What are the difficulties in the construction of lime kilns
As a high energy consuming and long-period industrial thermal equipment, the construction of lime kilns involves multiple aspects such as process design, civil engineering construction, equipment installation, and system debugging, and there are many technical and management difficulties. The following analysis will be conducted from the core dimensions:
1、 Difficulties in compatibility between geology and civil engineering
The foundation of the lime kiln needs to withstand the triple pressure of high temperature radiation, heavy load, and geological settlement of the kiln body. If the bearing capacity of the foundation is insufficient or there is a risk of uneven settlement, the kiln body is prone to tilting, cracking, and even collapse. For example, in karst landform areas, it is necessary to explore the distribution of caves and fissures in advance, and adopt pile foundation reinforcement or replacement techniques; Construction in frozen soil areas needs to address seasonal frost heave issues by increasing foundation burial depth and laying insulation layers to ensure stability.
2、 Precision control of kiln structure construction
The welding deformation of kiln shell and the deviation of refractory masonry directly affect the airflow distribution and calcination efficiency inside the kiln. The diameter error of the kiln body needs to be controlled within ± 5mm, otherwise it will cause the burner flame to deflect, material segregation, or kiln wall nodules. The masonry of refractory bricks should take into account the reserved expansion joints and the sealing of brick joints, otherwise peeling and air leakage are prone to occur in high temperature environments. In addition, the construction of the dome structure of large vertical kilns relies on high-altitude curvature templates and 3D laser positioning technology to ensure that the curvature error is less than 0.5%.
3、 Multi system cross construction and safety control
The construction of lime kilns involves parallel operations of multiple disciplines such as machinery, electrical, automation, and pipelines, requiring the resolution of spatial conflicts and process connections. For example, the installation of the kiln top material distributor needs to be completed within 24 hours after the acceptance of the kiln shell steel structure, otherwise the reference point may shift due to the release of welding stress; However, there is a safety risk overlap between the pressure testing of the gas pipeline network and the kiln drying stage, which requires measures such as nitrogen replacement and oxygen content monitoring to avoid explosion hazards.
4、 Environmental standards and commissioning cycle pressure
With the implementation of ultra-low emission policies, the sealing requirements for kiln bodies have increased, and it is necessary to complete the pre embedding and commissioning of dust removal pipelines and interfaces for desulfurization and denitrification equipment on the kiln roof during the construction phase. At the same time, the integration and debugging of the automation system need to match the process parameters, such as the speed of the material feeder and the pressure inside the kiln, which need to undergo a 72 hour dynamic balance test, otherwise it is easy to cause the over burning rate of lime to exceed the standard.
The difficulty of lime kiln construction is essentially a reflection of the complexity of industrial engineering. It is necessary to optimize the construction process through BIM modeling, use prefabricated modular technology to shorten the construction period, and introduce intelligent monitoring systems to ensure quality, in order to achieve a balance between technical feasibility and economy.
