Marblehead Lime Co.
Rotary Kiln Additions
Buffington Plant
Buffington, Indiana
Roberts & Schaefer provided engineering, procurement, and
construction services at Marblehead Lime's Buffington, Indiana
plant, to furnish and install two additional rotary kilns and
all ancillary equipment and facilities. The additional items include
two new silos (one each for coal and limestone), new kiln feed
belts, a reversible fines belt, a fines recycling system, screening
and presizing systems for lime and pebble products, and a complete
truck loading and product compacting system.
Limestone is stored in two 1,600-ton capacity silos, of which
one is new. Limestone is reclaimed using variable speed weigh
feeders from the new silo and via a splitter gate and a variable
speed feeder from the old silo. Kilns 4 and 5 are fed via two
new kiln feed belts.
Coal is stored in two 750-ton capacity silos, of which one is
new. From the new silo, belt feeders reclaim coal; the old silo
has a splitter gate and twin weigh belt feeders. Each unit feeds
a 200 HP coal pulverizer mill to provide fuel.
Each of the two new kilns is 16 feet six inches in diameter and
300 feet long, and includes drive trunnions, lubrication system,
and a cooling chamber. Each kiln has its own dust collection system,
consisting of a refractory-lined expansion chamber, a dust housing,
an exhaust gas fan and kiln gas bag house, including reversing
fan air locks, fire protection, and heat tracing.
Processed material collects on the existing product conveying
system, which has been modified to handle the increased capacity.
Other modifications to the existing facility include addition
of a 24 inch reversible fines belt, and a fines recycling system
(bucket elevators, screw conveyors, and transfer belt conveyors)
to recycle kiln or process fines.
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