Lime making process - A Business Perspective

Topics:
1. Introduction
2. Lime and Lime making Process
3. Limestone and Limestone Sourcing
4. Parallel Flow Regenerative Kiln Process
5. Quality Assurance
6. Customer Requirements & Lime Balancing
7. Environmental management
8. Our Performance
9. Laboratory Tests
LIME MAKING SM DIVISION
Lime making process - A Business Perspective

LIME MAKING SM DIVISION

Introduction

Lime is the most important flux used in the LD steel making.

The development of the LD process, the essence of which, is
it’s speed, calls for stringent control on the quality and a
steady supply of lime to be used for the steel making process.

When Tata Steel opted for basic oxygen steel making, two Twin shaft kilns
(Maerz make) were commissioned in the year 1983 for making lime.

Subsequently, when LD shop # 2 came into operation, three more Twin

shaft kilns were commissioned and put into operation in the year 1991– 92.

Again during 3 million Ton expansion, to cater to the need of LD#3 , 2 twin
shaft kilns (600 TPD) were commissioned in 2012.
Again

LIME MAKING SM DIVISION

Lime Plant Journey

3550 tpd

8th & 9th

2350 tpd

1925 tpd 7th 7th

1500 tpd 6th 6th 6th

3rd, 4th & 5th 3rd, 4th & 5th 3rd, 4th & 5th 3rd, 4th & 5th
600 tpd

1st & 2nd 1st & 2nd 1st & 2nd 1st & 2nd 1st & 2nd

Introduction of Two 600 tpd kilns

Rotary kilns + Larger capacity (425 lean gas fired kiln with Suspended
All rotary kilns tpd) kiln with Rotary of 425 tpd.
two Shaft kilns hopper charging cylinders using lean
phased out. Use of Liquid ring gas (first of its kind
introduced. system introduced.
gas boosters in the world).

1983 1992 2005 2008 2012

LIME MAKING SM DIVISION

Technological Journey
• 600 TPD Twin Shaft PFR Lime kiln with
suspended cylinder and Lean Gas 7 Pillar-Arch PFR
• Absence of arch support enables more Kilns & 2 Suspended
uniformity in gas distribution Cylinder PFR Kiln

• Use of low CV gas for better soft

Lime-making using
burnt lime
Lean Gas(CO+BF gas)
• Introduction of Liquid ring Booster

• Arch supported Twin vertical shaft Parallel

Flow Regenerative Lime Kiln
• High thermal efficiency of around 90% Twin Shaft Kiln
• Soft burnt lime making possible introduced

• Counter current Rotary Lime Kiln

• Poor thermal efficiency of 60%
Rotary kilns &
2 PFR kilns

LIME MAKING SM DIVISION

Plant facilities
Facilities Details Suppliers
New Tippler Hydraulic Operated Side Arm Charger , 90 Tonnes with 150° L&T
tippling
Stacker cum Stacking Capacity-1800 TPH Reclaiming Capacity- 1500 TPH L&T
Reclaimer
Ground Hopper 3 Vibro Feeders underground
Old Tippler Loco Operated Rope drum Tippling
DD Screen 25 mm and 80 mm Double deck screen for Limestone TRF

Arch-Pillar type 7 No. Operating capacity-300 TPH And One 425 TPH M/S Maerz,Switzerland
Kiln
Suspended 2 No. Operating capacity-625 TPH M/S Maerz,Switzerland
Cylinder Type
Kiln

Bag Filters 11 DE system bag Filter 9 Process Bag Filter Thermax

DFDS System 156 DFDS Points TPS & Aerochem
IVC System 6 No. TPS

LIME MAKING SM DIVISION

Purpose Of Department

Uninterrupted supply of Lime to Steel Melting Shops as per specification and at planned cost.

LD Shop # 1
Workforce Structure
11
LD Shop # 2
Operating LCP
Key Customers
12
Section
MECH & IEM
Maintenance 13 LD Shop # 3
Supporting
Section Technical
Services

HR/IR

Key Inputs: 1) Limestone sourced from Jaisalmer, Dubai, Oman & Fujairah and Vietnam as raw
material for Lime - 2.32 million ton in FY20
2) Coke oven gas & Blast Furnace gas

Key Products : Soft Burnt Lime produced - 868712 MT in FY’20

LIME MAKING SM DIVISION

Lime Plant Process Flow & Layout

Limestone Planning for Limestone

procurement

Wagon Limestone
Lime stone conveying & Lime stone
Transporting in unloading Weighment
Screening
wagons

Coke oven Lime stone Testing of Lime Lime Draw by

gas supply Calcination Lime Conveying LD shops

Supplier Lime making process Customer

LIME MAKING SM DIVISION

Lime making process - A Business Perspective

LIME MAKING SM DIVISION

Conversion of Limestone to Lime

Calcination of lime is a simple chemical process.

