Professional Documents
Culture Documents
NO PROBL EM.
Maerz lime kilns are extremely efficient in every climate. For decades.
Is the air a bit thin where you are? No problem: maerz.com
| 01
THE LARGEST MAER
BIG IS NOT ENOUGH I N P. R .
It is true that plant size helps to optimise pro- Impressive plant, impressive commissioning and
duction costs. This was the spirit behind Liu- impressive kiln performance of 3,600 tons burnt
zhou Iron & Steel’s project in P.R. China for lime per day at highest efficiency – this is the larg-
6 × 600 tpd kilns, which were successfully
est realised Maerz lime kiln plant in the world, (so
commissioned and are now in operation and
far)!
living up to their promises. These consid-
erations were also the driving force behind
As we reported in our December 2017 edition of
Tangshan Gangyuan Metallurgical and Furnace
“Insight Lime”, Sinosteel Co., Ltd. China, entrusted
Co. Ltd.’s project, where we will initially install
5 x 800 tpd Maerz PFR kilns on a greenfield Maerz with the supply of six PFR lime kilns for
basis. Liuzhou I&S Co., Ltd. as the end-user. We are very
proud to provide our proven technology to Liuzhou
It is important, however, to also invest in new I&S Co., Ltd. again to cover the high demand of
developments and further optimisation of our energy-efficient burnt lime in steel production.
products: the new design of our C-series of Together with the new plant in South West China,
circular PFR kilns combines all the know-how Liuzhou Iron & Steel now operates eleven 600 tpd
and experience we have gathered in recent Maerz PFR kilns.
years. The up-to-date design not only im-
plements process relevant features such as The six new 600 tpd kilns of the circular type R4S
a conical refractory lining, but also allows an
process limestone with a grading from 40 to 80 mm
easy upgrade in the future with a firing system
and use pulverised hard coal as fuel for firing, which
for a second fuel without having to modify the
is milled directly at the calcination plant. Within the
existing installation.
scope of the contract, Maerz in cooperation with
We are also proud to introduce our hybrid thyssenkrupp Industrial Solutions (China) Co., Ltd.,
PFR kiln technology to you, which we pre- Shanghai, supplied engineering, license, know-how
sented for the first time at the International as well as technical assistance services for commis-
Lime Association’s conference in Buenos Aires. sioning of the new lime plant together with on-site
This advancement of the PFR principle per- training of the end-user’s operating personnel.
mits controlling lime reactivity (medium and
hard-burnt), still maintaining a thermal effi- So much to the benchmarking data of this mile-
ciency very close to a PFR kiln’s efficiency and stone project; but what does completion of such a
thereby not only saving your money but also large lime plant in China look like?
CO2 emissions coming from the fuel. It further
allows you to produce soft, medium or hard-
burnt lime according to market demands with
ultimate flexibility.
02 |
R Z L I M E P L A N T - L I U Z H O U I & S C O ., LT D .
.C H I N A N O W I N O P E R AT I O N
Start-up of the first kiln in January 2019, start-up of the sixth kiln in June 2019
The first kiln was ready to be ignited at the end of lenge and required the utmost commitment from
January 2019, right before the Chinese New Year all involved parties. With the ignition of the last
celebrations. The remarkable journey culminated kiln on site in June 2019 and the achievement of
in the ignition of kiln no. 1 on 26 January 2019 at the guaranteed production parameters the project
15:58, according to Chinese tradition both a lucky came to a successful and satisfying completion for
date and a lucky time – a good omen for the contin- Maerz and its business contributors.
uing successful course of the project. While the lo-
cals were celebrating the Chinese New Year, nightly Another great example where excellent site man-
fireworks and an energetic atmosphere accompa- agement meets reliable Swiss technology – that is
nied the gentle heating up procedure of kiln no. 1. what Maerz stands for, now and in future
by Michael Räber
The remaining five kilns became operative in June
2019. Three kilns were erected and commissioned,
at times simultaneously, which was a huge chal-
| 03
I L A I N F O R M AT I O N E X C H A N G E F O R U M
IN BUENOS AIRES, ARGENTINA
This year’s International Lime Assciation’s Gener- The meeting also provided the participants with
al Assembly and Information Exchange Forum took the opportunity to catch up with old friends and to
place 9 - 11 October 2019 in Buenos Aires, Argen- make new interesting contacts, while enjoying an
tina. The annual meeting provides a valuable com- excellent “Bife de Lomo” with a few glasses of “Mal-
munication framework for the global lime industry bec”. The event was concluded with a trip to Men-
to exchange information, knowledge, and experi- doza and San Juan, where the two favourite terms
ences. The event was accompanied by an exhibition of every lime producer - lime and wine - unite.
of international suppliers, equipment and compo- Further, in Cienaguita we visited the beautiful and
nent manufacturers, in which Maerz Ofenbau AG spotless lime facility “Padre Bueno” from Cefas of
was strongly represented by Mr. Stephan Lechner, the Calidra group, where two Maerz PFR kilns are
Managing Director, Mr. Xaver Inglin, Deputy Manag- located, one since 2009 and one which was recently
ing Director and Head of Sales Division, Mr. Hannes put into operation.
