IS : 1861 (-Part II ) - 1977

I ndian Standard
GUI DE FOR
MANUFACTURE OF LI ME I N VERTI CAL
MI XED-FEED TYPE KI LNS
PART I I FROM LI MESHELL
( First Revision )
First Reprint MAY 1990
UDC 666.923.3.041.464 (036)
@ Copyright 1978
BUREAU OF INDIAN STANDARDS
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
,i 4
NEW DELHI 110002
f,
Gr 2
;9
4.4
f
May 1978
( Reaffirmed 1998 )
IS : 1861( Part II ) - 1977
I ndian Standard
GUI DE FOR
MANUFACTURE OF LI ME I N VERTI CAL
MI XED-FEED TYPE KI LNS
PART I I FROM LI MESHELL
( First Revision )
Building Limes Sectional Committee, BDC 4
Chairman Representing
DR I QBAL ALI Engineering Rewarch Laboratories, Government of
Andhra Pradesh, Hyderabad
Members
SHRI V. S. AQARWALA Engineer-in-Chiefs Branch, Army Headquarters
SHRI K. R. BHAMBHANI ( Alternate )
SRRI SRI DHAR BANDYOPADEYAY Khadi and Village I ndustries Commission, Bomb&
CHI EF ENOI NE~LI . Tamil Nadu Housing Board, Madras
EXECUTI VE ENGI NEER
( HCJ DGO CELL ) ( Alternate )
DR S. K. CHOPRA Cement Research I nstitute of I ndia, New Delhi
SHRI P. C. CHOWDJ UZY Lime Manufacturers Association of I ndia,
New Delhi
SHRI G. C. DAS National Test House, Calcutta
SHR~S. DAS GUPTA ( Alfernafe )
DR N. G. DAVE Central Building Research I nstitute ( CSI R ),
Roorkee
SHRI S. P. GARB ( AI t emat e )
SHRI 1. N. DAVE Department of Mines and Geology, Government of
Rajasthan, J aipur
SHRI R. G. GUPTA ( Alternate )
DI REOTOR, ERI , VADODARA Public Works Department, Government of Gujarat,
Ahmadabad
RESEARCH OFFI CER
( MATERI AL TESTI NQ DI VI -
BI ON ) ( Alternate )
DI RECTOR, LRI PRI , AY~RI TSAR I rrigation Department, Government of Punjab,
Chandigarh
RESEARCH OFFICER ( B & M ) ( Alternate )
( Continued on page 2 )
@ Copyright 1978
,i
BUREAU OF INb,IAN StANbAtiDS
This publ%ation is protected under the Indian Copyright Act ( XI V of 1957 ) and
reproduction idwhole or in part by any means except with written permission of the
publisher shebe deemed to be an infringement of copyright under the said Act.
/
IS : 1861 ( Part II ) - 1977
( Continucdfrom page 1 )
Members Representing
DIRECTOR, MERL, NASIK Irrigation and Power Department, Government of
RESEARCH OFFICER
Maharashtra, Bombay
( ~~ATERIAI. TESTINO DIVI-
~111s ), MERI, NASI~ ( Alternate )
DR R. 1;. CHOYII Central Road Reacarch Institute
New Delhi
( CSIR ),
Snrct h,l. 1,. RHATIA ( Alternate )
SHRI J. S. G1r.1.
SIIICI S. C. linr.~t.\ ( Allernarc )
Punjab Housing Development Board, Chandigarh
~IOUSlXa &MISS~ONRi ' Rajasthan Housing Board, Jaipur
JOINT
~WXTOR RESIXIICII Ministry of Railways
( B & S ), RDSO
ASSISTANT DIRECTOR RK-
SKAILUI ( B & S ), RDSO ( Alterwte )
SARI N. H. lGmrw.4~1
SHRI N. hl:\c:rsno
Ministry of Transport and Shipping ( Roads Wing )
Dyers Stone Co Pvt Ltd, Delhi
SARI H. L. MA~~AR Builders Association of India, Bombay
SHRI HARISII C. KO~I,I ( Alternate )
Dn A. V. R. RAO
SHRI J. SEN CT.PTA ( Alternate )
National Buildings Organization, New Delhi
SHRI V. N. RAO
SHRI s. B. SEN SAns1.1
Madhya Pradesh Housing Board, Bhopal
Geological Survey of India, Calcutta
SUPERINTYNDINQ
ENGINEER Public Works
( DESIGNS 1
Department, Government of
Madhva Pradesh, Bhonal
EXECUTIVE
. .