760 KCal When heated, the carbonate decomposes. The
reactions in the burning zone are as follows:
Fuel gas combustion:
1.7 Kg 1 Kg
CO (coke oven gas) + O2 = CO2 + (heat)
Reaction inside a Kiln
Lime calcination:
CaCo3 = CaO + CO2 + 753 kcal/kg of CaO

The decomposition temperature depends on the

partial pressure of CO2. In a gas of combustion
Conversion of Limestone atmosphere at normal pressure and 25 % Co2,
to Lime
the dissociation commence at 810 C.

LIME MAKING SM DIVISION

Conversion of Limestone to Lime

In order to decompose the stone core, it is

Progress of Reaction inside Limestone
Decreasing Reactivity
necessary to transfer the required
dissociation heat from the surface area of the
stone through an insulating shell of calcined
lime down into the core; the stone surface
area, therefore, has to be heated to above
900 C.

When producing soft burnt lime, the surface

temperature of the charge must not
exceed1100 C to 1150 C to avoid re-
carbonation of CaO.
Increasing degree of conversion
Soft Burnt Over Burnt Hard Burnt

LIME MAKING SM DIVISION

Lime making process - A Business Perspective

LIME MAKING SM DIVISION

Basics of Limestone
It most commonly forms in clear,
warm, shallow marine waters. It is
usually an organic sedimentary rock CaO 53-55
that forms from the accumulation of Chemical SiO2 0.1-0.4
shell, coral, algal, and fecal debris. Composition of S 0-0.01
CP Limestone: MgO 0.3-0.6
It can also be a chemical
Al2O3 0.1-0.3
sedimentary rock formed by the Fe2O3 0.05-0.1
precipitation of calcium carbonate
from lake or ocean water.

Appearance: Increasing percentage of iron oxide

Density Comparison:

2.7 7
Times Times
Water Increasing percentage of carbonaceous material
Limestone Iron
Impurities and Limestone colour

LIME MAKING SM DIVISION

Limestone Planning & Sourcing
Steel making
quantity Crude Steel Tons 100
(As per ABP) Lump Lime Tons 6.5
(@65Kg/Tonne)
Lump Lime Required Gross Lime Tons 8.55
at 65Kg/Ton of steel UAE/Dubai Jaisalmer
Limestone Charged Tons 14.5
(As per ABP) Oman TSJ Vietnam
Limestone Bought Tons 18.6

Gross Lime required

(Considering 24% lime
fines generation) • Limestone Sources
Source wise procurement planning is Based On
Limestone charged Total limestone • Rank in VIU
considering 59% quantity shared • Past performance
yield to Procurement • Capability to supply
Limestone required • Geopolitical scenario
Considering 22%
undersize loss

LIME MAKING SM DIVISION

Limestone Source Selection Process
Due Diligence
LAB Trial • Mines planning
Porosity Test • Capability
Samples from Chemical test • Bore hole report-deposition
different mines Decrepitation Test • Licenses/Clearance checking
received at TSJ Calcining test • Quality System assesment
• NRD Reactivity test • Site visit
• Procurement • Price negotiations

1st Plant Trial

(Dedicated Kiln)
2nd Plant Trial Suitability of Limestone
Included in The • Charged in all Kilns • Undersize generation
List of Sustainable Final selection • Compatibility with • Fuel Consumption
Sources other sources • Product Quality
• Fines generation

LIME MAKING SM DIVISION

Value In Use Model
• Value in use calculation
• Developed jointly by Lime Plant, Technology Group and Procurement
• Properties considered
VIU (Value In Use) Model: Limestone Screen loss(-25 mm)
• The VIU(Value In Use) model is a Limestone Meansize
process to iterate the actual
value that a material is yielding Limestone Fines generation
at the end of value chain through Porosity of limestone
step wise value calculation.
SiO2% in Limestone
• In order to estimate the value we CaO% in Limestone
get at the end of the value chain,
the effect of impurities and loss Decrepitation index
at different stages of supply
LOI of Lime
chain is studied and analysed and
put in the VIU model to Shatter index of Lime
determine the ranking of the
Impurities
sources.
Reactivity of lime

