Lime Manual PDF

Lime Handling
Systems
Executive Summary
Lime Handling Systems is a general article dealing with the storage and feeding of lime slurries.
Design considerations involved in selection of equipment are discussed in addition to general
information on lime.
Recommendations for system designs are discussed with information presented on equipment
options.
The article is designed to acquaint the reader with the considerations involved in achieving an
efficient and practical lime system.
CHAPTER 1: GENERAL INFORMATION ON LIME 4
Lime 5
Lime Uses 5
Types of Lime 6
Quicklime 7
Hydrated Lime 8
Selecting what type of Lime to use 10
Lime Deliver 11
CHAPTER 2: FACTORS AFFECTING LIME SLAKING 13
Factors Affecting Lime Slaking 14
Lime Slaking 14
Quicklime Properties 14
Water Properties 15
Water to Lime Ratio 16
CHAPTER 3: LIME SYSTEM COMPONENTS 18
Bulk Storage 19
Typical Silo Configurations 21
Dust Control 22
Silo Flow Promotion 23
Flooding Control 25
Chemical Feeders 26
CHAPTER 4: LIME SLAKERS 30
Lime Slakers 31
Paste Type Slakers 31
Detention Slakers Conventional 32
Detention Slakers Grinding Mill Type 33
Factors Affecting Slaker Selection 34
CHAPTER 5: SYSTEM ACCESSORIES 37
Slaker Accessories 38
Grit Removal 38
Slurry Tanks 38
Slurry Pumps and Piping 39
CHAPTER 6: CONTROL PANELS & INSTRUMENTATION 42
Control Panels 43
Instrumentation 43
Silo Level and Inventory Controls 43
Slurry Measurement 44
CHAPTER 7: LIME ADDITION CONTROL 45
Lime Addition Control 46
Good Design Practices 49
Other Considerations 49
CHAPTER 8: SMALL FEED SYSTEMS 50
Small Feed Systems 51
Pre-Made Lime Slurries 53
CHAPTER 9: OTHER CHEMICALS 54
Other Chemicals 55
Soda Ash 55
Powdered Activated Carbon (PAC) 57
Chapter 1: General Information on Lime
CHAPTER 1: GENERAL INFORMATION ON LIME
Page 4 of 60
Lime
The term lime is used to refer to a variety of calcium based substances, which include or may be
derived from limestone. Except for sulfuric acid, limestone and its derivatives are the most widely
used chemicals in the United States. Approximately 25 million tons of lime is used each year for a
variety of different applications such as steel making, acid neutralization, water treatment,
wastewater treatment, and air pollution control.
Lime Uses
FIGURE 1
Currently lime usage is growing rapidly with the major investments being made upon acid rain
control and environmental protection, both of which use lime in large quantities. In addition, new
leaching processes for certain types of mineral ores and new sludge composting requirements will
require large new quantities of lime.
Page 5 of 60
This introduction to lime handling equipment is intended to acquaint users with the design
considerations involved in setting up a lime handling facility for maximum efficiency and minimum
maintenance considerations.
Types of Lime
The two most common derivatives of limestone are quicklime and hydrated lime. For substances,
properties such as particle size, purity, and chemical reactivity vary considerably between grades.
Following is a more complete definition of each lime type:
Limestone: Limestone is a naturally occurring substance, which consists primarily of calcium

carbonate (CaCO3). Limestone is typically quarried for use in its native form or for further
processing to produce derivative substances such as quicklime. One form of limestone is marble.
Figure 2 shows the types and properties of limestones.
FIGURE 2. Limestone Names, Grades, and Properties
Common Name and Grades or Forms Appearance and Bulk Density

Formula Available 1 Properties
High Calcium Large Lump White rock with intermediate 90-115 lbs/cf
Limestone CaCO3 Pebble or Crushed hardness [Mohs hardness of
Ground, Screened or 3-5], product is quarried,
Granular typical purity is 95% CaCO3
Pulverized
Dolomitic Limestone Large Lump White rock with intermediate 90-115 lbs/cf
CaCO3 & MgCO3 Pebble or Crushed hardness [Mohs hardness of
Ground, Screened or 3-5], product is quarried.
Granular
Pulverized
1
Limestone is available in a large range of sizes often specified as percentages passing standard sieve sizes. Sizes listed in
the table are defined by ASTM C 51 as Large Lump [8 and smaller], Pebble or Crushed [2.5 and smaller], Ground, Screened
or Granular [1/4 and smaller], and Pulverized [100 % Passing a No 20 sieve].
The purity of limestone varies widely. The purity is measured by the percentage of available CaCO3
and MgCO3. Limestone is primarily used for flue gas desulfurization, acid neutralization, and to
produce quicklime. Limestone delivery is available in barges, dump trucks, rail car and bulk trucks.
Once mined and processed for size, purity, and chemical constituents, the raw material is subjected
to a variety of mechanical processes to produce various grades of lime.
Page 6 of 60
Exshaw
Lime Kiln
Aerial photo compliments of Graymont Lime

FIGURE 3: TYPICAL PRODUCTION PLANT
Quicklime:
Quicklime consists primarily of calcium oxide (CaO) and is produced from limestone in a
process known as calcining as defined below:
High Calcium Quicklime
CaCO3 (Calcium Carbonate) + Heat CaO (Calcium Oxide) + CO2 (gas)
Dolomitic Quicklime
CaCO3 MgCO3 (Calcium Carbonate and Magnesium Carbonate) + Heat
CaO MgO (Calcium Oxide and Magnesium Oxide) + CO2 (gas)
Page 7 of 60
Figure 4 below defines the different types of quicklimes and the basic properties of each type:
FIGURE 4. Quicklime Types, Grades, and Properties
Common Name Grades or Forms Appearance and Bulk Density

