Kiln Process Optimization

The Kiln Process Plus system helps optimize lime quality and maximize throughput and efficiency of the kiln process in manufacturing operations. Using the hardware and software tools found in a modern distributed control system, and the instrumentation typical of a kiln, the system provides the benefits of increased lime quality and reduced process energy consumption.

With this system, variability of residual CaCO₃ in reburned lime is reduced such that the Btu used per pound is decreased overall. The ratio of fuel and total air to moisture content is constantly and automatically controlled providing a stable heat balance and further reduction in fuel usage.

With the kiln operating on optimized control, operating targets that have traditionally included a "comfort zone" are tightened. Resultant lower Oxygen levels minimize dust losses and reduce exit gas temperatures. Higher quality lime positively effects white liquor such that digesting is stabilized, liquor strength is increased, and evaporation costs are reduced.

The user interface to the lime kiln process is improved such that functions requiring manual intervention are automated. Additionally, optimization of flame shape and precise control of the overall heat balance prevents overfiring in any section of the kiln. The system can be installed both on new kilns and as a retrofit to existing lime kiln processes. Additional features include:

•Reduction in standard deviation of residual carbonate
•Reduced fuel consumption
•Overall lime kiln stability increase
•Increased production capacity
•Increased efficiency
•Reduced emissions
•Improved protection of process equipment
•Complete operator acceptance of control system
•Single knob process control
•Control based on Btu heat balance through the kiln
•Three zone "decoupled" control
•Residual CaCO₃ stabilization
•Complete process data monitoring, trending, and historical logging

Automation Applications, Inc., 717 Constitution Drive, Ste. 101, Exton, PA 19341. Tel: 610-458-0500; Fax: 610-458-1905.