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Help CenterJY-400 Mixed-Fuel Lime Shaft Kiln | 400 TPD Eco-Smart Calcination System
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Next-Gen Mixed-Feed Shaft Kiln — Where Tradition Meets Intelligence
Engineered for large-scale lime production (300–600 TPD), the JY-400 Mixed-Fuel Lime Shaft Kiln delivers metallurgical-grade quicklime with industry-leading energy efficiency, ultra-low emissions, and full automation. Built on 20+ years of mixed-feed shaft kiln technology, refined through continuous R&D — this is the new benchmark for lime calcination.
Core Advantages at a Glance
| Advantage | Detail |
|---|---|
| 🏭 High Output | Up to 400 tons/day, volume utilization rate 80–100% |
| ⚡ Ultra-Low Energy | Heat consumption |
| 🧪 Premium Quality | Overburn rate |
| 🌿 Eco-Compliant | Dust emission ≤30 mg/Nm³; desulfurization rate >70% |
| 🤖 Full Automation | PLC-controlled, one operator per kiln, 24/7 stable operation |
| 💰 Low Opex | Electricity: ~10 kWh/ton lime (excl. dust collection); water: 50–80 kg/ton |
Technical Parameter Table
| Parameter | Specification |
|---|---|
| Model | XHL-400 |
| Kiln Type | Mixed-Fuel Shaft Kiln (Improved Mixed-Feed) |
| Daily Capacity | 400 tons/day (TPD) |
| Kiln Diameter (Internal) | 4.0 m |
| Effective Height | 21 m |
| Height/Diameter Ratio | 5.25 |
| Effective Volume | ~750 m³ |
| Calcination Temperature | 1,150–1,200 °C (burning zone) |
| Decomposition Start | ~850 °C |
| Decompletion | ~1,200 °C |
| Kiln Top Temperature | 150–200 °C |
| Discharge Temperature | |
| Limestone Feed Size | 40–80 mm |
| Coal Specification | Washed clean coal, volatile 18–22%, fixed carbon ≥55%, size 10–30 mm |
| Calcination Time | 18–22 hours |
| Excess Air Coefficient | 1.15–1.25 |
| Kiln Gas CO₂ Content | 30–42% |
| Kiln Gas CO Content | ≤0.8% |
| Dust Emission (after treatment) | ≤30 mg/Nm³ |
| Desulfurization Rate | ≥70% (in-kiln alkaline self-desulfurization) |
| Overburn Rate | |
| Lime Activity | 280–350 mL (HCl method) |
| Free CaO Content | 2–3% |
| Product Standard | Metallurgical Lime Grade II |
| Lining — Working Layer | 200–400 mm high-alumina brick (Al₂O₃ 65–70%) |
| Lining — Insulation Layer | 200–230 mm lightweight castable refractory |
| Lining — Outer Layer | Silicate aluminum fiber blanket |
| Heat Loss (shell) | |
| Charging System | Double bell-type distributor (sealed, layered feeding) |
| Discharge System | Energy-saving screw-cone discharge machine with ring air duct |
| Air Supply | Central blower, 24 adjustable tuyeres, uniform cross-section distribution |
| Control System | PLC-based with 16 real-time monitoring points (kiln top temp, kiln pressure, exhaust composition, etc.) |
| Sealing | Fully enclosed feeding, discharging & blowing; concentrated dust collection |
| Overhaul Cycle | 5–6 years |
| Operators Required | 1–2 per shift (full automation) |
🔬 How It Works
Step 1 — Charging: Limestone (40–80 mm) and washed clean coal are fed simultaneously through the double bell-type distributor at the kiln top, creating multiple parallel burning zones for uniform heat distribution.
Step 2 — Calcination: As material descends counter-current to rising hot gases, CaCO₃ begins decomposing at ~850 °C and completes at ~1,200 °C, releasing CO₂ and producing high-reactivity CaO.
Step 3 — Cooling & Discharge: Preheated combustion air (up to 700 °C via heat recovery) enters from the bottom. The discharge machine ensures uniform, dust-free lime removal at
Step 4 — Emission Control: Kiln gas passes through cyclone dust collector → impact water-film scrubber → bag filter. Final dust concentration
JY-400 vs. Traditional Lime Kilns
| Metric | JY-400 Shaft Kiln |
|---|---|
| Capacity | 400 TPD |
| Coal Consumption | 120–130 kg/ton |
| Lime Activity | 280–350 mL |
| Automation | Full PLC, 1 operator |
| Investment Cost | ⭐⭐⭐ Medium |
| Footprint | ⭐⭐⭐ Small |
| Emission Level | ≤30 mg/Nm³ |
Included Systems
| System | Description |
|---|---|
| 🔧 Smart Batching | Automated proportioning — coal-to-limestone ratio self-adjusts per cycle |
| 📡 PLC Control | 16-point real-time monitoring with expert system auto-tuning |
| 💨 Dust Collection | Cyclone + water-film + bag filter, three-stage purification |
| 🧪 Desulfurization | In-kiln alkaline self-desulfurization (>70% efficiency) |
| 🏗️ Civil Works | Kiln shell, lining, charging/discharging equipment, ductwork |
🎯 Ideal For
✅ Steelmaking & ironmaking flux lime (activity ≥350 mL)
✅ Carbide / calcium cyanamide production
✅ Flue gas desulfurization (power plants, steel mills)
✅ Calcium-based chemical industry
✅ Large-scale projects with strict environmental compliance
📞 Get Your Custom Quote
The JY-400 is built to order. Contact us with your limestone grade, fuel type, and output target — we'll engineer the exact configuration you need.
"One kiln. One operator. Zero compromise on quality or compliance."
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