and Formula Available Properties
High Calcium Pebbled [3/4 1/4 ] Soft [Moh hardness less 48-70 lbs/cf
Quicklime CaO Granular [1/4 minus] than 3], white pebbles to
Pulverized [100 % powder, typical purity is
Passing # 20 sieve] above 90% available CaO
Dolomitic Quicklime Pebbled [3/4 1/4 ] Soft [Moh hardness less 49-72 lbs/cf
CaO & MgO Granular [1/4 minus] than 3], yellowish white
Pulverized [100 % pebbles to powder, contains
Passing # 20 sieve] 5 to 40% MgO
The quality of quicklimes varies greatly. The quality of the lime is determined by the purity and
reactivity of the quicklime. Purity is a measurement of the quantity of calcium oxide (CaO) in a
given sample that is chemically available. The purity of commercially available quicklime in the
United States typically ranges from 85% to 95% available CaO.
Reactivity is a measurement of the heat released in the reaction between quicklime and water. This
reaction is commonly known as lime slaking or hydration, the product of which is hydrated lime. As
noted in Figure 5 below, reactivity is determined by slaking quicklime (at specific ratios of water to
quicklime) and measuring the rate at which the product temperature rises.
It should be noted that while purity and reactivity are related, they are not the same; that is, a high
purity does not always indicate a highly reactive quicklime.
Quicklime is shipped via in barges, railcar, bulk truck, sea containers, bulk bags and paper bags.
The most common delivery is in 25 Te bulk trucks.
Quick lime is either sold as quick lime containing approx 85-95% CaO or is further treated by
hydration to produce hydrated lime Ca(OH)2 which contains approx. 72-74% CaO
Hydrated Lime:
Hydrated lime consists primarily of calcium hydroxide, Ca(OH2) and is the product of the
reaction between quicklime and water as defined below:
High Calcium Hydrated Lime
CaO (Calcium Oxide) + H2O Ca(OH)2 (Calcium Hydroxide) + Heat
Page 8 of 60
Dolomitic Hydrate (type N)
CaO MgO (Calcium Oxide, Magnesium Oxide) + H2O Ca(OH)2 MgO (type N hydrate) +
Heat
Dolomitic Hydrate (type S)
CaOMgO (Calcium Oxide, Magnesium Oxide) + 2H2O Ca(OH)2 Mg(OH)2 (type S hydrate)
+Heat
Each pound of calcium oxide will react with 0.32 pounds of water to form 1.32 pounds of calcium
hydroxide. Commercial hydration of quicklime occurs in hydrators, which control the water to
lime ratio precisely to this ideal ratio to produce a dry powdered product. Where quicklime is
reacted with water in excess of the ideal ratio, the process is known as lime slaking which
produces a slurry of water and solid hydrated lime particles.
Figure 5 below defines the different types of hydrated limes and the basic properties of each
type:
FIGURE 5. Hydrated Lime Names, Grades, and Properties
Common Name and Grades or Appearance and Properties Bulk Density

Formula Forms Available
High Calcium Hydrated Powder [80% Soft [Moh hardness less than 3] 25-40 lbs/cf
Lime Ca(OH)2 passing 200 mesh white powder, dusty, typical
size} purity is 97% Ca(OH)2
Normal Dolomitic Powder [80% Soft [Moh hardness less than 3] 30-40 lbs/cf
Hydrated Lime (Type passing 200 mesh white powder, comes from
N) Ca(OH)2 & MgO size} dolomitic quicklime, typical
composition is 46 to 48% CaO,
33 to 34% MgO and 15 to 17%
Ca(OH)2
Pressure Dolomitic Powder [80% Soft [Moh hardness less than 3] 30-40 lbs/cf
(Type S) Hydrated Lime passing 200 mesh white powder, comes from
Ca(OH)2 Mg(OH)2 size} dolomitic quicklime, typical
composition is 7% CaO and
MgO and 90% Ca(OH)2 and
Mg(OH)2
The properties of hydrated lime from different sources in the United States are fairly consistent with
those properties described previously. The purity of the hydrated lime is expressed as a percentage
of the material that is calcium hydroxide (Ca(OH)2). The typical range of purity in the United States
is above 95% calcium hydroxide (Ca(OH)2).
Hydrated lime is available in bulk trucks, bulk bags, and paper sacks.
Page 9 of 60
Selecting what type of Lime to use
The type of lime is to be utilized in the process is dependent on a variety of factors, chiefly the
anticipated consumption of lime (as CaO) to be used. As consumption increases the overall savings
in chemical costs will justify cost increases in capital equipment. Keep in mind that if quick lime is
used it has to be converted to hydrated lime prior to its use in the process in almost all cases.
Choice of Lime to Use Lime Particle Size

QUICKLIME
2 x 3/4 3/4 x 3/8 3/8 minus

Pebbled Crushed Pulverized Quicklime available in variety of particle
sizes from pulverized to pebble lime
HYDRATED LIME (usually 3/4minus)
Hydrated Lime - usually pulverized
FIGURE 6 FIGURE 7
Lime in either form is available in either bags or in bulk. As a rule of thumb the following differentials
apply to the various types of lime.
Cost difference between bagged hydrated lime and bulk hydrated lime Approx. $ 90.00 per ton
(Based on unit costs, trucking, unloading, housekeeping, space requirements and labour costs for batch makeup)
Cost difference between bulk hydrated and bulk quicklime Approx. $ 40.00 per ton
(Based on unit costs and the differential between CaO content in hydrated and quick lime plus trucking and storage
costs).
In general the use rate will dictate the form of lime used as illustrated in the following (Figure 8)
Page 10 of 60
Recommended Selections
Approximate
Lime Types Savings
FIGURE 8
> $40/Ton
Tons 4
per > $90/Ton
Day 1
0
Lime Deliveries
Lime is shipped in a variety of containers as illustrated below. Bulk deliveries are either in
railcars (100 tons) or in self-unloading bulk trailers (20-25 tons). Rail cars are either the hopper
type, which unload by dumping by gravity to a storage pit (See Fig.10) or unloading device or a
PD car, which is unloaded by pneumatic transfer. Truck trailers are usually equipped with a
pneumatic unload system which will unload 15 - 20 TPH through a 4" line using up to 600-1100
cfm of convey air. (See Fig.11)
S h ip m e n t C h o ic e s
B ag FIGURE 9
R a il C a r
T o te
B u lk T r u c k
Page 11 of 60
Rail Car Unload
FIGURE 10
Truck Delivery
FIGURE 11
Page 12 of 60
Chapter 2: Factors Affecting Lime Slaking
CHAPTER 2: FACTORS AFFECTING LIME SLAKING
Page 13 of 60
Factors Affecting Lime Slaking
The lime slaking process and product quality depend on three primary factors: quicklime properties,
water properties, and water to lime ratio. In most applications, water to lime ratio is the single most
important factor in lime slaking; as this ratio is decreased, product quality increases.
Lime Slaking
The term lime slaking refers to the reaction between calcium oxide (as a component of quicklime)
and water to form calcium hydroxide. This process is represented by the following equation:
CaO + H2O Ca(OH)2 + Heat
(Calcium Oxide) (Water) (Calcium Hydroxide)
In this reaction, each 1.0 lbs of calcium oxide combines with 0.32 lbs of water to yield 1.32 lbs of
calcium hydroxide. The reaction releases heat (490 btu/lb of CaO) and is the same as that which
takes place in a lime hydrator to produce commercial hydrated lime. Commercial hydration
processes typically yield a dry product, whereas lime slaking occurs with an excess of water to
produce a slurry of hydrated lime solids in water.
Quicklime Properties
Three properties of quicklime: type, purity, reactivity, and particle size should be considered in lime
slaking.
Type:
The grade of quicklime, high calcium or dolomitic effects the slaking rate. A dolomitic lime will slake
at a slower rate than high calcium quicklime. In the United States, the most common form of
quicklime is high calcium quicklime.
Purity:
Purity describes of the amount of quicklime that is chemically available as Calcium Oxide (CaO).
The purity of quicklime affects the reactivity and determines the purity of the hydrated lime product.
The purity of commercially available high calcium quicklime in the United States typically ranges
from 85% to 95% available CaO.
Reactivity:
Reactivity describes the relative capacity of quicklime to reciprocate chemical change with water.
Reactivity is a function of purity, particle size and other factors such as particle porosity. The slaking
rate is a measurement of the time for the slaking process to reach completion. The
reaction is considered complete when the temperature of a given sample reaches a maximum. As
reactivity increases, the slaking rate, ultimate temperature rise, and surface area of hydrated lime
increase also.
Page 14 of 60
Particle size:
Quicklime particle size and mixing methods have a significant affect on slaking rate. Commercial
grade quicklime is available in a variety of sizes including pulverized (powder), granular (1/4
minus), pebble (1/4-3/4 minus) and lump (2 minus). When adequately mixed with water,
quicklime reactivity increases as particle size decreases. Ultimate temperature rise and product
quality are not significantly affected by particle size with pebble or finer grades. The smaller the
size of quicklime the more susceptible the lime is to air slaking.
Water Properties
Two properties of water: dissolved solids and temperature should be considered in lime slaking.
Dissolved Solids: Water containing sulfites or sulfates in excess of 400 ppm should not be used for
lime slaking as they inhibit the slaking process. Water containing bicarbonate hardness will not
affect the slaking process, however it should be noted that bicarbonate ions will precipitate (scale)
as calcium carbonate on contact with slaked lime. Softened process water or potable water is
recommended for lime slaking.
FIGURE 12 FIGURE 13
Temperature:
Page 15 of 60
In general, higher incoming water produces better product quality. Water that is too cold may
drown the quicklime and slow the slaking reaction down. Water that is too hot may boil during the
slaking reaction. For reliable slaking with most lime types and slakers, water temperature should be
between 55 deg F and 70 deg F.
Water to Lime Ratio
In most applications for slaked lime, surface area of the hydrated lime particles is of paramount
importance. Water to lime ratio is the principal determinant of product surface area; as this ratio is
decreased, surface area increases.
The water to lime ratio is defined as the ratio of water mass to quicklime mass. This ratio does not
include dilution or process water, which may be added to slaked lime downstream of the slaking
compartment. In conventional lime slakers, water to lime ratio varies from 2.5:1 (for paste type
slakers) to 6.0:1 (for detention type slakers). The water should be evenly distributed into the slaker.
Surges or pulsating of the water flow may cause improper slaking.
As shown in Figure 14, specific surface area of slaked lime particles is highly dependent on the
water to lime ratio, with surface area increasing as water to lime ratio decreases. As the graph
shows, this increase is greatest when water to lime ratio varies in the region between 2.5:1 and
6.0:1.
Figure 8. - Specific Surface of Calcium Hydroxide with Different Water

