducing the specific
surface and the burnt lime's reactivi-
ty. High reactive lime is therefore
often referred to as "soft burnt lime".
Lime kilns can only influence the
above-mentioned properties - contra-
ry to a cement kiln no other chemical
reactions except for calcination take
place. Hence the purity of the raw
material fed to the lime kiln is deci-
sive for the quality of the burnt lime.
Burnt lime is widely used in industri-
al process such as in the iron & steel
industry for sintering of ores, as rea-
gent for slag formation in the melting
shop or for desulphurisation of pig
iron.
Further uses are in the building in-
dustry for the production of aerated
concrete and sand-lime bricks, vari-
ous mortars and plasters as well as
for soil stabilisation.
In the mining industry burnt lime is
mainly used for the neutralisation of
tailings and for the control of the pH-
value of flotation liquids.
Lime Burning Economics
Besides the investment costs of a
lime plant, the main costs during
operation are caused by fuel and
limestone. Figure 1 shows a typical
production cost structure of a Euro-
pean lime plant.
It becomes obvious that the main cost
driver is energy resp. fuel costs and
the second largest influential factor is
the costs of limestone.
Figure 1: Typical cost structure of a European lime plant
3
Hence it is vital for an overall cost
effectiveness to use a kiln technology
with a lowest possible fuel consump-
tion, and optimise the yield of the
limestone quarry.
Until recently, mostly rotary lime
kilns were used for the typically
large capacity lime plants in the min-
ing industry, despite their significant-
ly higher fuel consumption and lower
quarry yield compared to modern
shaft kiln technology.
The heat input required for the calci-
nation process is the same for all
lime kilns. Their specific designs do
however influence the extent of heat
loss.
The main source of heat loss is the
excess energy (sensible heat) in a
lime kiln's off gas: the temperature
level required for calcination has to
be so high, that the off-gasses con-
tain more energy than needed for
calcination. On the other hand, the
ability of the limestone to pick up
heat from the off-gases in the pre-
heating zone of any lime kiln is too
low to make use of all the energy
still contained in the off gasses.
Hence the off-gas temperature is
comparatively high (up to 350 °C in
some kiln types) and the contained
energy is wasted.
A further significant source of heat
loss is radiation through the kiln
shell.
The rotary kilns - even modern ones
equipped with efficient preheaters -
have comparatively high heat losses
through both of the above mentioned
sources (Figure 2).
In the early 1960ies a kiln principle
was invented in Austria to overcome
the deficiencies of rotary kilns - the
Maerz PFR Kiln - which is today the
most widely used lime kiln in the
industry.
The Maerz PFR Kiln
The “PFR - Parallel Flow Regenera-
tive Lime Kiln” has the lowest heat
consumption of all modern shaft
kilns which is explained by its mode
of operation. It is characterised by its
parallel flow heating system, i.e. the
parallel flow of limestone and com-
bustion gases in the kiln, and the
regenerative preheating of combus-
tion air.
Figure 3 shows the basic principle of
the kiln and illustrates two phases of
the flow. The two shafts are com-
pletely filled with the material to be
calcined and are connected to each
other by a crossover channel at the
bottom end of the burning zone. The
stone charging equipment, the rever-
sal devices for air and off-gases as
well as the lime discharging arrange-
ment have been omitted from this
diagram.
Both shafts are charged alternately
with limestone, and lime is dis-
charged continuously at the bottom
of each shaft. Fuel is supplied to
only one of the two shafts, in the
phase shown in Figure 3 to the left
shaft. Fuel is introduced via evenly
over the cross section of the shaft
distributed burner lances at the bot-
tom end of the preheating zone.
Combustion air is introduced under
pressure at the top end of the pre-
heating zone above the stone charge
(blue arrows) and the system is pres-
surised throughout. The combustion
air is then preheated in the regenera-
tor (preheating zone) before it mixes
with the fuel. The combustion gases
(orange and red arrows) pass through
the burning zone from top to bottom
(parallel flow heating).
At the same time cooling air is intro-
duced under pressure via the dis-
charge tables of both shafts at the
bottom (blue arrows pointing up).
Cooling air and combustion gases
mix and leave the "burning" shaft via
the slope of material to enter the "offFigure 2: Heat balance of a preheater rotary kiln
Figure 3: Operating principle of the Maerz PFR kiln
4
-gas" shaft, passing upwards in oppo-
site direction to the charge. They
calcine, even if to a small degree, the
limestone in the off-gas shaft.