LIME MAKING SM DIVISION

Limestone Conveying Circuit

Tippling of Limestone Wagon Stacking and

Reclaiming at
Limestone Yard
PFR Lime Double Decker
Kiln Screen(80mm
& 25mm)

Secondary Screening Limestone

Before Kiln(25mm) Storage Bins

LIME MAKING SM DIVISION

Limestone Balancing

Oversize
Limestone
Lime from Kiln
2 Tonnes Limestone to Kiln
(Yield factor-59%)
Limestone Right size 72 Tonnes(94 %)
43 Tonnes (59 %)
Limestone
Supplied 77 Tonnes
Undersize from
secondary screener
100 Tonnes
Undersize 5 Tonnes(6 %)
Limestone 21 Tonnes

Sinter Plant

LIME MAKING SM DIVISION

Lime making process - A Business Perspective

LIME MAKING SM DIVISION

Construction of Typical PFR Lime Kiln

FIRING SHAFT NON-FIRING SHAFT

LIME MAKING SM DIVISION

Construction of Typical PFR Lime Kiln-Video

LIME MAKING SM DIVISION

Process Parameters
Stage Sources of variation Limestone Waste gas flow
to Bag Filter ▪ Limestone charged from top and lime
Charging
discharge from bottom.
➢ Variation in physical Combustion
properties i.e porosity air flow
Input and abrasion resistence ▪ Fuel: CO gas/ Mixed gas; Combustion
➢ Variation in size Material
➢ Variation in inpurities flow inside the kiln.

➢ Combustion Air Flow

➢ Gas flow
➢ Pyrometer Temp.
➢ Lance choking Heat
➢ Decrepitation index flow
➢ Loss On Ignition
Process ➢ Air gas ratio
➢ Lance length
➢ Shaft differential
pressure
➢ Kiln pressure
➢ Cooling Air flow
➢ Cooling air pressure
Output ➢ Lime temperature
➢ Waste gas heat
➢ Heat carried by dust
LIME MAKING
C. O. gas ▪ CO/ Mixed gas pumped into the kiln
flow
through gas boosters and combustion air
fed through twin lobe blowers.
▪ Gas firing done in alternate shaft
▪ Refractory Lining (Kiln): Pillar & Arch type;
Annular space for equal distribution of
Cooling hot flue gases
air flow Lime discharge
▪ Bag filter: Dust release below 10mg /
Nm3 dust against norms of 50 mg/ Nm3
norms.
Lime sample collection point
SM DIVISION
Heat Balance in PFR Lime Kiln

Input 876 KCal Output 876 KCal

Heat Balance
Off Gas -82 Kcal 9%
Dry Limestone 0 KCal 0%
Dust - 0.2 Kcal 0.9%
Combustion Air 15 KCal 1.7%

Vapourisation of H2O -10 KCal 1%

Fuel 855 KCal 97.6%
Dissociation Heat -725 KCal 83%

Heat Loss Through Shell -40 KCal 5%

Cooling Air 6 KCal 0.7%

Lime -19 KCal 2%

LIME MAKING SM DIVISION

Lime making process - A Business Perspective

LIME MAKING SM DIVISION

Lime Quality

BOF process use lime as the LOI Reactivity

main fluxing agent. Speed of
BOF process demands high LIME
dissolution rate of lime.

High CaO High reactivity

The lime produced must meet Microstructure
the multiple requirements of availability in lime helps in quick
dissolution of lime of Lime
high CaO availability, high reduces cost in
reactivity for faster and slag formation depicting
steel making
dissolution, and low LOI for increasing
Increasing crystal size
reduced consumption.
reactivity leading to
reduced
reactivity
Chemical CaO 92%
Composition SiO2 0.4%
of Steel S 0.03%
making
MgO 1%
grade Lime:
Al2O3 0.3%
Fe2O3 0.2%

LIME MAKING SM DIVISION

Quality Assurance- Digital transformation of Action Standards

The flowchart of action standard is programmed in Level-2

The kilns are twin shaft, and both are automation and the system prompts the operator to take
alternatively fired. For better heat distribution, action as per the action standard.
both the shafts need to behave similarly.
This requires many comparisons to be done by
the operator to take decisions. And more often
it becomes quite cumbersome for the operator.