to Lime Ratios [68 Deg. F Water]
55000
Blaine Specific Surface (sq cm / g)
Paste
50000
45000 Detention
FIGURE 14
40000
35000
2 4 6 8 10 12 14
Water to Quicklime Ratio
Source: A Study of the Reaction Between Calcium Oxide and Water, T.C. Miller, Published by the National Lime
Page 16 of 60
FIGURE 15 illustrates the temperature rise of varying Water to Lime Ratios
Page 17 of 60
Chapter 3: Lime System Components
CHAPTER 3: LIME SYSTEM DESIGN
Page 18 of 60
Bulk Storage
Storage silos are generally vertical cylindrical units with a straight side to diameter ratio of between
3:1 and 4:1 for best flow characteristics. A conical bottom is generally supplied with a minimum
cone angle of 60 degrees.
Sizing the silo is a function of the usage rate. A 7-10 day minimum storage is typically used up to a
maximum of 6 months. The minimum storage time may be altered depending on lime availability,
transportation constraints or special problems. Minimum recommended silo size is 1-1/2 truckloads
to allow delivery of a full truckload while still maintaining function of the lime system during the re-
order process.
Silo design should account for local seismic, wind and snow loadings as well as potential mass flow
of the product. For quicklime 65 pcf is commonly used for structural calculations and 55 pcf for
volumetric calculations. For hydrated lime use 35 pcf structurally; 25 pcf for volumetric purposes. An
allowance should be made for some freeboard in the silo; typically 3 to account for the angle of
repose of the product. This freeboard also increases the efficiency of the bin vent filter operation.
Material of construction for the silos include welded or bolted steel, concrete, or stainless steel.
In all cases the material of construction for the silo must be compatible with the material stored.
Steel construction is the most popular for these systems. Shop fabricated welded steel silos are
economic up to 14 diameter. Beyond this size shipping constraints preclude their use and field
fabricated silos are used. Bolted steel factory coated steel silos offer an attractive option at
diameters >12. They are shipped knocked down and can be quickly erected on site with local
labour.
Steel silos are generally supplied with epoxy or inorganic zinc coated exteriors. Interior product
areas can be left uncoated but are more commonly coated with an epoxy primer. For difficult
products the cone area can be coated with special superslick Teflon based coatings, which
greatly improve flow in this area.
The silos can be supported in a variety of methods. Typical supports include skirt supported, leg
supported or using structural steel. Some of these are illustrated below.
S ilo D e s ig n
S ilo s u p p o rt
S k irt, s tru c tu re o r le g
Page 19 of 60
A variety of discharge arrangements can be used depending on the application. For systems
requiring duplicate trains for the lime make down equipment, silos can be equipped with a
bifurcated cone outlet which provides dual outlets or a splitter valve can be installed on the cone
discharge to direct product to two or more trains. Some examples are shown below.
Silo Cone Design
In the case of a duplicate train system, if it is anticipated that both sides will be in use most of
the time, then either a splitter valve arrangement or a bifurcated cone arrangement can be used.
If only one side is in use, as is the case of a backup system, then it is recommended to use the
splitter arrangement. In this case the idle side will tend to compact in the silo discharge and
create flow discharge problems.
Silo accessories should include the following:
Access ladder (caged) with rest platforms (if required) and perimeter guard rail
Vacuum pressure relief hatch
4" fill line with long radius elbows typically of Sch. 40 or 80 carbon steel c/w compression
couplings and grounding strips. Pipe restraints are recommended for operator safety.
High and low level probes (capacitance type)
Knife gate shut off valve for maintenance
Other accessories as desired for inventory control.
With regard to silo coatings we recommend that the silo interior be epoxy primed after
surface preparation to SSPC-SP6 with special anti friction coatings applied to assist in
flow promotion. The exterior and skirt interior area are usually epoxy primed with an
acrylic finish coat.
Page 20 of 60
Typical Silo Configurations
PARTIALLY INSULATED DRIVE THROUGH INTERMEDIATE WALKWAY
MULTIPLE SYSTEMS
STRUCTURE SUPPORTED STAND ALONE
INSIDE BUILDING
Page 21 of 60
Dust Control
It is necessary to provide dust control on the silos to enable the conveying air to exit the silo
during offloading. Bin vent filters of the reverse air purge type are recommended with 150-250
sq. ft of filter area, which will handle the average truck delivery system. For quick lime with
larger particle sizes a filter of this type with 150 sq. ft. is satisfactory. For hydrated lime or
pulverized quick lime the filter area should be approx. 250 sq. ft. which results in an acceptable
surface to air ratio of < 4:1.
Shaker type filters can also be utilized if compressed air is not available. With this type of filter
additional filter area is required as the dust builds up on the filter bags during the off-load cycle
thereby increasing the pressure drop across the bags. This type of filter is generally mechanically
cleaned at the end of the of unload cycle. A minimum of 400 sq. ft. of filter area is recommended in
addition to an exhaust fan to assist air flow.
In rail car unload systems additional filter capacity will be required sized to match the conveying air
flow.
FIGURE 16
Shown: WAM Reverse Pulse Bin Vent Filter
Page 22 of 60
Dust Filters
Need to vent and clean the
pneumatic convey air
Usually located on roof of silo
Design for 3-4 cfm /sq. ft. filter area

