The Use of Parametric Analysis to Identify Opportunities for Improved Operations of Lime Kilns, 2017PEERS

Kraft mill lime kilns are typically sized and evaluated for production rates on 2 key parameters; total internal volume (inside refractory lining) and length/diameter ratio.  Lime kilns can be subsequently divided into classifications based on additional processing equipment within the kiln system from older kilns with no coolers through those with ESPs and ultimately the most modern kilns with coolers, ESPs and external dryers.

Using these as commonalities amongst kiln groupings, a parametric analysis of the key process and mechanical values can be used to compare key performance indices.  These reveal areas for potential improvement and provide confidence that such improvements can be achieved.  The results can be applied to existing operations to allow improved day-to-day operations, increase efficiency and to plan for improvement projects on the kiln system to gain additional beneficial results.  Kiln layouts, benchmarking and parametric analysis with results are reviewed for several working kilns.

This paper will address the important parameters required for the process.  Kiln layouts and key parameters for benchmarking including mechanical dimensions relating to production capacity, key process temperatures, impacts on kiln performance such as gas vs. oil, coolers vs. no coolers, and mud dryness are examined.  The mechanics of the benchmarking process including data collection method (remote or on site), analysis via material and energy balances, confirmation of audit finding with stack test data, and parametric analysis methods are reviewed.  Finally, the details of several operating kilns are compared, parametric study observations and potential recommendations for improvements are reviewed.

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