ENGINEER
( RESIXARCA ) ( Alternate )
S u P E R I N T E N D I N Q ENQI- Public Works
NEER ( PLANNING & DESIONS )
Department,
Andhra Pradesh, Hyderabad
SUPERINTENDINO ENOINE~~ ( PLY Public Works Department,
& DESIGN )
Tamil Nadu, Madras
EXECUTIVE ENCINEE~ ( BUIL-
Government of
Government of
DINO CENTRE DIVISION ) ( Alternate )
SUIIVEYOR OP WORKS IV, SSW Central Public Works Department, New Delhi
(NDZ)
SHRI D. AJITHA SIMIIA,
Director ( Civ Engg )
Director General, IS1 ( Ex-oJicio Member )
Secretary
SHRI R. M. MATHUR
Deputy Director ( Civ Engg), IS1
2
IS : 1861
I ndian Standard
GUI DE FOR
( Part II ) - 1977
MANUFACTURE OF LI ME I N VERTI CAL
MI XED-FEED TYPE KI LNS
PART I I FROM LI MESHELL
(First Revision)
0. FOREWORD
0.1 This Indian Standard ( Part II ) ( First Revision ) was adopted
by the Indian Standards Institution on 30 September 1977, after the draft
finalized by the Building Limes Sectional Committee had been approved
by the Civil Engineering Division Council.
0.2 Though lime is one of the most important materials available for
building construction, the technique of manufacture of building lime is
still not well established in the country. A satisfactory building lime
should have certain essential characteristics in regard to slaking and its
subsequent performance in mortars and concrete. These characteristics
will be satisfactorily developed only if the limestone is calcined in the
kiln at the right temperature and with the right, type of fuel.. The
industry has, therefore, felt the need for not only specifying the quality
of building lime that is required but also to lay down a guide which will
give necessary guidance to manufacturers to achieve its quality.
0.3 With the present experience in lime manufacture in the country, it is
found that the most suitable type of kiln for burning lime is the mixed-
feed vertical type, with ,regard to both performance and economy.
Accordingly, this standard has been prepared to cover the manufacture
of lime in vertical mixed-feed kilns.
0.4 The Sectional Committee responsible for the preparation of this
standard has taken into consideration the views of producers, consumers
and technologists and has related the standard to the manufacturing and
trade practices followed in the country in this field.
0.5 This standard was first published in 1961 to cover manufacturing
of lime from limestone. The revision is now being done in two parts.
Part i sipvers manufacture from
limestone, and Part II from limeshell.
I_
3
IS : 1861 ( Part II ) - 1977
While revising this standard work done at Central Building Research
Institute, Roorkee; Khadi and Village Industries Commission, Bombay;
and Gujarat Engineering Institute, Vadodara has been fully utilized and
more details in regard to requirements for the operations have been
provided.
0.6 For the purpose of deciding whether a particular requirement of
this standard is complied with, the final value, observed or calculated,
expressing the result of a test or analysis, shall be rounded off in
accordance with IS : 2-1960*. The number of significant places retained
in the rounded off value should be the same as that of the specified value
in this standard.
1. SCOPE
1.1 This standard ( Part II ) covers essentially the operations for burning
of limeshell in vertical kilns of mixed-feed type up to 3 tonnes per day
capacity used in small scale industry.
2. TERMINOLOGY
2.1 For the purpose of this standard, the definitions given in IS : 6508-
1972? shall apply.
.
3. NECESSARY INFORMATION
3.1 For the efficient manufacture of lime, information with regard to the
chemical composition of the limeshell and the fuel will be necessary.
4. MANUFACTURE
4.0 Principle
- The charge of limeshell and fuel is fed from top and
the burnt product is drawn from bottom of shaft through openings.
Initial firing is started by means of firewood at the bottom and due to
draft the burning zone gradually travels upwards. Burning is restricted
to the central burning zone by regular withdrawals of burnt pioduct.
The down-coming product COOIS off while heating the incoming air
before it en&s the burning zone. The hot air and combustion gas
leading the burning zone preheat the charge as it enters from the top.
During burning three distinct zones are formed which are lower (cooler),
central ( burning ) and upper ( preheater >.
4.1 Preparation of Limesbell -The limeshells should be washed well
to remove clay and other foreign material or else the end product will
be of inferior grade with the possibility of sticking of limeshell inside the
kiln. The size of the shell may generally be 5 to 50 mm.
i !
les for rounding off numerical values ( revi sed ).
tGl &Lry of terms relating to building lime.