i.e. Truck 200 - 250 sq .ft. filter area
Rail 300 - 500 sq .ft. filter area
Mechanical shaker or reverse air
pulse type
FIGURE 16A
Silo Flow Promotion
Once the lime is in the silo it is necessary to ensure a continuous smooth flow from the silo to the
downstream equipment. Bulk products stored in silos can be subject to bridging, rat-holing and
flooding as illustrated below. If not addressed, these problems can cause catastrophic failure of the
silo structure.
Every bulk product stored in cylindrical silos will have its own unique flow promotion characteristic.
S ilo F low P rom o tio n
FIGURE 17
N ecessary to avoid brid gin g or rat-holin g

E fficient use of silo volu m e
Page 23 of 60
Silo Flow Promotion Silo Flow Promotion

Bin activator Fluidization
Imparts vibration energy Fluidizes product with air
pads, air cone, impactors to
to product promote flow
Excellent for coarse Excellent for powdered
products products
Interlock with feeder Used only on refilling feeder
hopper
Do not use for continuous
Necessary to control flooding
feed of small amounts

FIGURE 18 FIGURE 19
For pebble lime and other products shipped as a larger particle size, a vibrating bin activator sized
at a minimum of 1/3 the diameter of the silo is recommended.(See Figure 19) These devices impart
vibration energy to the product and promote smooth flow. Caution is required when using these
devices in situations where a small quantity of product is removed continuously as in a direct feed
application. In these cases it is recommended to use a transition hopper above the feeder and refill
this hopper periodically.
For hydrated lime, pulverized quick lime and other powdered products, a fluidization system works
very well. This system consists of an aeration cone on the hopper outlet plus air pads assisted by
low frequency, air operated impactors on the cone. (See Figure 18)
Both of the above flow promoters can be used on either type of lime but some restrictions apply
depending on particle size, air dryness, etc.
Page 24 of 60
These devices should be interlocked with the feeding equipment to allow operation only when
feeding.
Flooding Control
Flooding of the material can be a problem with hydrated lime due to material size or excess
aeration. An anti-flood system should be used which generally consists of a rotary valve above a
transition feed hopper. The rotary valve is used to maintain the level in the feed hopper between
two set points. This arrangement prevents flooding of the product through the feeder and
provides a constant head of product on the feeder for repeatable flow characteristics.
(Figure.20)
An electromagnetic vibrator is generally installed on this hopper to provide flow promotion to the
feeder. (See Figure 21)
Page 25 of 60
Typical Feed Hopper Setup
FIGURE 20
Electric Vibrator Feed Hopper Flow Problems
Used on Hoppers
FIGURE 21 FIGURE 22
Chemical Feeders
A variety of feeding devices is available for controlled metering of lime to the slurry tank. For lime
service a volumetric screw feeder provides an economical, accurate device with minimum
maintenance requirements. The accuracy of this device is approx. +/- 2%, which is normally
satisfactory on lime service.
Alternately a loss-in-weight feeder can be used which will give accuracy to +/- 0.2- 0.5% and also
provide instantaneous and totalized product usage for inventory control. Other types of feeders
include gravimetric belt feeders and rotary airlock feeders.
Page 26 of 60
Feeders with accuracy to +/- 0.2% (FIGURE 23)
G ra v im e tric F e e d e r
IN F E E D
M OTOR
SHEAR GATE
BELT
C O U N TER B ALAN C ED
M OTOR
W E IG H P L A T F O R M
SPEED
S IN G L E L O A D C E L L C O N TR O LLER
D IS C H A R G E
BELT
SPEED
P IC K U P M IC R O - C O M P U T E R
C O N TR O LLER
FIGURE 26 Belt Feeder

Shown: Merrick Belt Feeder
Page 27 of 60
Volumetric Screw Feeder
FIGURE 25 Volumetric Screw Feeder

