Φ5×72 m active lime kiln line in the DRC: desulfurization-grade quicklime with wear- and corrosion-resistant internals for high-sulfur ore processing.

Customer & Feedstock

The project serves a high-sulfur ore processing operation in the DRC. Smelting and concentrating high-sulfur ore generates sulfur-bearing flue gas; the plant's desulfurization circuit scrubs that gas with quicklime, and the lime must be produced in volume, with reactivity that keeps the scrubber chemistry stable. The customer therefore commissioned a large-diameter calcination line — the Φ5×72 m kiln at its core — as the plant's lime backbone.

Challenges & Requirements

• Scale. A Φ5×72 m shell is a large single-unit machine: mechanical, refractory and drive design all move to a higher class, and the kiln's thermal profile must be managed across a much longer firing zone than standard lime kilns.
• Desulfurization-grade quality. FGD lime must react fast and completely; burning uniformity and reactivity specifications are tighter than for general industrial lime.
• Wear and corrosion duty. Sulfur-bearing service attacks both the process gas side and the wet end of the plant; the parts package was engineered for wear and corrosion, not just abrasion.
• Long campaigns, remote location. With limited specialist support on site, the design bias was toward long overhaul intervals and simple, proven operation.

Solution & Equipment

The line is built around one large machine, with the parts package as the second engineering deliverable:

Rotary kiln (Φ5×72 m) — the core calcination unit; high single-line output from the large shell.

Wear- and corrosion-resistant parts (engineered package: shell components, liners, wet-end components) — extended campaign life in sulfur-bearing service.

Belt conveyor (DT / TC / ST series) — transfer.

Process notes. The distinguishing engineering of this line is the parts package: standard lime-kiln components do not survive a sulfur-bearing duty, so shell and internal components were specified for the combined wear-corrosion load.

Design Results

• High single-line design output from the Φ5×72 m shell
• Desulfurization-grade quicklime at stable reactivity
• Wear/corrosion parts package sized for extended campaigns

Why DMTC

• Large-kiln class engineering — the same kiln family DMTC builds for cement, lime and pelletizing duty, pushed to its large end.
• Corrosion-aware design, not just abrasion-aware: the parts specification follows the actual gas chemistry of the customer's process.
• Campaign-length thinking — engineered for the overhaul interval the site's remoteness demands.

Related Products

Rotary Kiln System