G
4
IS : 1861 ( Part II ) - 8977
4.2 Size of Fuel - As charcoal which has lower density and calorific
value, size of charcoal should be nearly double that of 1imesh;ll.
4.3 Reserve Storage - Quantities suf%ient for one days use of lime-
shell .and fuel should be kept in reserve at the site ready for loading.
4.4 Charging and Discharging
4.4.1 The proportions of the limeshell and fuel in the mix for charging
into the kiln should be calculated with regard to the heat requirements
for calcination and the calorific value of the fuel. On an average
charcoal used should be 14 to 15 percent by mass of limeshell.
4.4.2 Kiln loading and drawing may be done manually or mechanically.
It is impractical to weigh limeshell and fuel each time. Weights may be
converted into volumes and correct weight volume factors (relationship)
be arrived at. When newly constructed kiln is ready for commissioning
it should be well-dried for a week and slowly fired before charging, so as
.to draw out the inside moisture of the masonry shell and to avoid
cracking of kiln wall. While commissioning a new kiln or restarting an
old one, sufficient ignition material, such as wood, may be placed and
thus alternate layers of fuel and shell charged in. The,drawing of lime
should be done regularly at intervals that have been fixed with due
regard to retention time, which normally be 3 hours for limeshell. The
.best practice should be to establish intermittent operations at as close an
interval as possible, so as to approach a continuous cycle. The interval
between two consecutive withdrawals of lime from the kiln may not be
longer than 6 hours.
4.4.3 Lime will be drawn equally from each of the drawn holes
ensuring that the charge comes down evenly in the kiln.
4.5 Temperature Cont;ol, - The temperature in the kiln should be
regularly observed during operation of the kiln. Temperature observa-
tions should be taken at not less than three points as stated below:
a) Temperature of the calcination zone,
b) Temperature of exhaust gas, and
c) Temperature of drawn lime.
4.5.1 Temperufrcre of Calcinatior~ - In normal practice the temperature
in the calcination zone will be maintained between 1 000 to 1 120C.
This should be measured through poke holes by means of thermocouple.
This can also be assessed roughly by the colour of the flame as below:
Colour of Flame
Just visible red
Dark red
.i
G J
ust cherry red
I
Bright red
. ; ,Bright orange
/j.&
Temperature, C
500.
700
800
1000
1 200
IS : 1861 ( Part II ) - 1977
4.5.2 Temperature of Drawn Lime - The temperature of drawn lime
should be kept as low as possible generally not higher than 100C.
4.5.3 Temperatureof Exhaust Gas - For obtaining the maximum efficiency,
the temperature of the exhaust gas should be as low as possible preferably
within 100C. This should be achieved by maintaining the proper
height of pre-heating zone. For controlling the operations in the kiln,
it wit1 be necessary to know the composition of the exhaust gas. Presence
of carbon monoxide will indicate incomplete combustion within the kiln.
To ensure complete combustion of the fuel, certain quantity of excess
air, say about 10 percent, will be necessary; larger quantities of excess
air, however, will reduce the efficiency of the kiln. For conditions of
efficient operation, the carbon dioxide content in the exhaust gas should
be as high as possible and may range from 25 to 40 percent depending
upon the type of kiln and raw materials used; whereas the carbon
monoxide should not exceed 0.5 percent and that of oxygen not more
than 3 percent.
4.6 Observation of Operation of Kiln - Kiln conditions can also
be judged to some extent from visual observation of conditions at the
top of the kiln and guidance may be obtained from the condition of the
flame as given below:
a) Heavy black smoke, or black smoke from the top of the kiln
indicates incomplete combustion.
b) Flame on the kiln top indicates very wasteful condition.
c) Light haze at the kiln top and appearance of smoke with ,slight
reduction in air supply indicates satisfactory condition.
d) Clear at the top of the kiln indicates too much air.
4.7 Kiln Control - During the operation of the kiln the quantity of
feed and the limeshell/fuel ratio should be adjusted to rectify imbalances.
4.8 Quality of Drawn Lime
4.8.1 The quality of lime drawn from the kiln should be regularly
observed fc,r presence of core or over-burnt lime and discolouration.
4.8.2 Presence of core or over-burnt lime may be minimized either by
increasing or decreasing respectively the retention time in the calcination
zone and also by adjusting the limeshell/filel ratio.
