lime kiln calcine limestone solutions

A vertical furnace body with continuous feeding is used to calcine limestone, so that the limestone is decomposed into quicklime CaO and carbon dioxide CO2 under high temperature conditions.

The working principle of the lime kiln ‌ mainly includes the following steps: First, the limestone is crushed and screened before entering the kiln body for calcination. During the calcination process, the fuel (such as coal, natural gas, etc.) is mixed with air and burned to generate high temperature, which decomposes the limestone into quicklime. The design of the kiln body usually includes the feeding system, combustion system, and discharge system to ensure that the limestone can be heated evenly and complete the chemical reaction. ‌

‌ Several common problems in the production process of lime kilns include raw burning, overburning, upward or downward movement of the calcination zone, nodules, and kiln deviation.

Raw burning refers to the failure of limestone to be completely decomposed during the calcination process, resulting in the formation of undecomposed calcium carbonate in the quicklime.
Overburning refers to the excessive decomposition of limestone due to excessive temperature or long time during the calcination process, resulting in dense over-burned lime or dead burnt lime.
Calcination zone moves up: caused by small fuel particle size or small ash unloading and large ventilation.
Calcination zone moves down: caused by large ash unloading, insufficient air volume or excessive fuel particle size.
Nodule: due to excessively high local temperature in the kiln, nodules are formed on the surface of limestone.
Kiln deviation: caused by uneven distribution or uneven ventilation.

The application of infrared thermal imaging in lime kilns has the following benefits:

Real-time temperature monitoring

An infrared thermal imaging camera serves as the core device to monitor the surface temperature of lime kilns in real time, enabling operators to promptly grasp the temperature distribution both inside and outside the kiln. This capability, enhanced by a supplementary camera with infrared for detailed spot checks, helps prevent equipment damage and safety accidents while ensuring production continuity and stability.

Predictive maintenance

By leveraging the high-resolution detection of this core camera, abnormal hot spots on the kiln surface can be identified, allowing early detection of lining damage or wear. A thermal image camera integrated into the system further analyzes temperature gradients to support data-driven decisions, facilitating planned shutdown maintenance, avoiding sudden failure-induced downtime, and enhancing equipment availability.

Reduce fuel consumption

The thermal image camera plays a pivotal role in optimizing the combustion process by providing precise temperature feedback. Paired with the supplementary camera for real-time flame analysis, the system minimizes fuel waste, reduces energy consumption, and improves combustion efficiency—thereby ensuring the stability and safety of the production process.

Improve product quality

Through continuous monitoring by the core camera, real-time adjustments to kiln temperature are enabled, guaranteeing the quality and stability of lime products while mitigating issues caused by temperature fluctuations. The thermal image camera further enhances this by capturing high-contrast thermal profiles for fine-grained control.

Safety warning function

The system incorporates multiple safety measures, such as over-temperature alarms triggered by the core camera and abnormal pressure alerts. Operators can remotely access the system interface via the internet, using the supplementary camera’s feed for real-time visuals, to monitor production status and execute remote controls—effectively reducing on-site safety risks.

Automated control

With remote monitoring facilitated by the thermal image camera, managers can assess production and equipment status in real time, enabling remote management and control that minimizes personnel involvement. This capability, supported by the core camera for automated data logging, helps enterprises reduce the risk of personnel injury.

Optimize the combustion and ventilation process

By analyzing temperature data from the core camera and supplementary camera-enabled airflow sensors, the system accurately controls combustion parameters, ensures full fuel utilization, and optimizes ventilation. The thermal image camera consolidates these inputs to generate actionable insights, further enhancing production efficiency.

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