LIME MAKING SM DIVISION

Quality Assurance- Level 2 Quality Prescription Model

Output

8 Hours Needs to be
eliminated

Analysis & Adjustment
Product analysis used to take 8 hours, so the operator had
to wait for 8 hours for taking corrective action.
Predictive model gives product quality 8 hours before the
lime actually comes out of kiln.
The prescriptive model also suggests the operator, what
action to take to improve the quality in case of deviation.

LIME MAKING SM DIVISION

Lime making process - A Business Perspective

LIME MAKING SM DIVISION

Customers Need and our Performance

Customers Requirements Average Reactivity(T2)

GOOD
72.00
CaO% T2 Std. Dev. Of CaO%
70.00

Reactivity in Deg C
LD#1 >92 >65 <1.2 68.00
66.666.966.2
66.0
66.00 65.2

LD#2 >92 >65 <1.2 64.00 Target

62.00
LD#3 TSCR >92 >65 <1.2 60.00

Standard Deviation of CaO% Average CaO content

GOOD
2.5 95
2.2 94.0
93.8 93.8
94

Lime CaO content in %

2
1.7
1.5 93
1.5 91.5
92
1.1 1.0
91 90.7
1
Target 90
Target
0.5
89
0 88

LIME MAKING SM 5DIVISION

Lime Balancing
Limestone to
Kiln
Kiln Dust
Lime Fines from DE system

Lime from Kiln

Sinter Plant

LD#1 LD#2 LD#3

Lump Lime Lump Lime Lump Lime

Lime Fines from Lime Fines from Lime Fines from

screen screen screen

Lime Fines from Lime Fines from Lime Fines from

DE system DE system DE system

LIME MAKING SM DIVISION

Lime making process - A Business Perspective

LIME MAKING SM DIVISION

Environmental Endeavour-Lime plant
Sources of Pollutants: Transfer Points
• Kiln waste gas
• Transfer Points Fines Loading
1) Hopper to Truck 2)Conveyor to Conveyor 1)Hopper to Truck
• Spillage ➢ All Bag filter hopper provided with
RAV for controlled discharge
Kiln Waste Gas ➢ All Truck loading points provided
with Jet Loader for spillage free
➢ All kilns provided with Bag Filter.
transfer
➢ Protection for Bags-Waster Gas temperature controlled within 150° C.
➢ Kiln stops if Bag filter is not in line. ➢ Innovative Triple axis Jet Loader
Rotary Air Lock valve for conceived and incorporated for Lime
➢ Interlock provided for stoppage of kiln in controlled discharge transfer to LF
case bag filter is by passed
➢ One additional bag filter MKC(Common bag Bulk Loading
Before
filter) provided for maintenance purpose
➢ Spillage from Bulk Loading Spout for
transfer to LF in LD Shops a major
concern
After
Review Mechanism
➢ Operational and maintenance
ownership defined
➢ Bag pulsing checking covered in Daily
Management.
➢ Hopper level checking covered in Bulk Loading Spout
Daly management ➢ Innovative Triple Axis Jet Loader conceived and
➢ All stacks have online CEMS incorporated for Lime transfer to LF
instrument installed. ➢ Ownership defined for proper functioning

LIME MAKING SM DIVISION

Environmental Endeavour-Lime plant
Transfer Points Stacker cum Reclaimer Spillage
Conveyor to Conveyor (Limestone)
• DFDS(Dry Fog Dust
IVC(industrial Vacuum Cleaning) System
Suppression system) at all
transfer points. Sprinkler

DFDS System review Water tank

• Cleaning of air & water
solenoid valve and Nozzle • Unique project done 1s time at Tata Steel
header. • Water tank is installed on ground to avoid any
• Operational & maintenance extra load on stacker
ownership defined • Scheduled inspection of suction points and
Conveyor to Conveyor (Lime) monitoring of suction pressure.
• All transfer points • Cleaning of deposition inside suction pipes. .
provided with Dust IVC System review
Evacuation system
• Total of 10 DE systems
in Lime Plant
Before After
Wagon Tippler
• Dry Fog Dust
•
DATE: REV NO.:
DE REPORT
Scheduled maintenance of SHIFT:
Suppression
Mk #1 N
CONE

