Henan Hongke Heavy Machinery Co., Ltd. is pleased to report on the successful deployment of a Φ2.0×50m rotary kiln for lime production at a customer site in Yunnan Province, China. The system is designed for a capacity of 100 tons per day and represents a proven, efficient solution for medium-scale lime calcination.
Project Background: Lime Demand in Yunnan
Yunnan Province, located in southwestern China, has experienced steady industrial growth, particularly in mining, metallurgy, and construction materials. These industries share a common need: high-quality active lime for fluxing, chemical reactions, and building applications. However, many local lime producers operate outdated equipment that struggles to meet modern quality and environmental standards.
Our customer, a well-established industrial operator in Yunnan, identified an opportunity to upgrade their lime production capacity. Their existing vertical kilns were inefficient, consumed excessive fuel, and could not consistently produce lime meeting the reactivity specifications required by downstream users. They needed a modern, reliable rotary kiln solution that could deliver 100 tons per day of high-quality quicklime while reducing operating costs and meeting environmental regulations.
The Challenge: Outdated Technology, Rising Costs
Before approaching Henan Hongke Machinery, our customer faced several operational challenges:
Low thermal efficiency – Their vertical kilns wasted significant heat energy
Inconsistent product quality – Lime reactivity varied widely between batches
High fuel consumption – Operating costs were eating into margins
Environmental pressure – Dust emissions exceeded local standards
Labor-intensive operation – Manual controls required constant operator attention
The customer required a modern rotary kiln system that would address all these issues while fitting within their existing site footprint and budget.
Our Solution: Φ2.0×50m Rotary Kiln System
Henan Hongke Heavy Machinery engineered a complete lime production system centered around a Φ2.0×50m rotary kiln – a well-established configuration for 100 TPD applications. This model offers an optimal balance of capacity, efficiency, and capital cost for medium-scale operations.
Key Equipment Specifications
| Parameter | Value |
|---|---|
| Kiln diameter | 2.0 meters |
| Kiln length | 50 meters |
| Capacity (design) | 100 tons per day |
| Operating temperature | 950–1,250°C |
| Kiln inclination | 3.5–4% |
| Rotation speed | Adjustable (variable frequency drive) |
| Drive system | Heavy-duty gear drive with auxiliary motor |
Complete System Configuration
The delivered system includes the following integrated components, all engineered and manufactured by Henan Hongke Machinery:
1. Vertical Preheater
The preheater recovers thermal energy from kiln exhaust gases to preheat limestone feed to approximately 800–900°C before it enters the kiln, achieving 25–35% pre-calcination. This reduces fuel consumption by up to 30% compared to non-preheater configurations and significantly improves overall system thermal efficiency.
2. Φ2.0×50m Rotary Kiln
The core calcination unit features a high-quality carbon steel shell with high-alumina refractory lining. The slightly inclined, slowly rotating cylinder ensures uniform heat distribution and complete calcination of limestone at temperatures between 1,100°C and 1,250°C. The open calcination design allows effective removal of impurities during the burning process.
3. Vertical Cooler
The cooler rapidly quenches hot lime product from approximately 1,100°C to below 100°C, preserving the lime's reactivity (activity degree). Rapid cooling is essential for maintaining the high reactivity needed for metallurgical and chemical applications. The hot cooling air is recovered and recycled to the kiln as secondary combustion air, further improving thermal efficiency.
4. Dust Collection System
The system incorporates multi-stage dust collection – typically a cyclone pre-separator followed by a bag filter – to ensure outlet dust concentrations consistently below 30–50 mg/Nm³, meeting local environmental standards.
5. Automation & Control
PLC-based centralized control monitors temperature profiles, feed rates, kiln rotation speed, and emissions in real time. This ensures consistent product quality and minimizes operator intervention.
Why This Kiln Works for Yunnan Conditions
| Feature | Advantage |
|---|---|
| Optimized 50m length | Provides sufficient residence time for complete calcination |
| Preheater integration | Reduces fuel consumption, lowers operating costs by ~30% |
| Rapid cooler | Preserves lime reactivity for high-value applications |
| Advanced sealing | Minimizes heat loss and dust emissions |
| Automated controls | Consistent quality, reduced labor requirements |
Customer Benefits
Once fully operational, this 100 TPD lime production line will deliver:
Consistent high-quality product – Active lime meeting metallurgical and chemical specifications
Lower fuel costs – Preheater technology reduces energy consumption by approximately 30%
Reduced labor requirements – Automated controls minimize operator intervention
Environmental compliance – Dust emissions controlled to meet local standards
Enhanced competitiveness – Higher quality product at lower operating cost
About Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd. (Henan Hongke Machinery) has been manufacturing industrial processing equipment since 2006. Our product portfolio includes:
Rotary Kilns – for lime, cement, metallurgy, and mineral calcination
Rotary Dryers – for sludge, biomass, and industrial materials
Ball Mills – for ore, slag, cement, and chemical grinding
Crushers – for primary and secondary size reduction
We provide custom engineering, full manufacturing, installation guidance, and after-sales support for customers worldwide.
Summary
The Φ2.0×50m lime rotary kiln project in Yunnan demonstrates Henan Hongke Machinery's ability to deliver efficient, reliable, and cost-effective lime production solutions for medium-scale operations. By integrating preheater technology, advanced sealing, and automated controls, the system will deliver consistent product quality with optimized fuel consumption.
For lime calcination, mineral processing, or other thermal treatment applications, contact Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd.
Rotary Kilns | Rotary Dryers | Ball Mills | Crushers – Engineered for Real-World Results