Shown: Metalfab DB-1 Screw Feeder
Loss-
In -
W e ig h t
Feeder
Feeders with accuracy of +/- 2% (FIGURE 24)
Page 28 of 60
Loss-In-Weight
Feeder
FIGURE 27
Rotary Valve
FIGURE
Page 29 of 60
Chapter 4: Lime Slakers
CHAPTER 4: LIME SLAKERS
Page 30 of 60
Lime Slakers
The objective in slaking quick lime is to thoroughly hydrate the CaO to form Ca(OH)2 and produce a
very small particle size with a large surface area. The slaking reaction produces a great deal of
heat, which is useful in sustaining and initiating further reactions.
There are two types of lime slaker commonly used today: paste type slakers and detention type
slakers. The principal difference between paste slakers and detention slakers is the ratio at which
water and lime are mixed during the reaction phase of the slaking process; paste type slakers react
quicklime with water at a ratio of approximately 2.5:1 whereas detention slakers react quicklime
with water at ratios of 3.5:1 or greater. Paste and detention type slakers come in a variety of
different configurations and sizes, each suited to specific applications.
Paste Type Slakers
Paste slakers automatically control the water to quicklime ratio and rely on the heat released from
the reaction as energy to complete the slaking. By controlling this ratio the slakers are able to
effectively handle frequent changes in the quicklime feed rate for both batch and continuous
process applications. Optimum paste slaker performance is designed for short reaction times and
maximum utilization of the lime. For these reasons, the paste slaker is best suited for applications
using high quality quicklime. Paste slakers also consume substantially less power than comparably
rated detention type slakers.
Paste Slaker
(.5, 1, 2, 4 TPH)
1000, 2000, 4000, 8000, Lbs./Hr.
Operate by mixing lime & water in
1:2 ratio
FIGURE 28
Heat of reaction breaks particles Shown: Merrick Paste Slaker
apart
Very efficient slaking
Low hp, low speed, minimal
maintenance
Able to operate without additional
water heating
Page 31 of 60
The paste slaker consists of two horizontal paddle shafts, which counter-rotate to mix water with
quicklime. The mixture is driven toward the discharge (weir) end by means of pitched paddles
attached to the shafts. Water to lime ratio in the slaking compartment is automatically maintained at
an user adjustable ratio between 2.5:1 and 2.8:1. Beyond the weir end, slaked lime is further
diluted by means of manually controlled spray jets integral to the slaker assembly. Grit (inert
material in quicklime) is removed either by screening or inclined classifier.
Paste type slakers are available in quicklime slaking capacities of 500, 1000, 2000, 4000 and 8000
lbs/hr. They operate at water to lime ratios (in the slaking compartment) between 2.5:1 and 2.8:1
which produces specific surface area (hydrated lime) of approximately 53,000 cm2 per gram.
Typical operating temperature rise of a paste type slaker is approximately 140 deg F above the
temperature of the incoming water and steady state is usually reached within 5 minutes of startup.
Standard slurry discharge is 18-20% solids at the slakers rated maximum capacity.
Detention Slakers - Conventional
Conventional detention type slakers are best suited to applications in which the lime quality is
medium to high and the lime feed rate changes neither frequently nor automatically. They are the
least expensive of the slaker types and are well suited for batch type operations where lime quality
is reliable.
As shown in Figure 29, a typical detention slaker consists of two slaking compartments, each
agitated by a conventional slow speed mixing impeller. Water and lime are fed into the first
compartment and then overflow a weir into the second compartment. Additional agitation takes
place in the second compartment after which the product discharges into the grit removal system.
The water to lime ratio in the slaking compartment is adjusted and monitored manually with the
hand valves and flowmeters integral to the slaker assembly. Grit is removed either by screening or
inclined classifier.
Conventional detention type slakers are available in a variety of quicklime slaking capacities up to
16,000 lbs/hr. They operate at water to lime ratios (in the slaking compartment) between 3.5:1 to
6.0:1which produces specific surface area (hydrated lime) of approximately 47,000 cm2 per gram.
Typical operating temperature rise of a detention type slaker is approximately 100 deg F above the
temperature of the incoming water and steady state operation is usually reached within 15 minutes
of startup. Standard slurry discharge is 18-25% solids at the slakers rated maximum capacity.
With slakers of this type it is necessary to incorporate heating of the slaking water for efficient
operation in cold weather locations.
Page 32 of 60
D e ten tio n S la ke r
500, 1250, 2500, 5000,
10,000 L bs . / H r.
O perated by m ixing ratio
of 1:3.5 - 4.0
M echanical agitation at
high speed drives Slaking
S laking
reaction.
H igher H P , higher speed
R equires additional heating of m akeup w ater in
w inter conditions
FIGURE 29
Shown: BIF Slurry Slaker
Detention Slakers - Grinding Mill Type
Grinding mill type detention slakers are best suited to applications where the lime quality is poor, grit
handling is costly or when the processing rate exceeds that achievable in a conventional slaker.
Grinding mill slakers operate on the same principle as conventional detention slakers, however they
have the ability to grind inert materials (grit) contained in the quicklime and generally require little or
no grit removal or disposal facilities. Grinding mill slakers are horizontal or vertical ball mills (as
commonly used in the mineral processing industry) modified to withstand the temperature of lime
slaking. They have the advantage of being relatively simple and rugged. However, grinding mill
slakers are the most expensive of the slaker types, have limited capacity for turndown, and
consume the most energy.
As shown in Figure 30, a typical grinding mill slaker (horizontal type) consists of a rotating drum
supported by external rollers. The mill contains a grinding media (typically steel balls) agitated by
means of horizontal lifting bars attached to the interior of the drum assembly. Slaked lime product
discharges from the drum and is pumped to a hydrocyclone, which classifies the slurry to recirculate
oversize particles to the mill inlet. As with a conventional detention slaker, water to lime ratio in the
slaking compartment is adjusted and monitored manually with hand valves and flowmeters.
Grinding mill type detention type slakers are made to order in quicklime slaking capacities up to
60,000 lbs/hr. Operating parameters and characteristics are similar to conventional detention
slakers.
Page 33 of 60
An alternate version of the ball mill is a Vertimill which is basically a ball mill operated in a vertical
manner. This type is useful where very fine grinding is desired. (Figure 31)
Ball Mill
1 TPH and up
Operates as a
slurry slaker
Ball impacts and
rotation drives
slaking reaction
Very High HP
Requires water heating for winter operation
Especially suitable for poor quality limes &
High use ratio > 2- 4 TPH
FIGURE 30 FIGURE 31
Shown: Svedala SRR Ball Mill Slaker
Factors Affecting Slaker Selection
Many factors other than price and operating costs will influence the selection of a slaker. Some
of the factors are outlined in the following:
Product Quality
Surface area of the hydrated lime product is of paramount importance in many applications. Tests
show a correlation between the diameter of slaked lime particles and the water to lime ratio used
during slaking. As the water to lime ratio is reduced, the diameter is reduced also, resulting in a
substantial increase in surface area of the slaked lime product. Due to the difference in water to
lime ratios, paste type slakers deliver more neutralizing capacity (as measured by free base
titration) than comparable detention slakers. For certain applications, this difference can result in
substantial improvements to the process as well as chemical cost savings.
Page 34 of 60
Grit Disposal Costs
The cost of grit disposal can be a significant factor in the selection of lime slakers. The inert portion
of quicklime which is captured by a screen or inclined classifier is relative to the purity and particle
size quicklime. This grit must be transferred from the grit removal device to a bin, which is emptied
periodically. While the grit itself is not a hazardous material (as defined by EPA), however, the pH
exceeds 12.0 and caution must be exercised in handling and disposal. The grinding mill slaker
eliminates the grit disposal problem by grinding the grit to very fine particles, which are carried along
with the lime slurry. This type of slaker should be considered where grit disposal costs are high.
Slaking Water Quality
For reliable operation of any lime slaker type, water used for lime slaking should be at a
temperature not less than 55 F / 12 C. For slakers, which are expected to start and stop
frequently, the time to reach operating temperature (with associated hydrated lime quality) may be a
factor. Paste type slakers reach their steady state operating temperature in approximately 1/3rd the
time required by comparable detention type slakers. In general, paste slaker performance is less
susceptible to cold slaking water (less than 55 F / 12 C) than detention and grinding mill slakers.
Water heaters may be added to raise the temperature of the slaking water for all types of slakers.
Space Constraints
Like all process equipment, lime slakers require regular cleaning and maintenance. They are often
placed within the skirt support structure of the quicklime storage vessel where space is at a
premium. The size and shape of the slaker may be a determining factor in slaker selection; in
general, paste slakers are the most compact (in plan view). Some conventional slakers are
configured with vertical mixing chambers and require less horizontal space, however headroom
requirements are greater. For grinding mill slakers, the vertical type require the least space in plan
view, however they can be up to 30 ft in height depending on the processing capacity.
Capital Cost
Budget constraints frequently determine slaker selection. Conventional detention type slakers are
the least expensive of the three type considered, with paste slakers priced approximately 15%
higher for comparable capacities. The higher price of the paste slakers can often be recovered
quickly by the more efficient slaking and lower chemical usage. Grinding mill slakers are typically 3-
5 times the price of comparable conventional slakers, however this premium can also be offset by
the reduction in grit disposal cost.
Operator Experience
Page 35 of 60
The users level of experience with lime slaking and prior experience with specific types of slakers
should be a factor in slaker selection. For safe and effective lime slaking, operators should have
knowledge of the theory and practice of lime slaking. In general, detention type slakers are more
forgiving of inaccuracies in lime and water feedrate; however manual slaking water control requires
calculation of slaking/dilution water flowrates each time the lime feed rate is changed. In cases
where quicklime feed rate is changing frequently, the automatic water proportioning system in paste
slakers should be considered. In addition to knowledge of lime slaking, grinding mill slakers require
a knowledge of the grinding process and related equipment. For this reason; grinding mill systems
require more operator knowledge than conventional slakers and appropriate consideration should
be made in the selection process.
A summary of selection criteria and comparative features is presented in Figure 32 below.
FIGURE 32 Lime Slaker Selection Criteria and Comparison