The supply of fuel and combustion
air is switched from one shaft to the
other at approx. 12-15 minute inter-
vals, to effectuate the regenerative
pre-heating of combustion air: The
hot gasses pass through the off-gas
shaft's preheating zone and thereby
heat up the limestone in the preheat-
ing zone (Figure 4 left side). They
transfer their excess energy (sensible
heat) to the limestone and thereby
cool down. In the following cycle,
this shaft becomes the "burning
shaft" and cold combustion air passes
through the now hot stone (Figure 4
right side). The combustion air picks
up the stone's sensible heat and
thereby heats up. The stone is cooled
down and prepared for the next cycle
- the perfect regenerator!
Due to this sophisticated use of heat
the thermal efficiency of a Maerz
PFR Kiln is 85%!
The direct comparison of the PFR
kiln's heat balance with a preheater
rotary kiln impressively demon-
strates the energy savings:
Quarry Yield
Another important
factor for the eco-
nomic viability of
a lime plant is the
optimal use of the
limestone re-
sources. Not only
in densely popu-
lated areas is it
extremely diffi-
cult to expand
existing quarries
or to develop new
limestone depos-
its, but also in
certain areas of
the world, such as
the Andean region, where high quali-
ty limestone is scarce and precious.
Rotary kilns and shaft kilns require a
minimum limestone grain size for
processing. Rotary kilns typically
operate on stone sizes between 15
and 50 mm, whereas classic shaft
kilns commonly use 50 - 120 mm
limestone.
Another constraint for the limestone
size is the ratio between the smallest
and the largest limestone grain,
which is classically 1:3. The reason
for this is to avoid overburning of
small limestone pieces and a possible
incomplete calcination of oversize
limestone pieces, which would leave
unburnt cores in the limestone.
To avoid excess generation of fines
during limestone crushing and to
generally reduce crushing costs the
maximum stone size should be as
large as possible. Although smaller
size limestone may be sold as gravel
for various applications, the added
value for a lime plant is maximised
by producing quicklime.
Figure 6 compares the usability of
various limestone grain sizes be-
Figure 4: Off gas heats up the stone (left) and combustion air cools it down again in the following cycle (right)
Figure 5: Heat balance of a PFR kiln vs. a preheater rotary kiln
Figure 6: Comparison between quarry yields of a rotary kiln vs. a classic Maerz PFR Kiln
5
tween a rotary kiln and a classic
Maerz PFR Kiln. The comparison
assumes a linear grain size distribu-
tion after crushing and therefore
demonstrates the principle only.
As seen below, the rotary kiln has a
significant advantage over a classic
Maerz PFR kiln as the quarry yield is
approx. 70% versus the PFR kiln's
quarry yield of just below 60%.
However, Maerz developed a PFR
kiln which allows calcining lime-
stone down to a grain size of approx.
15 mm - the Maerz Finelime® Kiln.
A combination of a Maerz Finelime®
Kiln and a classic Maerz PFR Kiln
results in a significantly better quarry
yield than when just using a rotary
kiln (Figure 7). With this combina-
tion the quarry yield is increased to
nearly 90%!
Classic Maerz PFR Kilns may how-
ever also process a certain quantity
of smaller stone by charging separate
layers of limestone sizes. This pro-
cess developed by
Maerz is called
Sandwich Mode
(a principle of this
charging mode is
shown in Figure
8) and allows also
smaller lime
plants with single
kilns to better use
their quarries. The
minimum stone
size may not be as
small as in a
Maerz Finelime®
Kiln, but still re-
sults in a significant gain in quarry
yield as shown in Figure 9.
Summary
Modern lime shaft kiln technology -
i.e. the Maerz PFR Lime Kiln - is the
most economic and ecological kiln
for large capacity lime plants which
are usually required to serve the min-
ing industry.
The Maerz PFR Kiln's fuel efficien-
cy as well as its flexibility to use
various gaseous, liquid and pulver-
ised solid fuels reduces overall pro-
duction costs together with the CO2-
footprint of the lime plant.
The wide range of limestone grain
sizes the Maerz PFR Kiln may pro-
cess optimises the use of precious
limestone resources.
