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INTRO
About FEECO...................................................................................................................................1
Intro to Limestone.................................................................................................................................. 3
Types of Lime...............................................................................................................................................3
PROCESSING
Limestone Material Characteristics.............................................................................................................................8
Pelletizing Limestone........................................................................................................................................................... 9
Drying Limestone..................................................................................................................................................................12
CONSIDERATIONS
Challenges in Processing Limestone..................................................................................................................................17
Additional Resources...........................................................................................................................................................22
Introduction
FEECO International was founded in 1951 as an engineering and manufacturing company. We quickly became
known as the material experts, able to solve all sorts of material processing and handling problems, and now
serve nearly every industry, from energy and agriculture, to mining and minerals.
As experts in the fields of particle size enlargement and thermal processing, FEECO has been an expert in
limestone processing since the 1950s. We’ve helped our customers process hundreds of materials into value-
added products, eliminating handling and transportation problems, improving product characteristics, and
For further information on our limestone processing capabilities, contact a FEECO expert today.
FEECO US Headquarters
3913 Algoma Rd. Green Bay, WI 54311, USA
Phone: (920)468.1000
Fax: (920)469.5110
FEECO.com/contact
Find us on:
DISCLAIMER
FEECO is committed to publishing and maintaining this Handbook. As we continue to grow and evolve, information in this document is subject to change with-
out notice. FEECO does not make any representations or warranties (implied or otherwise) regarding the accuracy and completeness of this document and
shall in no event be liable for any loss of profit or any commercial damage, including but not limited to special, incidental, consequential, or other damage.
Please note that some images may display equipment without the proper safety guards and precautions. This is for photographic purposes only and does not
represent how equipment should be properly and safely installed or operated. FEECO shall not be held liable for personal injuries.
An Overview of
LIMESTONE
INTRO| TYPES OF LIME| PELLETIZED LIME VS. ALTERNATIVES
Easy to Transport
limestone pellet can be produced. The following Powdered limestone can tend to clump if not properly
material characteristics have key influences on the dried, which is why many limestone manufacturers
limestone pelletizing process: utilize a drying process before storing the material.
Clumping can also occur during drying of the final
Mined limestone is abrasive as a raw material. As a dislodge any potential clumping within the rotary dryer.
Various customizations may be recommended for effect on the end product. Low-quality pelletized lime
different processing equipment in order to withstand products reduce the advantages that are sought after
the abrasion of limestone processing. when selecting a pelletized lime product. For example,
inconsistent pellet sizes in low-quality pelletized lime may
Limestone can vary considerably in texture, porosity, the calcium content of the raw limestone plays a major
and composition. All of these issues can have an part in product quality and effectiveness. Therefore, it
effect on the limestone pelletizing process. For this is always important to not only start with a quality raw
reason, testing is recommended to define the best lime, but also to have a process that produces a high
3
8
Oversize
7 6 Product
Undersize
PELLETIZING LIMESTONE
Pelletizing limestone has proven to be an effective solution to many of
DIAGRAM KEY:
the problems presented by more traditional forms of lime. But exactly
how does lime go from a finely ground powder to a premium pellet 1. Pin Mixer
product? The following steps outline a typical pelletizing process and 2. Disc Pelletizer
3. Liquid Spray System
the limestone processing equipment used.
4. Transfer Conveyor
5. Rotary Dryer
PRECONDITIONING 6. Vibrating Screen
Mined limestone is first crushed into a fine powder. If necessary, a rotary 7. Oversize Mill
dryer is used to dry the mined limestone before it is crushed. Next, a raw 8. Surge Hopper
DRYING
The limestone pelletizing process adds moisture to the
pellets, making drying a necessary step before storing
or bagging the product. Rotary dryers are a common
drying choice due to their efficiency and ability to
handle a high amount of volume and variability in
feedstock. Flights within the dryer lift and cascade the
limestone pellets as they travel through the dryer’s
rotating drum to create optimal heat transfer. Similarly, FEECO Disc Pelletizer
if cooling is required, a rotary cooler is also commonly FEECO DISC PELLETIZERS AT A GLANCE
used. This equipment provides the same lifting and
SIZE 24” - 25’ (0.6 - 7.5m)
cascading motion as a rotary dryer, but reduces the CAPACITY 100 lb/hr - 100 TPH
temperature of a product using a counter-current, CUSTOMIZABLE? Yes
INCREASED PRODUCTION
Adding a pin mixer to the pelletizing process also
allows for increased production. Because moisture
must be gradually added on a pan pelletizer,
reaching the desired moisture level on this piece of
equipment can take a fair amount of time. With a pin
mixer, however, the majority of the moisture can be
added to the process and uniformly blended, before
it even enters the pelletizer. This means the limestone
can spend significantly less time on the pelletizer, and
the rate of production is then considerably increased.
