Microlime (EC - Calcination)

Hurricane system to recover fine particles from a calcination kiln decreasing the load to the final dust collector bag filter, placed in a tail end position.  

  • The system is composed by 1 hurricane cyclone
  • Operating conditions from 18,747m3/h at 120ºC to 22,408m3/h at 131ºC
  • Expected separation efficiency varies  from 90.37 to 97.12%.
Microlime
Portugal
2012
Moengo (PR - Calcination)

Hurricane system designed for product recovery of very fine metakaolin particles, operating at 21,368 m3/h at 650 ºC. 

  • The system is composed by one hurricane cyclone 
  • Emissions: 89.2-92.6 %
Moengo Minerals
Suriname
2010
Hurricane
Numerically optimized cyclones, considering particle agglomeration
Hurricane lines of cyclones can be optimized to be an efficient pre-separator to reduce concentration after the calciner, as it can amount to several g/m3, but also to work as a final stage dedusting system.
ACS has experience in several calcining applications, including low temperature dolomitic lime (MVD = 27µm; µ=97%), or quicklime (MVD = 27µm; µ=91%) and high temperature metacaolin (MVD = 7µm; µ=91%).
In calcination processes, concerns have to be taken regarding the abrasiveness of some dusts, which implies the cyclones to be inner lined with ceramic titles or ceramic bases cement. In high temperature applications, the selection of steel is is very important.
  • Very high efficiencies: down to 10-20 % of the emissions of other high efficiency cyclones;
  • Custom designs (single or parallel arrangement)
  • Low pressure drop: [80 - 120]mm w.g.
  • No temperature restrictions with the right choice of steel. Carbon Steel - P355NH Steel - 16M03 Steel - 253MA Steel
  • Robust construction with no moving parts
  • Near zero maintenance and downtime costs
  • Very low operating costs
  • Pre-assembled modular system with very easy and fast installation. Batteries of 2, 4, 6 or 8 cyclones are shipped pre-assembled in a supporting structure with or without thermal insulation.
  • Low investment cost
1. Air and Dust from Dryer or Boiler
2. Hurricane Cyclone
3. Valve
4. Collected Particles
5. Clean Air
ReCyclone MH
Optimized cyclones with mechanical recirculation

Mechanical ReCyclone Systems (ReCyclone MH) are a solution to improve cyclone efficiency, when working as a final dedusting system. They can work with several lines of Hurricane cyclones with different performances depending on the requests of the clients.


ReCyclone® MH decreases emissions of Hurricane cyclones alone by 40 to 60 %


As with cyclone systems, ReCyclone® MH systems are very robust, do not have temperature limitations and do not have moving parts to be frequently changed.


In calcination lines, concerns have to be taken regarding the peripheral equipment, namely recirculation fan and rotary valves to stand abrasive dusts and high temperatures.   

  • Very high efficiencies: decreases emissions of Hurricane Cyclones by [40-60]%
  • Pressure drop: [120-150] mm w. g.
  • No temperature restrictions with the right choice of steel. Carbon Steel - P355NH Steel -16M03 Steel - 253MA Steel
  • Robust construction with no moving parts
  • Near zero maintenance and downtime costs
  • Low operating costs
  • Pre-assembled modular system with very easy and fast installation. Batteries of 2, 4, 6 or 8 cyclones or mechanical recirculators are shipped pre-assembled in a supporting structure with or without thermal insulation.
  • Low investment costs
Features

1. Air and dust from boiler or dryer
2. Hurricane cyclone ( Batteries of 2, 4, 6 or 8 units )
3. Discharge valve
4. Collected Particles
5. Clean air
6. Recirculator
7. Fan

Note: supporting structure, insulation and ductwork are not represented
ReCyclone EH
Optimized cyclones with electrostatic recirculation

Electrostatic ReCyclone Systems (ReCyclone EH) are a solution to improve cyclone or ReCyclone MH efficiency, when working as a final dedusting system. They can work with several lines of Hurricane cyclones with different performances depending on the requests of the clients.


A ReCyclone® EH decreases emissions of a ReCyclone® MH alone by 40 to 70 %


As with cyclone systems, ReCyclone® EH systems are very robust, can stand temperatures up to 400ºC and do not have moving parts to be frequently changed.


In calcination lines, concerns have to be taken regarding the peripheral equipment, namely recirculation fan and rotary valves to stand abrasive dusts and high temperatures.   

  • Very high efficiencies: decreases emissions of a ReCyclone MH by [40-70]%
  • Pressure drop: [100-130] mm w. g.
  • Operates up to 400oC
  • Robust construction with no moving parts (no rapping mechanisms)
  • Low maintenance and downtime costs
  • Low operating costs (Electrical field power = 5 % fan power)
  • Pre-assembled modular system with very easy and fast installation. Batteries of 2, 4, 6 or 8 cyclones or electrostatic recirculators are shipped pre-assembled in a supporting structure with or without thermal insulation.
  • Reasonable investment costs
  • Not sensitive to variable flow rates
Features

1. Air with fly ash from the boiler or from the pre-separator
2. Hurricane Cyclones. (Batteries of 2, 4, 6 or 8 units )
3. Rotary discharge valve
4. Collected particles
5. Cleaned Air
6. Electrostatic recirculators.
7. Recirculation fan
8. DC High Voltage

Note: supporting structure, insulation and ductwork are not represented
Calcination Processes

In calcination processes, solid intermediates and products are regularly handled in the fine powder form (ex: kaolin or metakaulin). 


There is a need to separate these very fine powders from the exhaust streams of calciners, fluid bed dryers or incinerators, often at critical temperature conditions. 


For PM emission control at very high temperature ( >600 ºC), traditional bag filters following temperature exchangers or scrubbers are used as end stage dedusters.


For most arrangements, a primary high temperature separator, namely a cyclone, is important to reduce as much calcined dust as possible. A good efficiency is important to reduce concentration of solids to the final stage dedusting system, thereby minimizing product losses and emissions.


Most arrangements have considerable investment and operation costs. Traditional bag filters imply the frequent change of bags and a high investment in temperature exchangers. Scrubbers are alternative end stage dedusters, but at the cost of secondary wet pollution.


Client's needs include an efficient and robust cyclone pre-separator and a very high efficient final stage dedusting system, which can operate at high temperatures for many years with low maintenance/operating costs.

Calcination Processes
Calcination Processes
Calcination Processes
Calcination Processes
Calcination Processes (vertical calciner) | General Arrangement 

The general arrangement of a calcining process with a vertical calciner includes a cyclone to return the calcined dust to the calciner and a bag filter following a temperature exchanger / economizer. 


The Median Volume Diameter (MVD) of the PM coming directly from dolomitic lime or quicklime furnace is typically between 20µm and 30µm with 2% to 18% under 1µm. 

Calcination Processes (rotating calciner) | General Arrangement
 

A rotating calciner follows a similar principle, where a scrubber can also be used as a final stage dedusting system.


The Median Volume Diameter (MVD) of the PM coming directly from dolomitic lime or quicklime furnace is typically between 20µm and 30µm with 2% to 18% under 1µm.