Figure 7: Quarry yield with a combination of classic Maerz PFR Kiln and Maerz Finelime® Kiln
Figure 9: The effect of the Maerz “Sandwich Charging” mode on the limestone quarry yield
Figure 8: Principle of the Maerz “Sandwich Charging” mode
A Maerz Finelime® Kiln and a Maerz PFR Kiln in Cal Química Mexicana’s Lime Plant in San Luis Potosí, Mexico
6
Latest Orders and References
CALCIT JSC, Bulgaria
Some fifteen years ago, in 1999,
CALCIT JSC, domiciled in
Asenovgrad, Bulgaria, ordered their
first Maerz PFR lime kiln, followed
by a second kiln in 2004. Both kilns
are of identical design – kiln type E3
– with rectangular shaft cross section
and natural gas fired. Each kiln pro-
duces 200 tons of quicklime per day.
Now CALCIT entrusted Maerz with
the supply of engineering, license,
know-how, material, equipment as
well as technical assistance for the
installation of a petcoke firing system
on both kilns in addition to the exist-
ing natural gas firing systems.
Maerz’s scope of material and equip-
ment supply comprises lance cooling
air blowers, the petcoke dust firing
system – including key components
of the petcoke silo – and the pertinent
electric, measuring and control sys-
tem. Maerz will also delegate experi-
enced personnel to supervise erection
and commissioning of the new firing
system which will be ready for com-
missioning in the middle of 2014.
KFN Netstal
KFN Kalkfabrik Netstal AG, domi-
ciled in Netstal (Glarus), Switzerland
and Maerz Ofenbau signed a contract
for the supply of engineering, license,
know-how and equipment as well as
technical support and erection work
for the conversion of the existing
Maerz PFR kiln from heavy fuel oil
to natural gas firing. After successful
implementation of the new natural
gas firing system, the heavy fuel oil
equipment will no longer be used,
thus allowing the continued use of an
important part of the existing equip-
ment including the burner lances.
Maerz’s scope of material supply
comprises the new gas firing system
with the appending electric, measur-
ing and control equipment. Maerz
will also be responsible for the erec-
tion work of the new equipment in-
cluding any adaptation work on the
existing plant which may be required.
All quality and performance parame-
ters achieved during kiln operation
with heavy fuel oil will also be
reached with the new gas firing sys-
tem.
Calidra de Michoacán S.A.
de C.V., Mexico
Calidra de Michoacán S.A. de C.V., a
member of Calidra Group, entrusted
Maerz with the supply of engineering
services, license, know-how, equip-
ment as well as supervision services
for the construction of a Maerz PFR
Kiln in their Piedras de Lumbre, Jun-
gapeo (Michoacán) plant.
The Maerz Kiln to be built within the
scope of this contract will be of the
rectangular kiln type E2 and will
produce 150 tons of quicklime per
day. Pulverised petcoke or coal dust
will be used as fuels and limestone
with a grain size of 40 to 80 mm and
50 to 100 mm will be processed in
this kiln.
Maerz’s scope of supply comprises
the complete engineering, materials
and equipment such as petcoke/wood
dust firing system, hydraulic equip-
ment, electric, measuring and control
equipment as well as the limestone
skip hoist winch. Maerz will also
delegate experienced personnel to
supervise erection and commission-
ing of the kiln plant.
The new plant is due for commis-
sioning in the middle of 2014.
Xinjiang Zhongtai Chemical -
Tuokexun Energy Chemical
Co., Ltd., China
Taigang Group International Trade
Co., Ltd., as the Buyer, and Maerz
Ofenbau AG, as the Seller, signed a
contract for the installation of 3 x 600
tpd Maerz PFR Lime Kilns for Xin-
jiang Zhongtai Chemical Tuokexun
Energy Chemical Co., Ltd., domi-
ciled in Urumqi, Xinjiang.
The new R4P type kilns of circular
shaft design will each produce 600
tons of burnt lime per day . They will
be fired with carbide gas, having an
average calorific value of approx.
10’000 kJ (2’400 kcal)/m3n. Lime-
stone with a grading of 40 to 80 mm
and 50 to 100 mm will be processed
in the kilns.
Besides supplying know-how, license
and the complete engineering, Maerz
will supply the firing system for car-
bide gas as well as key components
for the electrical, measuring and con-
trol system. Furthermore Maerz will
delegate experienced personnel to
supervise erection and commission-
ing of the kilns.
CALCITs two identical 200 tpd Maerz PFR Kilns, now to be converted to petcoke dust firing.
