Synthesis PFR lime kiln PLUS POINTS

QualiCal identified the PFR, Parallel Flow Regenerative technology, as the best for the CALCINATION in vertical lime kilns and for this reason we implemented this technology in the very original design of the Synthesis® TWIN SHAFT LIME KILN.

QualiCal® is proposing Synthesis® as an original design, and represents the ultimate solution in the vertical parallel flow lime kiln (PFR). The originality of the design, which allows the regenerative burning process to take place in the most effective way, consists in the “synthesis” of the most effective solutions, in part adopted in the others kind of kilns in operation today.

This makes QualiCal® Synthesis® the lime kiln with the lowest investment and running costs, capable of providing the proven highest quality of quick lime.

Variable shape of kiln shafts

the shape of the preheating and burning zones is different from the shape of the cooling zone.

Synthesis design is original, and a patent is pending, because the shape of the preheating and burning zones is different from the shape of the cooling zone.

The first two are circular, the third is rectangular.

The passage from the circular section (the best shape for the limestone preheating and lime burning) to the rectangular one (successfully proven for the lime cooling in hundreds of kilns in operation) is realized in a smooth manner.

ROUND shaft shape

ROUND shaft shape is the best for PREHEATING & BURNING ZONE.

• The solution is “symmetric” with “no angles“
• allow uniform fuel lances distribution as guarantee of an uniform lime quality

RECTANGULAR shaft shape and DIRECT CROSSOVER CHANNEL

RECTANGULAR shaft shape and DIRECT CROSSOVER CHANNEL ensure a proper passage of the gases from one shaft to the other:

• No built-up problem
• The RECTANGULAR shaft shape in the lower part of the kiln allows the even discharge of lime from both the external and internal parts of the shafts.
• The easier and simple lime discharging solution

Finally, passing from the circular zone to the squared cooling zone there is a natural enlargement of the sections of the shafts. This is the best pre-condition:

• To avoid “bridges” of material into the shafts,
• To burn and discharge in the best way also fine-lime material

DIRECT CROSSOVER CHANNEL

By Continuous Improvement through Innovation and Technology, QualiCal’s Direct Crossover Channel when compared to the Circular Ring Channel,

• ensures high speed and high temperature of the gases crossing the simple “single arch connecting channel”
• avoids the problems of “sticky” deposits in the channel caused, in part, by the presence of dirty material

and guarantees:

• Uniform high-quality lime across the kiln cross-section
• lower quantity of refractory lining maintaining minimal radiation losses
• Maintenance free connecting channel
• lower weight of the steel structure of the shafts.