The most commonly used equipment for limestone material surface and efficiently dries it. An advantage
drying is a rotary dryer. It can be used to dry both to using fluid bed dryers is that they are modular and
limestone ore and pelletized limestone. Also referred smaller than rotary dryers. However, they are unable
to as a limestone dryer, this piece of equipment is to polish granules and cannot accept variability in
popular for use in many processing stages, because feedstock, making them incompatible with many
it is a reliable drying solution. The high volume applications.
functionality and robust build of a rotary dryer can
easily withstand limestone processing demands. LIMESTONE DRYING BENEFITS
Additionally, the rotating motion and lifting flights The drying process accomplishes many benefits for
within a rotary dryer not only ensure that the material limestone, such as:
they tumble through the rotating drum. FEECO offers a material for subsequent manufacturing stages creates a
variety of customizations for rotary dryers, including: better final product. By correctly preparing the material
at the very beginning, manufacturers ensure better
• Customized flight design and pattern limestone processing and improved production at
• Customized linings every stage.
• Thicker shells for abrasion resistance
• Special burner options that limit emissions such IMPROVED PRODUCT HANDLING: Drying limestone
as NOx and CO
ore removes moisture from the surface by hardening
the material and avoiding equipment congestion in
An alternative to the rotary dryer is the fluid bed dryer,
future steps. For powdered limestone, limestone dryers
which uses pneumatic conveying to suspend
prevent issues such as clumping, making it easier to
limestone in a fluidized state. This exposes the entire
store and handle.
CHALLENGES IN CLUMPING
Limestone processing problems are not unlike the Fortunately, in addition to including a drying process
challenges faced with other naturally occurring to reduce clumping, there are additional solutions
materials. In addition to abrasion and buildup, issues available to combat limestone clumping issues:
Limestone does not always build up, but depending trajectory that naturally breaks apart material as
it is commonly seen in places such as disc plow forms based on material characteristics and
blades, the pin mixer discharge, and the flights at desired product results. A pug mill or rotary
the front end of the rotary dryer. When buildup coating drum is used to apply the additive to the
limestone maintenance issues, consistent material In addition to potentially causing buildup, the
buildup removal as part of an equipment’s regularly composition of limestone can have a direct effect
scheduled maintenance plan is essential. on process variables, such as how well a material will
agglomerate, or how much binder will be needed
to create desired product characteristics. And while scale, where small samples of material are tested to
varying composition in limestone sources cannot be gather initial data and determine feasibility of the in-
prevented, there are ways to work around it; testing tended goal. Once batch testing has been successful,
limestone in a facility such as the FEECO Innovation continuous pilot-scale testing can be conducted. This
Center will help to predict the material’s behavior in is a much larger scale test, where the process is tested
a process setting, as well as define process variables, as a continuous process loop.
confirm process success, and leave less chance for
unforeseen issues after scale-up. As often limestone producers are looking to target a
specific set of parameters, the Innovation Center can
LIMESTONE PROCESS AND measure and adjust a variety of particle characteristics
PRODUCT DEVELOPMENT during the testing process. This includes:
Limestone testing is frequently carried out in the FEECO
Innovation Center for a variety of reasons. This may be - Attrition
to confirm the viability of an intended process, trouble- - Bulk Density
shoot an existing one, develop a new product, or - Compression
enhance the characteristics of an existing product. - Crush Strength
- Flowability
No matter what the goal of testing, the Innovation - Green/Wet Strength
Center offers customized testing solutions around the - Moisture Content
unique project objectives to give you the answers - Particle Size Analysis
you’re looking for. - Physical Characteristics
- Solubility
For all types of testing, depending on the known infor- - Temperature
mation and what information the customer is looking
to gather, the testing process typically starts at batch
AUTOMATION
FEECO is a Rockwell Automation partner, providing
integrated process control solutions, both as a service
in the Innovation Center, and as part of a system
purchase.
