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limestone powder manufacturing process

challenges in limestone processing

challenges in limestone processing

Limestone is a versatile commodity used to create products for agricultural, environmental, and industrial purposes. Cement, paint, soil amendments, and even breakfast cereals all contain this resourceful mineral. Of course, mined limestone is not naturally found in a suitable form for many of these products. Therefore, various processing systems are needed to transform raw limestone rock material into a useful product. Common limestone processing methods that prepare the material for subsequent manufacturing stages include drying, calcining, pre-conditioning, and pelletization. The following information highlights limestone processing issues associated with these techniques, as well as general material challenges associated with limestone manufacturing.

A drying process is often used to precondition limestone rock for subsequent manufacturing steps. Like most rocks, limestone is abrasive as a raw material. As a result, heavy-duty rotary dryers are recommended to handle limestones abrasive characteristics. Equipment customizations such as heavy-duty linings may be necessary depending on the size of the rock being processed and other application specific criteria.

Drying processes may also be used on powdered limestone, with the recommended equipment again being rotary dryers. Many limestone manufacturers address moisture issues and prevent material clumping by utilizing a drying process before storing powdered limestone for extended periods of time.

Rotary kilns are most often used to produce lime products in the United States. Hot combustion gases and limestone move counter currently within the refractory-lined drum of the rotary kiln, applying a high-temperature process that ultimately changes the raw material into a high calcium lime or dolomitic lime. Particle matter pollutants are a common issue with rotary kilns, requiring the application of a particulate control in order to counteract this problem. FEECO also offers special burners to limit air pollutant emissions such as NO2 and CO.

Pelletization resolves a number of issues associated with limestone processing, from uniformity to nutrient delivery. Limestone pellets offer reduced dust, more accurate application, improved handling, and less product lost to dust. Fortunately, with such great benefits, limestone pelletization is a fairly straight-forward process.

However, there are still limestone processing problems that must be considered. For example, moisture is an important element in effectively pelletizing limestone. Throughout preconditioning, pelletization, and drying, moisture levels should be monitored and maintained to ensure optimal products are created through every stage of limestone processing.

Pre-Conditioning:A pin mixer imparts a powerful rotating motion upon limestone and its binder, creating an evenly distributed mixture with a moisture level best suited for pelletization. A successful pre-conditioning process creates an easily controllable mixture for forming limestone pellets on the subsequent disc pelletizer. Additionally, the material densification is greater than that of a disc pelletizer alone. However, pin mixers require special abrasion resistant pins due to the potential for accelerated wear when processing limestone. Consequently, proper maintenance is important to avoid equipment breaks and prevent costly downtimes.

Pelletization:A disc pelletizer gradually grows the pre-conditioned mixture into limestone pellets using a binder and the motion of the rotating disc. Monitoring the materials moisture level is critical at this stage, because pellet characteristics such as size and strength are secured by monitoring moisture ratios during this process.

Drying:A drying process is utilized to control moisture levels within the pelletized limestone. As an added benefit, drying adds pellet strength and prevents clumping related issues. Rotary dryers are recommended for their ability to uniformly dry pellets, handle a large throughput of material, and naturally polish the limestone as it tumbles through the drum. The resulting product is also easier to handle and store. Knocking systems are available to reduce material clumps by dislodging material build-up inside the drum.

Limestone processing problems are not unlike the challenges faced by many other naturally occurring materials. In addition to build-up and clumping problems, limestone composition can also vary from one region to another.

Limestone build-up has the ability to wear down equipment parts if left untreated. In order to prevent limestone maintenance issues, consistent material build-up removal (as part of an equipments regularly scheduled maintenance plan) is necessary.

Limestones composition, porosity, and texture can vary for a number of reasons, especially when the material is mined from different regions around the world. Consequently, FEECO recommends testing limestone before moving forward with processing strategies.

From drying to pelletizing, and even testing and material handling, FEECO is a complete processing solutions provider for the limestone industry. By combining over 60 years of experience with superior engineering capabilities and a unique material testing facility, FEECO is able to create the best limestone processing and equipment designs for our customers. For more information on our limestone processing experience, contact us today!

white limestone powder,limestone lumps,calcite powder manufacturers in orissa,india

white limestone powder,limestone lumps,calcite powder manufacturers in orissa,india

Gadodia Limes is among the leading Manufacturers and Suppliers of a wide range of Mineral Products. Our products include Limestone Powder, Limestone Lumps, Quicklime Lumps, Hydrated Lime Powder, Red Oxide Powder. These products are widely used across in many industries like Construction, Steel, Glass, Paint, Rubber, and many more. Owing to over 13 years of experience in this field, we understand the requirements of our clients and cater to them with perfection. Our professionals supervise every step the process from the quarrying of these products to their processing and packaging. Focused on providing the best, we are backed by latest technology for all these processes. With string production capabilities, we are able to take bulk orders and deliver in time. Due to this, we are also able to deliver products at market leading prices across the country.

production process | nordkalk

production process | nordkalk

Nordkalk extracts limestone and processes it into crushed and ground limestone, concentrated calcite, and quick and slaked lime. The product range also includes dolomite and wollastonite. Scroll down to explore the production process step-by-step!

Nordkalk is the leading limestone company in Northern Europe. We deliver essential raw materials to numerous industries, and our solutions contribute to clean air and water as well as productivity of agricultural land.

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