4.8.3 Discolouration in drawn lime may be due to the presence of
coloured matter or other impurities either in the limeshell or in the fuel
fed to the kiln.
4.9 Sqr$ing - The drawn lime should be spread over the floor for cool-
ing ahd$and picked for well-burnt and over and unburnt lime.
BUREAU OF INDIAN STANDARDS
Headqoaners:
Manak Bhavan, 9 Bahadur Shah Zafar Marg, NEW DELHI 110002
Telephones: 331 01 31, 331 13 75 Telegrams: Maneksanstha
( Common to all Offices )
Regional Offices:
Telephone
Central Manak Bhavan, 9 Bahadur Shah Zafar Marg. I 331 01 31
NEW DELHI 110002 331 13 75
*Eastern : 1 /14 C. I. T. Scheme VII M, V. I. P. Road, 36 24 99
Maniktola, CALCUTTA 700054
Northern : SC0 445-446, Sector 35-C, I 21843
CHANDIGARH 160036 3 1641
41 24 42
Southern : C. I. T. Campus, MADRAS 600113 ( t: 5: ::
1 tWestern : Manakalaya, E9 MIDC, Marol, Andheri ( East ), 6 32 92 95
BOMBAY 400093
Branch Offices:
Pushpak. Nurmohamed Shaikh Marg, Khanpur. I 2 63 48
AHMADABAD 380001 63 49
2
+,Peenya Industrial Area 1st Stage, Bangalore Tumkur Road
I
38 49 55
BANGALORE 560058 38 49 56
Gangotri Complex, 5th Floor, Bhadbhada Road, T. T. Nagar,
667 16
BHOPAL 462003
Plot No. 82183, Lewis Road, BHUBANESHWAR 751002 5 36 27
53i5. Ward No. 29, R.G. Barua Road, 5th Byelane, 3 31 77
GUWAHATI 781003
5-8-56C L. N. Gupta Marg ( Nampally Station Road ),
HYDERABAD 500001
23 1083
R14 Yudhister Marg. C Scheme, JAIPUR 302005 { 6 34 71
6 98 32
117/418 B Sarvodaya Nagar, KANPUR 208005
{
f: 8: ;;
Patliputra Industrial Estate, PATNA 800013 6 23 05
T.C. No. 14/1421. University P.O.. Palayam (6 21 04
TRIVANDRUM 695035 16 21 17
lnspecrion Offices ( With Sale Point ):
Pushpanjali. First Floor, 205-A West High Court Road, 2 51 71
Shankar Nagar Square, NAGPUR 440010
Institution of Engineers ( India ) Building, 1332 Shivaji Nagar, 5 24 35
PUNE 411005
*Sales Office in Calcutta is at 5 Chowringheo Approach, P. 0. Princep 27 69 00
!jt$ft. Calcutta 700072
* tSales Office in Bombay is at Novelty Chambers, Gr_ant Road, 89 66 29
Born& 400007
$SkMk Office in Bangalore is at unity Building, Narasimharajr Square, 22 36 71
Bangaf@e660002
.J
Reprography Unit, BIS, New Delh.$, India
AMENDMENT NO. 1 DECEMBER 1981
TO
I S: 1861(Part I I )- 1977 GUI DE FOR MANUFACTURE
OF LI ME I N VERTI CAL MI XED- FEED TYPE KI LNS
PART I I FROMLI MESHELL
(Fi re t Ruvisicm)
Al terati on
a- - - -
(Page 5, chue 4. 2)
- Substltute the following
for the existing clause:
' 4. 2 Size of Fuel - The size of charcoal which is
normal-u-used &-a fuel with limeshell because of
its lower density shall be about twice that of the
limeshell.'
(BE 4)
Reprography Unit, BIS, New Delhi, India
AMENDMENT NO. 2 APRIL 1999
TO
IS 1861( PART II ) : 1977 GUIDE FOR MANUFACTURE
OF LIME IN VERTICAL MIXED-FEED TYPE KILNS
PART I I FROM LI MESHELL
(First Revision)
(Page 4, c l ause 2.1) -Subst i t ut e the following for the existing clause:
2.1 For the purpose of this standard, the definitions given in IS 6508 : 1988t
shall apply.
( Page 4, fit-nofe marked t ) - Substitute the following for the existing
foot-note :
tGlossary of terms related to building lime (first re&iun ).
(CED04)
Reprography Unit, BIS. New Delhi, India