7
Industria DAYI S.A. de C.V.,
Mexico
Industria DAYI S.A. de C.V., domi-
ciled in Progreso de Obregón
(Hidalgo), Mexico, already operating
three 200 tpd heavy fuel oil/petcoke
fired Maerz Lime Kilns for several
years, has now placed an order with
Maerz for a fourth PFR Kiln.
The new kiln of rectangular shaft
design will produce 200 tons of
burnt lime or burnt dolomite per day,
using petcoke dust and natural gas as
fuels. The kiln can be operated either
with petcoke dust or natural gas or a
mixture of both fuels.
As for the existing kilns, Maerz will
supply license, know-how, engineer-
ing services and equipment for the
new kiln and will delegate personnel
to supervise erection and commis-
sioning work for the plant which will
be operative at the end of 2014.
Xinjiang Blue Ridge Tunhe
Energy Chemical Co., Ltd.,
China
Taigang Group International Trade
Co., Ltd., as the Buyer, and Maerz
Ofenbau AG, as the Seller, signed a
contract for the installation of 2 x
600 tpd Maerz PFR Lime Kilns for
Xinjiang Blue Ridge Tunhe Chemi-
cal Co., Ltd., domiciled in Changji
City near Urumqi, Xinjiang.
The new R4P type kilns of circular
shaft design will each produce 600
tons of burnt lime per day. They will
be fired with carbide gas having an
average calorific value of approx.
10’000 kJ (2’400 kcal)/m3n. Lime-
stone with a grading of 40 to 80 mm
and 50 to 100 mm will be processed
in the kilns.
Besides supplying know-how, li-
cense and the complete engineering,
Maerz will supply the firing system
for carbide gas as well as key com-
ponents for the electrical, measuring
and control system. Furthermore
Maerz will delegate experienced
personnel to supervise erection and
commissioning of the kilns.
Quzhou Yuanli Metal Product
Co., Ltd., China
HongKong MCC International Eco-
nomic and Trade Co., Ltd., as the
Buyer, and Maerz Ofenbau AG, as
the Seller, signed a contract for the
installation of 2 x 600 tpd Maerz
PFR Lime Kilns for Quzhou Yuanli
Metal Product Co., Ltd., as the End-
user and with Shanghai Baoye
Jianshe Industrial Furnace Engineer-
ing & Technology Co., Ltd., acting
as General Contractor.
The new R4S type kilns of circular
shaft design will each produce 600
tons of burnt lime per day. They will
be fired with 100 % coal dust. Lime-
stone with a grading of 40 to 80 mm
will be processed in the kilns.
Besides supplying know-how, li-
cense and the complete engineering,
Maerz will supply special refractory
materials, key components for the
coal dust firing and the electric,
measuring and control system. Fur-
thermore, Maerz will delegate expe-
rienced personnel to supervise erec-
tion and commissioning of the kilns.
Industria Dayi‘s lime plant in Progreso de Obregón, Hidalgo, Mexico and the signing of the new contract by Mr Dagda and Mr Inglin from Maerz
A battery of Maerz PFR Kilns in one of the plants of the Xinjiang Zhongtai Chemical group
8
Implemented Projects in China
Anhui Hwasu Corporation ...
In 2010 Huaibei Mining Xinsheng
International Trading Co., Ltd., as
the Buyer, and Maerz Ofenbau AG,
as the Seller, signed a contract for
Kiln capacity (tons/day) 600
Heat consumption (kJ/kg) 3’750
Residual CO2-content (%) < 2.0
Reactivity of lime (ml 4nHCl after 10 min.)
355
… Xinjiang Zhongtai Chemical Co. Ltd., Urumqi
As announced in our June 2012
“Maerz News”, Taigang Group In-
ternational Trade Co., Ltd., as the
Buyer, and Maerz Ofenbau AG, as
the Seller, signed a contract for the
installation of 2 x 600 tpd Maerz
PFR Lime Kilns for Xinjiang Zhong-
tai Chemical Co. Ltd., domiciled in
Urumqi, in addition to the 3 x 600
tpd Maerz PFR Kilns ordered at the
end of 2011.
The Maerz kilns No. 4 and 5 each
produce 600 tons per day of burnt
lime, using carbide gas and coal dust
as fuels.
