News_2013_12

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


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-


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


tons of burnt lime per day. They will

be fired with 100 % coal dust. Lime-


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.





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




CaO content in burnt lime (%)

94.24

Implemented Project in New Zealand

McDonald’s Lime Limited, Te Kuiti





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-




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: [email protected] 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


Heat consumption (kJ/kg) < 3’580


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.

News_2013_12

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