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Bringing Modern Lime Production to Western China
Nestled in the Bayingolin Mongol Autonomous Prefecture, Korla is rapidly emerging as an industrial powerhouse in Xinjiang. With vast limestone reserves in the nearby Tianshan Mountains and surging demand from the steel, construction, and chemical sectors, the region offered an ideal setting for a large-scale lime production facility. Henan Hongke Machinery was entrusted with designing and delivering a complete 3x60m environmentally friendly lime rotary kiln line — a project that now sets the standard for green lime manufacturing in China's western frontier.
Why Korla Was the Right Choice
Several factors made Korla the perfect site for this investment:
Rich Limestone Deposits: Local quarries supply high-purity limestone with CaCO₃ content above 95%, perfect for producing premium quicklime.
Booming Industrial Demand: Xinjiang's steel, aluminum, and carbide industries require millions of tons of lime each year. Local production slashes logistics costs dramatically.
Reliable Energy Access: Pipelines and coal reserves nearby ensure stable, affordable fuel supply for kiln operations.
Government Incentives: Western China development policies actively encourage modern, environmentally sound industrial projects.
Core Equipment: The Φ3.0m × 60m Rotary Kiln
At the heart of this production line stands a 3-meter diameter, 60-meter long rotary kiln engineered by Henan Hongke Machinery for peak thermal performance and product consistency.
Specifications at a Glance
| Parameter | Detail |
|---|---|
| Kiln Size | Φ3.0m × 60m |
| Daily Capacity | 300–500 tons of quicklime |
| Product Quality | CaO ≥ 92%, activity ≥ 350 mL |
| Fuel Options | Natural gas / coal gas / pulverized coal |
| Calcination Temperature | 1050°C – 1200°C |
| Feed Size | 20–50 mm |
| Shell Steel | Q345R boiler-grade, 25–40 mm wall |
| Heat Consumption | ≤ 3.8 GJ/ton |
| Emission Level | Ultra-low standard compliant |
Vertical Preheater
A vertical preheater at the kiln inlet captures exhaust heat, gradually warming incoming limestone to 800–900°C before it enters the main kiln. This cuts fuel usage by 15–20% and reduces particle cracking for better product quality.
Grate Cooler
A grate cooler at the discharge end rapidly cools finished quicklime from 1100°C to below 100°C. Recovered hot air is recycled as combustion air inside the kiln, further boosting energy efficiency while ensuring safe product handling.
Environmental Performance: Exceeding Standards
Strict environmental compliance was embedded into every stage of the design.
Three-Stage Dust Removal
1.Cyclone Pre-Separator — Captures 80–85% of coarse dust at the kiln outlet.
2.PTFE Membrane Bag Filter — Achieves ≥ 99.5% filtration efficiency, keeping emissions under 10 mg/Nm³.
3.Wet Desulfurization Tower — Removes over 95% of SO₂ for coal-fired operation.
Additional Measures
Acoustic enclosures and vibration dampers keep boundary noise below 65 dB(A).
Off-spec product and kiln dust are repurposed for agriculture or construction, achieving near-zero solid waste.
Overcoming Project Challenges
Harsh Climate
Korla's temperatures swing from -25°C to +42°C. Henan Hongke Machinery specified Q345R steel with expansion joints in the refractory lining and installed climate-controlled electrical cabinets with winter heating.
3,000+ km Delivery
The 60-meter kiln shell was fabricated in transportable segments with precision flanges, then assembled on-site under the supervision of Henan Hongke Machinery's installation team.
Multi-Fuel Flexibility
An automated multi-fuel burner system switches seamlessly between natural gas, coal gas, and pulverized coal, maintaining optimal combustion regardless of fuel type.
Results That Speak for Themselves
| Metric | Achievement |
|---|---|
| Daily Output | 380–420 tons |
| Quicklime Activity | 360–390 mL |
| CaO Content | ≥ 92% |
| Heat Consumption | 3.5–3.7 GJ/ton |
| Dust Emissions | < 8 mg/Nm³ |
| SO₂ Emissions | < 30 mg/Nm³ |
| Annual Uptime | > 92% |
| Refractory Life | 12+ months (calcining zone) |
The line consistently outperforms its original design targets across output, quality, energy efficiency, and emissions.
Why Choose Henan Hongke Machinery?
Full In-House Capability: Design, engineering, manufacturing, and quality control all under one roof.
Turnkey Delivery: From feasibility study through commissioning — a single, accountable partner.
Global Experience: Successful installations across China, Southeast Asia, Central Asia, Africa, and the Middle East.
Lifetime Support: Ongoing spare parts supply, technical assistance, and performance optimization services.
Wide-Ranging Applications
Quicklime from this rotary kiln serves critical roles in:
Steelmaking — flux for BOF and EAF processes
Flue Gas Desulfurization — power plants and industrial facilities
Chemical Manufacturing — calcium carbide, soda ash, PCC
Construction — soil stabilization, AAC blocks, mortar
Water Treatment — pH control and sludge processing
Build Your Lime Plant with Henan Hongke Machinery
This Korla project proves that high-capacity lime production and environmental responsibility can go hand in hand. Whether you are planning a new lime rotary kiln line or upgrading an existing one, Henan Hongke Machinery has the expertise to deliver a solution tailored to your raw materials, fuel supply, production goals, and local regulations.
Contact us today for a free project proposal and technical consultation.