Limestone materials are frequently tested in the FEECO Innovation Center for - Disc Pelletizer
a variety of reasons. This might include to test the feasibility of a new product - Pin Mixer
or idea, enhance the characteristics or performance of an existing product, - Rotary Dryer
improve upon or troubleshoot a process, or even develop a new process. - Rotary Cooler
- Conveyor
Our process experts can work with you to develop a customized testing program - Bucket Elevator
around the answers you’re looking for. Depending on your needs, we offer testing - Hammer Mill
services in four categories:
- Screen
- Pumping System (to pump binder
1. Feasibility/Proof of Concept - An initial, 2. Proof of Product - A more in-depth into a disc pelletizer or pin mixer)
non-witnessed batch testing phase in batch testing phase in which more time
which the possibility of creating a is spent determining whether a product
product is explored. can be made to desired specifications. A Note on Binder Selection:
Calcium-based and ammonium-based
lignins are commonly used when pelletizing
limestone, because of their ability to create
3. Proof of Process - A continuous testing 4. Process/Product Optimization - An
a desired pellet strength and readily break
phase that aims to establish the equip- in-depth study to optimize your specific
down in the field. Their economical and
ment setup and parameters required for material’s characteristics and/or nutrient differences are discussed prior to
continuous production of your production parameters in an testing, in addition to other binder options.
specific material. industrial setting.
Commonly Tested
Limestone Materials:
Processes Commonly Tested:
- Dolomitic Limestone
- Limestone Pelletizing - Limestone Drying
- Calcitic Limestone
- Chalk
www.FEECO.com
FEECO.com/contact
Algoma Rd. Green Bay, WI 54311, USA • Phone: (920)468.1000 • Fax: (920)469.5110 • FEECO.com/contact
sales@feeco.com
3913 THE LIMESTONE PROCESSING
LIMESTONE HANDBOOK | 20
PROCESSING|27
THE INNOVATION CENTER ADVANTAGE
Testing in the FEECO Innovation Center provides an invaluable opportunity to test Commonly Targeted
in a controlled environment, allowing you to gain a familiarity with your material, Material Characteristics:
while reducing the chance for unforeseen problems after process scale-up. Some
- Crush Strength/Hardness
of the many advantages to testing in the FEECO Innovation Center include:
- Abrasion/Attrition
- Material Composition
Material Experience:
- Bulk Density
FEECO has been a pioneer in material processing since the 1950s, and has extensive
knowledge around hundreds of materials and processing methods. - Flowability
- Moisture Content
Customers gain a valuable familiarity with their material and its unique - Green/Wet Strength
characteristics through testing in the Innovation Center. - Sieve Analysis
- Solubility
Complete Process Knowledge:
FEECO is familiar with each aspect of a process, from agglomeration and kiln
processing, to drying and cooling, allowing us to look at how the process will
function as a whole, instead of each individual portion.
Process Scale-up:
Once the process configuration has been defined, FEECO can aid in process
scale-up, as well as manufacturing the equipment needed to get the job done.
A variety of data points can be monitored, trended, and adjusted in real time, all
from a single interface or mobile device.
Historical data is also available for returning customers, allowing you to pick up
exactly where you left off.
SCHEDULE A TEST
To discuss your testing needs with one of our process engineers and schedule a test, contact us today at:
FEECO.com/contact
www.FEECO.com
FEECO.com/contact
sales@feeco.com
3913 Algoma Rd. Green Bay, WI 54311, USA • Phone: (920)468.1000 • Fax: (920)469.5110 • FEECO.com/contact LIMESTONE PROCESSING|28
ADDITIONAL RESOURCES
For further information or reading on limestone, we have provided some additional resources below. Please
note that the inclusion of any resource or company is not an endorsement and the views of that resource do
not reflect those of FEECO International.
BOOKS
Lime and Limestone: Chemistry and Technology, Production and Uses
by J. A. H. Oates
ISBN-13: 978-3527295272
The choice to work with FEECO means a well-rounded commitment to quality. From initial feasibility testing, to
engineering, manufacturing, and parts and service, we bring our passion for quality into everything we do.
Innovation
The FEECO Innovation Center can
aid in everything from feasibility
testing, to process design and
product development.
+
Parts & Service
Engineering
Our Customer Service
We engineer custom
Team is ready to Since 1951 solutions to meet
serve, from routine
your unique needs.
maintenance,
to emergency
service.
Manufacturing
We manufacture the best
heavy-duty processing
equipment around.
3913 Algoma Rd. Green Bay, WI 54311, USA • Phone: (920)468.1000 • Fax: (920)469.5110 • FEECO.com/contact
FEECO.com/contact THE LIMESTONE PROCESSING HANDBOOK | 23
For more information on processing limestone, material testing,
or custom equipment, contact FEECO International today!
US Headquarters
3913 Algoma Road | Green Bay, WI 54311 USA
Phone: 920-468-1000
FEECO.com/contact