N
SENSOR SUCTION

EN
MANUAL
VALVE
PNEUMETIC
VALVE
Dust Emission over the years
solenoid valves Mk #2
Mk #3
Mk #4
N
O
O
N
N
N
EN
EN
EN
System for
• Daily Inspection of ID fan Mk #5
Mk #6
Mk #7
O
N
N
N
N
N
EN
EN
EN
supressing huge Fugitive Dust Emission Trend
Mk #8 O N EN

and its bearing. Mk #9

DE #1A
O
O
N
N
EN
EN fugitive dust 6
DE #1B O N EN
4.2 3.9
•

mg/nm^3
DE #2 NA NA NA

Status monitoring of DE #3
DE #6
DE #7
FG
FG
N
N
N
N
NA
N
EN
emitted during 4 3.5
suction cones of DE unloading.
DE #9 FG N N
DE #10 FG N N
DE #12 N N EN
DE #15 N N EN
2
system PIT JUNC FG N N
• Special Self cleaning nozzles to minimize clogging
FOREMAN SIGN.:
OK NOT OK FLAP GATE NOT APPLICABLE
EQUIPMENT AVAILABLE BUT NOT WORKING frequency. 0

LIME MAKING SM DIVISION

Lime making process - A Business Perspective

LIME MAKING SM DIVISION

Environmental performance Over Years
Dust Emission over the years Power and Fuel Consumption over the years

Stack Emission at Lime Plant in Kg/hr Specific power consumption

12 90
10 Due to reduced
10 10 85
7
8 utilisation of Kilns

KwH/Ton of Lime
7
UoM

6 5.6 80
5 5
4 6
2.6 75
2 2.6 3
0 70
Sectoral FY18 FY19 FY20 FY21T FY25T
65
Benchmark
60
Global Indian(JSW Dolvi – FY20) Internal ( Lime Plant) Plan/Target Actual

Fugitive Dust Emission in mg/Nm3 Specific Fuel Consumption

6
840
5 5 5 5 5 5 835 Due to reduced
5 5 830

KCal/Ton of Lime
4 825 utilisation of Kilns
UoM

3 820
3 2.2 815
2 1.4 810
805
1 1.4 800
0 795
790
Sectoral FY18 FY19 FY20 FY21T FY25T
Benchmark
Global Indian Internal ( Lime Plant ) Plan/Target Actual
Axis Title

LIME MAKING SM DIVISION

Lime Cost Analysis

Gross Lime Cost Net Material Cost

9200 5000
9000 Due to reduced 4900
8800
8600 utilisation of Kilns 4800

8400 4700
Rs./Ton

Rs./Ton
8200 4600
8000 4500
7800 4400
7600
4300
7400
7200 4200
7000 4100

Cost Above Limestone Rate

5000 3000
4500 Due to reduced
2500
4000
3500
utilisation of Kilns
2000
3000
Rs./Ton

Rs./Ton
2500 1500
2000
1000
1500
1000
500
500
0 0

LIME MAKING SM DIVISION

Lime making process - A Business Perspective

LIME MAKING SM DIVISION

Porosity Test

Wt. of water(Volume)=W-D
(Volume of Pores)
W

Volume of orange portion(V)=W-S Schematic Diagram for Porosity Apparatus

S
Weighing in water
S=D-Orange area upthrust(volume)
W-S=D+Pore vol-(D-Orange area vol)
Porosity%=(W-D)/(W-S)*100
W-S=Pore Vol+Orange vol
LIME MAKING SM DIVISION
Decripitation test

1.5 KG of 25
mm cubes
At 1000 deg
C for 2 hours
Gyration and periodical impact
for 10 minutes

Percentage (-10 mm) fines

generated is taken as
Decripitation Index
LIME MAKING SM DIVISION
Reactivity Test

Reactivity of lime burnt up to different degrees

Soft -burnt Under-burnt hard-burnt
80

70

Temperature in ⁰C
60

50

40

30

20
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Time in min

Reactivity is measured indirectly by means of Reading after 120 sec(2 Min) is

measuring rise of temperature on slaking of taken as standard called T2
lime with water.

LIME MAKING SM DIVISION

LOI (Loss On Ignition)

CaCO₃ → CaO(s) +CO₂(g)

Heat(1000 Deg C)

Weight loss due to CO2 gas release

2 Gm of Lime (-0.25 mm) heated for 2 hours

at 1000 Deg C
Unburnt CaCO3

Percentage Weight Loss is LOI

LIME MAKING SM DIVISION

 Thank You

LIME MAKING SM DIVISION

Decision Matrix for Limestone selection

Yes

LIME MAKING SM DIVISION