Aging plants make it difficult to maintain plant operations efficiently, especially in regard to job safety, process reliability, plant availability and costs. This often means that either the modernisation or a complete restoration of such plants is the most worthwhile solution.
Most of the lime plants currently in use were commissioned between 1980 and 1995. As such, the plants are reaching a critical age of over 15 years – an age in which problems can begin to accumulate even in sound components. This is often accompanied by negative consequences:
- Today's requirements on job safety are not reflected in the construction of the plants.
- The process stability doesn't satisfy today's demands any more.
- The time and financing necessary for repairs and maintenance rise sharply.
- There is a corresponding drop in plant availability.
- Because of age, spare parts are often difficult to acquire.
Naturally, we will also be happy to point out the optimisation potential that exists in your plant.
When it comes to refurbishing and modernising your plant, we pay attention to:
Decide on expert knowledge:
Experts from our team shaped the development of lime plants over many years. We know the critical points and develop ideal solutions.
Our range of services in restoration, modernisation, optimisation comprises:
Modern vapour extraction systems are used to prevent the uncontrolled escape of hot and extremely unhealthy vapours. This produces a positive side effect: it prevents the contamination of the plant.
By using overfill prevention systems in connection with the fill-level of the silo and/or injection pressure, the lime supplier is prevented from overfilling.
The volume of residual dust generated when filling a silo can be considerably reduced by using modern dust extraction technology. This prevents caustic lime dust from endangering the health of employees. The contamination of the plant and the environment by lime dust is reduced to a minimum.
Through the targeted use of pumps, metering units suitable for lime milk, shut-off units and pipeline materials it is possible to reduce caking and abrasion phenomena in the pipelines. This reduces expenditure for maintenance and increases plant availability.
By subsequently installing mechanical silo release aids and/or improved pneumatic systems for breaking up the material (fluidisation systems), the flow of material out of the silo can be improved considerably. This is the first requirement of all for downstream metering units. This also considerably improves the handling of the plant.
By converting to gravimetric metering systems and modern measurement and regulation technology it is possible to maintain constant and reproducible concentrations of lime milk. This is decisive for stable processes. In many cases, lime consumption can be considerably reduced and fluctuations in the flow of lime and water can be compensated.
Precise proportional or pH-level-dependent metering of quantities can be achieved by adapting the process controls and using suitable flow measurement devices.
By converting to modern metering and weighing systems, it is possible to make precise adjustments to achieve the right amount of lime. This way the quality of the sludge conditioning can always be reproduced. And in many cases lime consumption is simultaneously reduced, too.