Condition Paste Type Detention Type Detention Type
Conventional Grinding Mill
Maximum Quicklime
8000 16,000 60,000
Slaking Rate (lb/hr)
85% CaO with high
Minimum Quicklime 85% CaO with 75% CaO with low
reactivity OR 80% CaO
Quality medium reactivity reactivity
with medium reactivity
Process Applications Batch or Continuous Batch Only Batch or Continuous
Water to Lime Ratio
2.5:1 4.5:1 4.5:1
(Typical)
Slaking Water
Automatic Manual Manual
Control Method
Turndown Ratio
20:1 5:1 2:1
(Typical)
0.5 Hp per Ton/hr of 1.7 Hp per Ton/hr 10 Hp per Ton/hr of
Horsepower Required
Quicklime of Quicklime Quicklime
Percent Free Base
81% 75% 75%
(Typical)
Ca(OH2) Product
Surface Area 53,000 Cm2/Gram 47,000 Cm2/Gram 47,000 Cm2/Gram
(Typical)
Typically 15% higher 2-5 times higher than
Capital Expense than conventional Least conventional
detention type slakers detention type slakers
Screen or Inclined Screen or Inclined
Grit Disposal Not normally required
Screw Screw
Operator Experience Important Important Critical
Page 36 of 60
Chapter 5: System Accessories
CHAPTER 5: SYSTEM ACCESSORIES
Page 37 of 60
Slaker Accessories
For efficient operation of the slaker additional equipment is required to monitor and control the
system. These include the following:
Grit removal devices

Vent exhaust fans
Dust control devices
Temperature controls and alarms
Warning devices
In line water heaters
Grit Removal
In order to extend the life of slurry piping, valves and pumps it is recommended that grit be removed
from the lime slurry. This is accomplished in either a screen type, screw type of conveyor type grit
remover.
Slurry Tanks
Sizing:
In batch makeup systems, slurry tanks should be sized for a minimum of 15 minutes retention time
of the lime slurry to allow the slurry to stabilize and complete the softening precipitation with the
dilution water. This will minimize scaling on slurry pipelines. The slurry tanks should be circular with
integral baffles and an adequately sized low speed agitator. For optimum mixing the tank diameter
to height ratio should be kept close to 1:1.
For continuous feed applications, smaller tanks are used to minimize the lag time when lime feed
settings are changed. These tanks are generally 50-100 usg capacity and are quipped with high
speed agitators. The water level in the tanks is maintained by either float valves or with a control
valve reacting to tank level indication.
Tanks can be fabricated of Carbon steel, FRP or polyethylene construction.
Agitation:
Agitators for lime service can be either belt or gear drive units designed for low speed operation with
radial flow impellers. For hydrated lime service the agitators need to be designed for wetting
service and generally are of the two blade design. Suspension applications common in quick lime
slaking service are usually of the single prop design.
Page 38 of 60
Agitation
Low speed agitator ( 350 rpm) FIGURE 32
Gear or Belt Drive
Dual prop for Wetting
Single prop for Suspension
CS or SS material
Slurry Tank Level Controls:
Non-contacting devices are strongly recommended for lime and/ or slurry service as they avoid the
build up problem common with any item immersed in the slurry. Ultrasonic level controls, air
bubblers or load cells have all given excellent service.
Slurry Pumps and Piping
Pump selection is critical in lime service. A properly designed lime slurry addition system will
operate virtually maintenance free whereas poorly designed systems will create extensive
maintenance and control problems.
Pumps should be designed for slurry service. Gland seals should be avoided as the seal water
creates scaling problems in the packing. Recessed impeller pumps with expeller options have
given excellent service. Other choices include peristaltic hose pumps, progressive cavity designs
and air operated diaphragm pumps.
Centrifugal slurry pump
Wilfley Pump
FIGURE 33
Page 39 of 60
Lime slurry piping should be designed to ensure a minimum flow velocity of 4/sec. with a minimum
line size of 1-1/2. Care should be taken to eliminate short radius elbows. Avoid in line dilution of the
lime slurry. Pump suction lines should be as short as possible with no bends. Piping materials can
be PVC, ABS or carbon steel.
Valves should be chosen with care to avoid problems. For pump isolation valving straight through
diaphragm valves are recommended. Lime slurry take off valves should be of the pinch valve type,
(Fig 33) which are self-cleaning with a 1 minimum diameter. Pinch valves can be of the straight
through, reduced port or tapered style operating in a timer controlled on-off manner. Alternately they
can be operated in a modulating manner provided an intermittent fully open pulse is provided by the
control scheme.
FIGURE 34
TYPICAL BATCH SYSTEM SHOWING FEEDER SURGE HOPPER, SLURRY TANK, RECYCLE PUMP
FIGURE 35
Shown: Red Valve Pneumatic Pinch Valve
Page 40 of 60
Pressure gauges should be of the isolation sleeve type, as shown below, to avoid plugging
problems.
Integrally
Pressure
Gauge
Molded
Flange
Housing Gasket
Sensing Isolation Sleeve Type