Piringer, Technical Director and Mr. Borislav Vladic,
Senior Key Account Manager. At this point we would like to sincerely thank the or-
ganisers, members of the association and of course
our customers and friends, who gave us the op-
portunity to participate in this important event and
hopefully until next year in Paris.
Raul (center) and German Cabanay (right) from Caleras San Juan
visiting Borislav Vladic (left) at the Maerz booth
04 |
HYBRID KILN FOR
VARIABLE LIME REACTIVITY
The hybrid kiln, combining the advantages of both the kiln charge is already completely calcined, very
the PFR and the HPS lime kiln, could be of signifi- high temperatures can be achieved and the reac-
cant interest for various applications. tivity of the product can thus be reduced to the de-
sired value.
The upper part, comprising two kiln shafts with
their preheating and calcination zones, would work In such an arrangement the rest of the calcination
in the same way as the classic PFR kiln. process takes place just above the sinter zone at
a safe distance from the connecting gas channel.
Due to the limitations imposed by the refractory lin- The energy for this final calcination is provided by
ing the middle part with the connecting gas channel the hot gases coming from the sinter zone. Due to
needs to be operated at a moderate temperature of the strongly endothermic calcination process these
less than 1,100° C just like a classic PFR lime kiln. gases are cooled down to a temperature of less
For this reason the heat input via the vertical main than 1,100° C, thus allowing them to safely pass
burner lances would need to be adjusted to achieve through the connecting channel without damaging
a calcination degree of approximately only 90 % at the refractory lining.
the lower end of the calcination zone.
The flexibility of this new kiln type will add value
The part of the kiln underneath the connecting gas to any lime plant because it can operate either like
channel of the two shafts is longer compared with a classic PFR lime kiln (without using the burners
a normal PFR lime kiln and comprises a sinter zone in the sinter zone), to produce high reactive / soft
and a cooling zone. burnt lime or - as described above - to produce me-
dium to hard burnt lime while still maintaining the
The sinter zone is fired with radially arranged and
excellent thermal efficiency of a PFR lime kiln
horizontally adjustable liquid cooled burners just
like in the HPS lime kiln. As these burners are lo- by Hannes Piringer
1.0
| 05
N E X T G E N E R AT I O N: F I R S T K I L N
O F C-S E R I E S I N O P E R AT I O N
stone distribution inside the shafts by charging
selectively to the outer or inner zone of the cross
section. All this has been designed to optimise the
burning process and to allow customers to maintain
a high stone output from the quarry.
06 |
The stone and lime handling systems of the kiln With a new data management system Maerz com-
have been equipped with an efficient dedusting sys- bines trending production, process and quality pa-
tem resulting in a dust-free and labour-friendly kiln rameters. Noteworthy is that this data can be ac-
environment. cessed from all over the world. Customers are thus
able to analyse their production more easily and
Next to the visible improvements, there are also to better optimise the calcination process. Another
many improvements which are not directly visible. nice side effect, which is valuable for the customer
One of them is the conical refractory design of the is, that should the need arise, Maerz is able to pro-
burning zone. The increasing kiln cross section, vide process support within a short timeframe.
from the lance tips to the cooling zone verifiably
improves the stone flow inside the shafts and there- All in all the new development is a great suc-
fore contributes to a more stable burning process. cess, confirmed by reliable operation with a mini-
mum of unplanned downtimes and a consistently
Nowadays modern kiln operation goes hand in hand high quality of lime. With an average heat input of
with highly sophisticated software and algorithms. 3,520 kJ / kg and a stone size of 25 - 90 mm the
Maerz has therefore invested a vast amount of time 550 tpd C3F kiln produced soft burnt lime with an
over the past years to take its software to a higher average residual CO2 content of 1.1 % and available
level. Among others, a very helpful feature to men- lime content higher than 94 %.
tion is the intelligent quality controller. It helps to
support the operators in controlling and stabilising The new C-type is not just a lime kiln. It combines
the kiln process. This new feature was successfully 60 years of experience and passion in the next
tested on the first installed C-type, natural gas fired generation of Maerz parallel flow regenerative lime
lime kiln. kilns
| 07
SELECTION OF RECENT ORDERS
D A E S U N G M D I – Y E O N G W O L- G U N ,
G A N G W O N-D O, KO R E A
by Christian Stampfli
Daesung MDI– Yeongwol-Gun - E5 kilns at 300 tpd each (photo courtesy of Daesung MDI Inc.)