In September this year the erection
work on the kilns was completed and
they were put into operation. The
contractual performance and quality
parameters as per the adjacent table
were reached in industrial operation.
The Provisional Acceptance Certifi-
cate was established and signed by
Taigang and Maerz Ofenbau AG.
Kiln capacity (tons/day) 600
Limestone size (mm) 60 - 120
Heat consumption (kcal/kg) 895
Residual CO2-content (%) < 2.0
Reactivity of lime (ml 4nHCl after 5 min.)
> 330
the installation of 3 x 600 tpd Maerz
PFR Lime Kilns for Anhui Hwasu
Corporation, domiciled in Chuzhou
City, Anhui Province.
The new kilns of circular shaft de-
sign each produce 600 tons of burnt
lime per day and are fired with car-
bide gas. Limestone with a grading
of 40 to 90 (or similar) mm is pro-
cessed in the kilns.
Besides the complete engineering,
Maerz was to supply the carbide gas
firing system, the measuring instru-
ments as well as spare parts and was
responsible for supervising erection
and commissioning.
In the meantime all three kilns were
erected and commissioned and have
reached the industrial production
stage where the contractual perfor-
mance and quality parameters as per
the adjacent table have been
achieved. After completing the train-
ing of the operating and maintenance
personnel, the kiln plant is now oper-
ating under the responsibility of the
customer.
9
The existence of local lime produc-
tion is one of the prime indicators of
a country's economic development.
Whilst there is existing lime produc-
tion in Zambia, large quantities of
lime still have to be imported.
Handyman's Paradise will set a mile-
stone for production of high quality
lime using the most energy efficient
process, thus protecting the environ-
ment we all live in. With the rapid
economic growth in Zambia and the
region, there is no doubt that more
beneficiation of local resources will
occur. The production of lime from
local limestone is only one example.
Handyman's Paradise Limited in a
joint venture with Astro Holdings
Limited Group of Companies em-
barked on a journey to build a lime
manufacturing plant in Ndola 's Ma-
saiti district. The project will be de-
veloped in several stages and when
all phases are complete it is expected
to cost in excess of US$ 50 million.
Being a greenfield project the entire
infrastructure for this state-of-the-art
lime plant has to be built from
scratch - including the access road to
the plant site.
In November this year the ground
breaking ceremony for the new lime
plant took place. With a long list of
highly honourable guests - including
several Ministers and Chiefs this
was a major event well received in
national newspapers.
The major part of the material and
equipment for the lime plant will be
imported from well known suppliers
world-wide. The project not only
consists of the lime kiln, but also of
all required equipment up- and
downstream from the kiln such as
crushers, conveyor belts, silos, coal
dust mill, etc.
The lime plant is scheduled to be
ready for start-up mid 2015.
Ground Breaking Ceremony in Zambia:
Handyman’s Paradise’s first Maerz Kiln installation has begun
The guests of honour at the ground breaking ceremony and the proud owners of the new lime plant.
Franz Sidler (Maerz) and Ralf Hesemann (Polysius) hand over a traditional Swiss cowbell as a symbol of good luck to the proprietors of the new plant Michael Pasquini and Sanmukh R. Patel
Ready to go ...
10
Implemented Project in Indonesia
PT Krakatau Steel (Persero) Tbk., Cilegon
Kiln capacity (tons/day) 155
Heat consumption (kcal/kg) 863
Residual CO2-content (%) < 1.56
CaO content in burnt lime (%)
94.24
Implemented Project in New Zealand
McDonald’s Lime Limited, Te Kuiti
Kiln capacity (tons/day) 170
Limestone size (mm) 40 - 80
Heat consumption (kcal/kg) 820
Residual CO2-content (%) < 1.3
In 2011 PT Krakatau Steel (Persero)
Tbk., domiciled in Cilegon, Indone-
sia, placed an order with Maerz for
the installation of a 150 tpd natural
gas fired PFR lime kiln. The kiln
produces high reactivity quicklime
for the Krakatau Steel Plant.
Maerz and PT Truba Jaya Engineer-
ing formed a consortium to perform
the work under the contract. The
consortium’s scope of supply com-
prised the turn-key installation of the
lime kiln plant.
In early June this year the contractual
guarantee test runs were carried out
with the quality and performance
parameters as stated in the adjacent
table being achieved.
After completing the training of the
operating and maintenance person-
nel, the kiln plant was accepted and
is now operating under the responsi-
bility of the customer.