Fluid
Flexible
Elastomer
Element
Where possible lime slurry should be added to the process with an air gap to avoid scaling
problems at the injection point. If this is not possible (i.e. Injection into a pipeline) then a retractable
injection lance assembly should be used to allow periodic cleaning.
FIGURE 35A
oce ss
to P r
g L im e
A d d in
Note: Addition of lime to process using an air gap to minimize scaling.
Page 41 of 60
Chapter 6: Control Panels & Instrumentation
CHAPTER 6: CONTROL PANELS & INSTRUMENTATION
Page 42 of 60
Control Panels
Generally the lime system supplier will supply a complete control panel to control and monitor the
lime slurry preparation process.
These panels can be supplied utilizing either relay logic or programmable controllers.
Panels should be designed to NEMA 4 or 4X standards and a separate truck fill panel should be
incorporated for the silo filling process to avoid having the truck driver access the main control
panel. In cases where the silo bin vent filter is of the mechanical shaker type, the motor starters for
this device should be located in the main panel or in an MCC section for overall economics.
Control Panels Control Panels

NEMA 4 or 4X
design
Usually with Recommend
integral PLC separate truck
Can have
integral MCC fill panel

section
FIGURE 36 FIGURE 37
Instrumentation
A variety of instrumentation is available to suit individual plant requirements.
Silo Level and Inventory Controls
Digital point sensors

Capacitance, radio frequency and vibrating tuning fork probes have all been used
successfully. Rotating paddle type sensors, although the most economical devices,
have resulted in higher maintenance costs than the other types.
Analog level sensors
Radar reflex units, capacitance cable probes and retractable Yo-Yo probes have
given good service. These devices all react to the shape of the product stored in the
silo and hence are subject to some inaccuracies relating to the varying profile of the
chemical as it is withdrawn from the silo.
Page 43 of 60
Load cells or strain gauges installed on the silo supports avoid this problem and will
give accurate total weights.
Another method of accomplishing inventory control is by means of loss-in-weight feeders, which

will give instantaneous as well as totalized usage readouts, which can be used to calculate
inventory levels.
Slurry Measurement
In general, lime slurry concentrations and flows are not measured. Instrumentation for this purpose
that works effectively is limited and is quite expensive. It is usually preferable and easier to measure
the dry product feed rather than the liquid feed. If absolutely necessary for process control
measurement of slurry density can be accomplished with nuclear density meters and flow with
coriolis meters.
Page 44 of 60
Chapter 7: Lime Addition Control
CHAPTER 7: LIME ADDITION CONTROL
Page 45 of 60
Lime Addition Control
Lime can be added to the process in a dry form direct from the silo or as a slurry. For most
applications a slurry feed is preferred as it ensures higher reactivity, better dispersion and the most
efficient use of chemical.
For slaking systems it is advisable to control the lime slaking process as follows:
Set slaking rate at approx. 120% of maximum process requirements

Operate the slaker as required to maintain the level of slurry in the slurry tank between the
high and low set points
Re-circulate the lime slurry in a recycle loop with the lime being added to the process
through a pinch valve takeoff
Adjust lime slurry feed by varying the timer cycle of the feed line pinch valve ON time
Note: It is not advisable to vary the feed rate of quick lime to the slaker as a means of controlling the
lime addition rate to the process as the lag time through the slaking process is too long for effective
response time.
Page 46 of 60
For hydrated lime systems either of the following methods can be used:
A) Variable Volume, Constant Strength (Batch Method)
Make up batches of hydrated lime slurry to pre -set concentrations as

required and adjust the slurry feed rate as above for the slaking systems.
B) Constant Volume, Variable Strength (Direct Feed)
Feed a constant volume of dilute slurry to the process through a gravity,

pump or eductor system.
Maintain a constant level of slurry in the slurry tank by introducing water
through a modulating control valve or float valve.
Vary the feed of dry lime to the slurry tank in response to the process
demands through a variable speed feeder.
Note:
1. Method A is useful when using an eductor feeding mechanism.
2. Method B should only be used when makeup water hardness and alkalinity are low.
FIGURE 38
METHOD A
Batch Makeup Process
Constant solution strength

Variable volume
Usually 5 - 20% slurry
Feed to Process through
recirculating loop system.
Page 47 of 60
FIGURE 39
METHOD B
Continuous Makeup Process
Variable lime feed