08 |
Tangshan Gangyuan - 4,000 tons of quicklime with 5 x R5S kilns (800 tpd)
L I M E P L A N T, A R G E N T I N A L A O T I N G , P. R . O F C H I N A
In 2016 and 2018 Caleras San Juan S.A., domiciled The foundation stone for the largest Maerz lime
in the San Juan Province, Argentina, placed two or- plant in history has been laid!
ders with Maerz Ofenbau AG for the supply of en-
gineering, license, know-how, equipment as well as The construction work of the Tangshan Gangyuan
technical assistance services during erection, com- Metallurgical and Furnance Co. Ltd. project has suc-
missioning and start-up of two Maerz PFR lime shaft cessfully started on a greenfield in Hebei province.
kilns, a stationary crushing plant as well as a roller Local contractors are carrying out the erection of
mill grinding plant for petcoke at the client’s Los buildings, steel structures and auxiliary installa-
Berros lime plant. tions, while Maerz is delivering key equipment.
The new kilns of the rectangular type E5 will process The plant will have an impressive production rate
limestone and dolomite with a grading of 44 - 110 of 4,000 tons of burnt lime per day (5 x 800 tpd
mm and will produce 2 x 300 tons of burnt lime per Maerz R5S lime kilns, lean gas fired). It will set new
day. Both natural gas and petrol coke dust will be benchmarks worldwide in terms of capacity, avail-
used as fuel. ability & efficiency. Lime production is planned to
commence soon
| 09
MEXICANA DE COBRE, MEXICO
by Christopher Schneider
Mexicana de Cobre - Impressions from the kick-off meeting and location for the new R4S-kiln (600 tpd)
10 |
The order includes the supply of engineering, li- A B I N S K E L E C T R I C S T E E L W O R K S LT D,
cense, know-how, equipment as well as technical
ABINSK, KRASNODAR REGION, RUSSIA
assistance services during erection, commissioning
and start-up of the Maerz PFR lime shaft kiln at the
customer’s lime plant. Natural gas will be used as Abinsk Electric Steel Works Ltd., domiciled in
fuel. Maerz’s equipment supply comprises the fol- Abinsk, Krasnodar Region, Russia, placed an order
lowing main items: for the supply of engineering, license, know-how,
equipment and technical assistance services during
• Suspended cylinders
commissioning and start-up of a Maerz PFR lime
• Process air blowers with electric motors
shaft kiln as well as the limestone and lime handling
• Electric, measuring and control system for the
systems designed by Parget Makina Ltd., based in
lime kiln
Ankara, Turkey.
• Firing system for natural gas, including the
start-up burner equipment
This new double shaft lime kiln of the rectangu-
• Hydraulic equipment
lar type E2 will calcine limestone with gradings of
• Limestone skip hoist winch, including the
20 - 40 mm and 55 - 100 mm respectivley and will
pertinent electrical measuring and control
produce more than 160 tons of lime per day, using
equipment
natural gas as fuel. Commissioning is scheduled for
• Air blast units
the middle of 2020.
• Refractory materials
Maerz’s specialised technicians will assist with hot The supply of this new lime plant is a cooperation
commissioning and acceptance test runs on the between the companies Parget Makina Ltd. from
lime kiln and the associated equipment Ankara, Turkey, and Maerz Ofenbau AG
| 11
CHINA´S FIRST HIGH-DUST
S C R P L A N T AT C O N C H C E M E N T
Major cement manufacturers have taken measures In various Chinese provinces the limit values re-
to ensure compliance with the gradually increased garding nitrogen oxide and ammonia emissions are
limitations for nitrogen oxide and ammonia emis- going to be reduced or have already been reduced
sions. Anhui Conch Cement Co., Ltd., a leading com- in the recent past. The target value for the CemCat
pany in the industry, has equipped three 5,000 tpd SCR plants in Jining and Zhongguo is 100 mg / Nm3
cement production lines with SCR technology from NOX (hourly average) and 8 mg / Nm3 of ammonia
Maerz, thus successfully demonstrating compliance slip (daily average). The current state of technology
with the most stringent emission standards for ce- allows these emission specifications to be achieved
ment production in China. reliably with CemCat’s High Dust SCR technology.