As reported earlier in “Maerz News”,
McDonald’s Lime Limited, domi-
ciled in Otorohanga, New Zealand,
placed an order with Maerz for the
installation of a new natural gas fir-
ing system on their existing 140 tpd
Maerz PFR kiln in the Te Kuiti
Plant.
Maerz’s scope of supply comprised
all engineering services required as
well as the materials and equipment
for the new firing system.
In early September this year the con-
tractual guarantee figures were tested
during several days of continuous
operation and the quality and perfor-
mance parameters as listed in the
table were achieved.
The kiln plant has been accepted and
is now operating under the responsi-
bility of the customer.
The new Maerz PFR Kiln in Krakatau‘s steel plant is installed to the left of an old smaller lime kiln
11
Implemented Project in Poland
ZPW Trzuskawica SA., Kujawy
As described in more detail
in the December 2012
“Maerz News”, ZPW
Trzuskawica SA., Sitkowka
-Nowiny, Poland, entrusted
Maerz with the supply of
new coal/lignite dust firing
systems for the existing 450
tpd Maerz kilns No. 1 and 2
at their Kujawy Plant.
Maerz’s scope of supply
comprised engineering,
license, know-how as well
as materials and equipment
such as the coal dust heat-
Kiln capacity (tons/day) 450
Heat consumption (kcal/kg) 890
Residual CO2-content (%) < 2.5
Reactivity of lime (t60 value in sec.)
180
ing system with the appending
electric, measuring and control
equipment.
Having successfully installed the
pulverised lignite firing system on
Maerz kiln No. 2 – see our special
report in the December 2012
“News” – the new firing system
on kiln No. 1 now has been com-
pleted and the contractual guaran-
tee test run has recently been car-
ried out, where the contractual
performance and quality parame-
ters as per the following table
were achieved:
Site Report: Mexicana de Cobre’s Second
Maerz PFR Kiln well on Track
In Fall 2012 Mexicana de Cobre placed an order with Maerz
for another Finelime Kiln to be erected adjacent to the first
Maerz PFR Kiln in their Agua Prieta lime plant.
As reported in our last Maerz news, the contract for the turn
-key erection of this kiln was awarded to Maerz’s sister
company Polysius de Mexico, domiciled in Mexico City. In
the meantime the civil works have been completed and the
first shaft sections as well a the off-gas filter have been
erected.
The steel structure, which has been manufactured in Mexico
by Polysius’ trusted workshops, is pre-assembled on site,
close to the kiln.
The smooth coordination between Maerz and Polysius en-
sures that the lime kiln will be ready for start-up mid-2014.
© Maerz Ofenbau AG 2013 Maerz Ofenbau AG A Company of ThyssenKrupp
Richard Wagner-Strasse 28 CH-8027 Zurich, Switzerland
Phone +41-44-287 27 27 Fax +41-44-201 36 34
e-mail: info@maerz.com http://www.maerz.com
12
Kalkfabrik Netstal AG, domiciled in Netstal (Glarus),
Switzerland, placed an order with Maerz for the instal-
lation of a new natural gas firing system on the exist-
ing heavy fuel oil fired Maerz PFR kiln in their Netstal
lime plant.
Maerz’s scope of supply comprised all engineering
services required as well as the materials and equip-
ment including erection work for the new gas firing
plant.
In early September this year the contractual guarantee
test runs were carried out during several days of con-
tinuous kiln operation. The adjacent table shows the
quality and performance parameters which were
achieved. The conversion of the kiln firing system
from heavy fuel oil to natural gas has thus successfully
been completed and the plant has been taken over by
the customer.
Implemented Project in Switzerland
Kalkfabrik Netstal AG
Kiln capacity (tons/day) > 200
Limestone size (mm) 40 - 110
Heat consumption (kJ/kg) < 3’580
Residual CO2-content (%) < 1.4
Reactivity t60 of burnt lime (sec.)
32
Chinese Lime Association Meeting - 2013 This year’s annual meeting was held in the city of Chongqing in Sichuan province
Chongqing is the largest city in
the world and this year’s host to
the Chinese Lime Association’s
meeting from 27th to 28th Novem-
ber.
Maerz was invited to give a
presentation on its latest develop-
ment and technology.
China is one of the most thriving
lime producing countries. Maerz
has been active since the 1980-ies
and has built more than 60 Maerz
PFR Kilns.