Constant lime slurry feed
Use only with softened makeup
High water requirements ~ min. 30-
35 usgpm
Very low slurry strength 0.1 - 1%
Page 48 of 60
Good Design Practices
Good design practices dictate that lime slurry piping and pump facilities be duplicated to ensure
continuous operation. The level of this redundancy is predicated on the actual plant process
requirements.
Other Considerations
A large variety of accessories can be incorporated into the lime system package to suit customers
individual requirements and other process needs such as remote instrumentation and alarms,
inventory control, heating and insulation of the silo skirt area, etc.
As a minimum a safety shower and eyewash should be incorporated at the working level for
operator safety when using quick lime in addition to safety glasses and protective clothing as
recommended when using any chemical. Safety showers should be equipped with a flow switch to
alarm in the event of use to protect workers working alone.
Lime preparation areas should be equipped with wash down provisions and a sump area with
pump.
In summary, if careful attention is given at the design stage to the lime handling and feeding
system, then an efficient, automated, low maintenance facility can be provided for the end user
at an economical cost.
Page 49 of 60
Chapter 8: Small Feed Systems
CHAPTER 8: SMALL FEED SYSTEMS
Page 50 of 60
Small Feed Systems
Bulk Bag Systems
For intermediate use applications lime may be purchased in 1 ton bulk bags. We have
developed a system to handle these effectively as shown below to avoid the common flow
problems associated with using these bags as storage bags for a feeder. The bulk bags are
dumped into the hopper and chemical is withdrawn as required to make up batches. Flow
promotion equipment is incorporated into the design. These skid mounted systems are shipped
completely assembled and are custom designed for each application.
FIGURE 40
Shown: Stanco Prepackaged Skid System
Bulk Bag Systems
For small to medium use applications
Page 51 of 60
Bag Systems
For low use applications utilizing 50# bags of chemical, a system illustrated below can be
supplied to handle these effectively. The chemical bags are dumped into the sack dump system
and then transferred to a batching system. The resulting slurries/solutions can be added to the
process through a variety of pumping methods. Shown in the slide are metering pumps typically
used for adding solutions.
Bag Systems
For small applications
Page 52 of 60
Pre-Made Lime Slurries
For smaller use applications several lime manufacturers have developed delivery systems to handle
high strength lime slurries approaching 35% solids. These slurries are shipped in bulk from the
manufacturer to liquid tanks at the use point.
This method of delivery saves on the expense of a dry lime makedown system at the cost of the
higher freight costs involved in shipping water.
An illustration of a typical system from Chemical Lime is outlined below.
FIGURE 41
Page 53 of 60
Chapter 9: Other Chemicals
CHAPTER 9: Other Chemicals
Page 54 of 60
Other Chemicals
All chemicals have their own particular design considerations that should be addressed in order
to provide trouble free feeding systems. Some design aspects are addressed for common water
treatment plant chemicals in the following sections.
Soda Ash
Special considerations for soda ash include its tendency to form hard lumps if exposed to
moisture and its complex phase diagram in water.
When designing soda ash systems special care should be taken to avoid long, complex
pneumatic fill lines. Soda ash is vulnerable to product size degradation if handled extensively or
off loaded at too high a pressure. The resultant fine powder is especially sensitive to moisture
and will cause flow problems in the silo.
Designers should note that there are two common forms of soda ash in industrial use. Light
soda ash is generally used as a filler in compounds and will have a product weight of 25-35 pcf.
Dense soda ash is generally used in water treatment and has a bulk density of 65 pcf. The
storage silo size and design should take the form of soda ash into account.
Consideration should also be given to the use of a lump breaker at the discharge of the silo
cone. This can be used in conjunction with or in place of bin activators and will reduce any
lumps that form in storage.
Soda ash dissolves in water to form a variety of compounds depending on the strength of the
solution and the temperature. The phase diagram is quite complex. Special care should be
taken to ensure that the decahydrate form of soda ash cannot form as it forms a hard glassy
solid that is difficult and dangerous to remove from pipelines and pumps. By maintaining the
temperature and solution concentration within defined limits to ensure an unsaturated solution,
this situation can be avoided. A phase diagram is shown below which illustrates the various
forms that can be produced.
Feeding soda ash solutions to the process can be accomplished using a batch tank makeup
system with the solution fed to the process with metering pumps. Alternatively soda ash can be
metered continuously in dry form using a volumetric feeder. This feeder adds the soda ash to a
wetting cone/eductor system for direct feed to the process using the transport water as a carrier.
Control over the addition is maintained by controlling the feeder speed in response to plant
flow/ph signals. A typical flow diagram is shown below to illustrate the direct feed system
Page 55 of 60
A---------------------A E------------E
F---------------------------------------------F
G----------------------------------------------G
D------------------------------------D
H-------------------H
B--------------------
C-----------------------C
A------- --------E
B------- --------F
C------- --------G
D------- --------H
Page 56 of 60
Page 57 of 60
Powdered Activated Carbon (PAC)
Special considerations for PAC include the type of carbon used and the flow promotion in the
silo.
Designers should note that there are two common forms of PAC in water treatment plant use.
PAC used in water treatment is produced from coal or wood each with its own characteristics.
Coal based PAC is generally heavier with a bulk density ranging from 25-35 pcf. Wood based
PAC is lighter with a bulk density ranging from 15-25 pcf. The storage silo size and design
should take these ranges into account.
Flow promotion devices are required to ensure smooth even flow form the silo. Fluidization
systems are very effective when using intermediate feed hoppers above the feeding device. The
use of bin activators is not recommended as these devices tend to compact the PAC and create
additional flow problems.
Many jurisdictions also require that any electrical devices used in feeding or storing PAC be
rated for explosion potential. Local regulations should be checked to determine their
applicability. The cost impact of this requirement can be minimized by locating many of the
devices such as control panels in an adjacent building as shown below.
Feeding PAC to the process can be accomplished using a batch tank or continuous makeup
system with the slurry fed to the process with slurry pumps. Alternatively PAC can be metered
continuously in dry form using a volumetric feeder to a wetting cone/eductor system for direct
feed to the process using the transport water as a carrier. Control over the addition is
maintained by controlling the feeder speed in response to plant flow signals.
Note that the volumetric feeder design should incorporate a conditioning screw around the feed
screw to avoid bridging and arching flow problems. Care should be taken to ensure that flooding
of the PAC through the feeder is effectively prevented.
A typical direct feed system utilizing a loss-in-weight feeder is shown in the following pictures.
This system also has a separate building to house some of its electrical equipment.
Page 58 of 60
Page 59 of 60
Summary
In conclusion, if the potential hazards and problems of feeding lime and other chemicals are
recognized and dealt with at the design stage, then effective, efficient and minimal maintenance
systems can be provided to the end users.
Page 60 of 60

Lime Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Lime Manual PDF

Uploaded by

Copyright:

Available Formats

Lime Handling

CHAPTER 1: GENERAL INFORMATION ON LIME

Limestone: Limestone is a naturally occurring substance, which consists primarily of calcium

FIGURE 2. Limestone Names, Grades, and Properties

Common Name and Grades or Forms Appearance and Bulk Density

Aerial photo compliments of Graymont Lime

High Calcium Quicklime

CaCO3 (Calcium Carbonate) + Heat CaO (Calcium Oxide) + CO2 (gas)

CaCO3 MgCO3 (Calcium Carbonate and Magnesium Carbonate) + Heat

CaO MgO (Calcium Oxide and Magnesium Oxide) + CO2 (gas)

FIGURE 4. Quicklime Types, Grades, and Properties

Common Name Grades or Forms Appearance and Bulk Density

High Calcium Hydrated Lime

CaO (Calcium Oxide) + H2O Ca(OH)2 (Calcium Hydroxide) + Heat

Dolomitic Hydrate (type N)

Dolomitic Hydrate (type S)

Common Name and Grades or Appearance and Properties Bulk Density

Selecting what type of Lime to use

Choice of Lime to Use Lime Particle Size

2 x 3/4 3/4 x 3/8 3/8 minus

Hydrated Lime - usually pulverized

Rail Car Unload

CHAPTER 2: FACTORS AFFECTING LIME SLAKING

Factors Affecting Lime Slaking

Water to Lime Ratio

Figure 8. - Specific Surface of Calcium Hydroxide with Different Water

FIGURE 15 illustrates the temperature rise of varying Water to Lime Ratios

CHAPTER 3: LIME SYSTEM DESIGN

Silo Cone Design

Silo accessories should include the following:

Typical Silo Configurations

PARTIALLY INSULATED DRIVE THROUGH INTERMEDIATE WALKWAY

Design for 3-4 cfm /sq. ft. filter area

Silo Flow Promotion

S ilo F low P rom o tio n

N ecessary to avoid brid gin g or rat-holin g

Silo Flow Promotion Silo Flow Promotion

Typical Feed Hopper Setup

Electric Vibrator Feed Hopper Flow Problems

Feeders with accuracy to +/- 0.2% (FIGURE 23)

FIGURE 26 Belt Feeder

Volumetric Screw Feeder

FIGURE 25 Volumetric Screw Feeder

Feeders with accuracy of +/- 2% (FIGURE 24)

CHAPTER 4: LIME SLAKERS

Paste Type Slakers

Detention Slakers - Conventional

Detention Slakers - Grinding Mill Type

Requires water heating for winter operation

Especially suitable for poor quality limes &

High use ratio > 2- 4 TPH

Factors Affecting Slaker Selection

Grit Disposal Costs

Slaking Water Quality

A summary of selection criteria and comparative features is presented in Figure 32 below.

FIGURE 32 Lime Slaker Selection Criteria and Comparison

Operator Experience Important Important Critical

CHAPTER 5: SYSTEM ACCESSORIES

Grit removal devices

Dual prop for Wetting

Single prop for Suspension

Slurry Tank Level Controls:

Slurry Pumps and Piping