NOX after SCR (10 % O2, dry) 100 mg / Nm3 < 50 mg / Nm3
NH3 slip after SCR (10 % O2, dry) 8 mg / Nm3 < 3 mg / Nm3
Table 1: Process data Jining plant
12 |
HIGH DUST / HIGH TEMPERATURE CEMCAT SCR PROVEN TECHNOLOGY SINCE 2006
PLANTS IN JINING AND ZHONGGUO
In more than 10 cement plants in several countries,
After a construction period of about 5 months, the CemCat has been able to gain years of experience
CemCat SCR plant in Jining was commissioned in reducing nitrogen oxide to such low values. For
August 2019 and the CemCat SCR plant in Zhong- more than a decade we have successfully demon-
guo in October 2019. CemCat designed these High strated that CemCat High Dust / High Temperature
Dust / High Temperature SCR plants for the deni- SCR plants in cement factories are ideally suited to
trification of 340,000 Nm / h flue gas per kiln line
3
reliably and continuously reduce nitrogen oxide and
(see table 1) thus ensuring permanent compliance ammonia emissions. Since August 2013 all estab-
with the emission specifications. lished SCR plants have been operating at an annual
availability rate of above 95 %
Compared with Semi Dust SCR plants, the High
Dust SCR plants are very low in pressure drop. The BUILDING THE NEW HIGH DUST / HIGH -TEM-
overall pressure drop of a High Dust SCR plant is PERATURE SCR PLANTS FOR CONCH IN JINING
about 500 Pa, with a temperature drop 10° C lower AND ZHONGGUO
than that of the Semi Dust plant. The ammonia in-
jection amount can be greatly reduced leading to an Anhui Conch was responsible for the complete
ammonia consumption of the cement plant of more concrete and structural steelwork, including
than 60 % lower than before the SCR was commis- provision of the material. Maerz supplied all core
sioned. Compared with Semi Dust plants, they have components including the catalyst modules from
a less variety of equipment and therefore stability Europe and Anhui Conch installed them. Anhui
is greatly improved. High Dust SCR plants have the Conch was responsible for the construction, Maerz
lowest operating costs. for commissioning. Due to good cooperation,
realisation of the project took place within 10
After applying CemCat’s High Dust / High Tempera-
months, which compared to typical European
ture SCR technology, the Jining plant (see table 1)
projects denotes a time saving of over 50 %.
can meet and undercut the minimum nitrogen oxide
and ammonia emission standards.
| 13
The SCR housing, where the catalysts are installed, DUST CLEANING SYSTEM
was preassembled in the workshop and then dis-
assembled for transport. At a preassembly site in The key component of a well-functioning High Dust
the plants at Jining and Zhongguo the reactor walls SCR installation in a cement plant is the dust clean-
could then be welded quickly and precisely using ing system (see below). The requirements differ
an assembling aid. Subsequently, the single layers significantly from classic soot blowers, which are
only needed to be lifted by crane and joined to their used in other industries.
final installation position. Preliminary work in the
workshop significantly reduced construction time at The proven CemCat dust cleaning system ensures
the plant and improved the quality of workmanship. that the high dust load of approx. 95 g / Nm3 (ap-
prox. 30,000 kg / h) in the Jining and Zhongguo
The High Dust / High-Temperature SCR plants in plants is blown through the catalyst elements to-
Jining and Zhongguo were built on concrete tables. gether with the flue gas and does not clog them
The footprint of the foundation of a single SCR plant up. Cement dust contains a lot of clay and is much
is approximately 16 x 17 m. stickier than dust in other industries. This makes
dust cleaning even more difficult
14 |
FRANZ SIDLER RETIRES
Nearly everybody in the industry knows Franz As you can see in the photo below, Franz’ passion
Sidler, one of the record-setters when it comes to for food has not changed – the only difference is
years served at Maerz Ofenbau AG. After more than that he now has much more time to travel the world
37 years, he retired in October and can proudly look with his wife and collect even more inspirations for
back on a variety of tasks and challenges he mas- delicious food.
tered with our company.
Franz, with your personality, competence and pas-
He started on 1 of January 1981 as a commission-
st
sion you shaped the perception of Maerz Ofenbau
ing engineer coming from a job as plant designer in the entire lime industry. We sincerely thank you
for investments within Brown Boveri, today’s ABB. for that and for your dedication and wish you and
Being a mechanical engineer by profession, he al- your family the very best for the decades to come !
ways loved to combine layout and design work with
by Stephan Lechner
the practical hands-on application of his abilities. A
virtue, which definitely became useful when com-
missioning Maerz kilns.
| 15
Happy Holidays
and best wishes for the New Year
© Maerz Ofenbau AG 2019, Richard-Wagner-Strasse 28, CH-8002 Zurich, Switzerland - info@maerz.com - www.maerz.com / www.cemcat.com
from the Maerz Team !
es
lanc
rn er
bu
s
ck
t blo
-c as
pre
spa
re p
arts
Please contact your Maerz Service Team at service@maerz.com for more information
We are also on social media! Check it out www.linkedin.com/company/maerz
16 |