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IS : 1861 -Part II ) - 1977

I ndian St andardGUIDE FOR

MANUFACTURE OF LIME IN VERTICALMIXED-FEED TYPE KILNS

PART II FROM LIMESHELL

Fi rst Rev i si onFirst Reprint MAY 1990

UDC 666.923.3.041.464 036)

( Reaffirmed 1998 )

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IS : 1861( Part II ) - 1977

I ndian St andardGUIDE FORMANUFACTURE OF LIME IN VERTICALMIXED-FEED TYPE KILNS

PART II FROM LIMESHELLFi rst Rev i si onBuilding Limes Sectional Committee, BDC 4

Chairman RepresentingDR IQBAL ALI Engineering Rewarch Laboratories, Government ofAndhra Pradesh, Hyderabad

MembersSHRI V. S. AQARWALA Engineer-in-Chiefs Branch, Army HeadquartersSHRI K. R. BHAMBHANI ( Alternate )SRRI SRIDHAR BANDYOPADEYAY Khadi and Village Industries Commission, BombCHIEF ENOINE~LI . Tamil Nadu Housing Board, MadrasEXECUTIVE ENGINEER( HCJDGO ELL ) ( AlternateDR S. K. CHOPRA Cement Research Institute of India, New DelhiSHRI P. C. CHOWDJ UZY Lime Manufacturers Association of India,New DelhiSHRI G. C. DAS National Test House, CalcuttaSHR~ S. DAS GUPTA ( Alfernafe )DR N. G. DAVE Central Building Research Institute ( CSIR ),RoorkeeSHRI S. P. GARB AItemate )SHRI 1. N. DAVE Department of Mines and Geology, Government of

Rajasthan, J aipurSHRI R. G. GUPTA ( Alternate )DIREOTOR, ERI , VADODARA Public Works Department, Government of Gujarat,AhmadabadRESEARCH OFFICER( MATERIAL TESTINQ DIVI-

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IS : 1861 Part II ) - 1977( Continucdfrompage 1 )

Members RepresentingDIRECTOR, MERL, NASIK Irrigation and Power Department, Government of

RESEARCH OFFICER Maharashtra, Bombay( ~~ATERIAI.ESTINO DIVI-~111s ), MERI, NASI~ ( Alternate )DR R. 1;. CHOYII Central Road Reacarch InstituteNew Delhi ( CSIR ),Snrct h,l. 1,. RHATA Aternate )SHR J. S. G1r.1.SIIICI S. C. linr.~t.\ ( Allernarc ) Punjab Housing Development Board, Chandigarh~IOUSlXa MISS~ONRi ' Rajasthan Housing Board, JaipurJOINT ~WXTOR RESIXIICII Ministry of Railways( B & S ), RDSO

ASSSTANT DIRECTOR RK-SKAILUI ( B & S ), RDSO ( Alterwte )SARI N. H. lGmrw.4~1SHRI N. hl:\c:rsno Ministry of Transport and Shipping ( Roads Wing )Dyers Stone Co Pvt Ltd, DelhiSARI H. L. MA~~AR Builders Association of India, BombaySHRI HARISII C. KO~I,I ( Alternate )Dn A. V. R. RAOSHRI J. SEN CT.PTA ( Alternate )National Buildings Organization, New DelhiSHRI V. N. RAOSHRI s. B. SEN SAns1.1 Madhya Pradesh Housing Board, BhopalGeological Survey of India, CalcuttaSUPERINTYNDINQ ENGINEER Public Works( DESIGNS 1

Department, Government ofMadhva Pradesh, Bhonal EXECUTIVE . .ENGINEER( RESIXARCA ) ( Alternate )S u P E R I N T E N D I N Q ENQI- Public WorksNEER ( PLANNING & DESIONS ) Department,Andhra Pradesh, HyderabadSUPERINTENDINO ENOINE~~ ( PLY Public Works Department,& DESIGN ) Tamil Nadu, MadrasEXECUTIVE ENCINEE~ ( BUIL-

Government ofGovernment 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. MATHURDeputy Director ( Civ Engg), IS1

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IS : 1861

I ndian St andardGUIDE FOR

( Part II ) - 1977

MANUFACTURE OF LIME IN VERTICALMIXED-FEED TYPE KILNSPART II FROM LIMESHELL

First Revision)0. FOREWORD

0.1 This Indian Standard ( Part II ) ( First Revision ) was adoptedby the Indian Standards Institution on 30 September 1977, after the draftfinalized by the Building Limes Sectional Committee had been approvedby the Civil Engineering Division Council.0.2 Though lime is one of the most important materials available forbuilding construction, the technique of manufacture of building lime isstill not well established in the country. A satisfactory building limeshould have certain essential characteristics in regard to slaking and itssubsequent performance in mortars and concrete. These characteristicswill be satisfactorily developed only if the limestone is calcined in thekiln at the right temperature and with the right, type of fuel.. Theindustry has, therefore, felt the need for not only specifying the qualityof building lime that is required but also to lay down a guide which willgive necessary guidance to manufacturers to achieve its quality.0.3 With the present experience in lime manufacture in the country, it isfound 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

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IS : 1861 ( Part II ) - 1977While revising this standard work done at Central Building ResearchInstitute, Roorkee; Khadi and Village Industries Commission, Bombay;and Gujarat Engineering Institute, Vadodara has been fully utilized andmore details in regard to requirements for the operations have beenprovided.0.6 For the purpose of deciding whether a particular requirement ofthis standard is complied with, the final value, observed or calculated,expressing the result of a test or analysis, shall be rounded off inaccordance with IS : 2-1960*. The number of significant places retainedin the rounded off value should be the same as that of the specified valuein this standard.1. SCOPE1.1 This standard ( Part II ) covers essentially the operations for burningof limeshell in vertical kilns of mixed-feed type up to 3 tonnes per daycapacity used in small scale industry.2. TERMINOLOGY2.1 For the purpose of this standard, the definitions given in IS : 6508-1972? shall apply. .3. NECESSARY INFORMATION3.1 For the efficient manufacture of lime, information with regard to thechemical composition of the limeshell and the fuel will be n ecessar y.4. MANUFACTURE4.0 Principle - The charge of limeshell and fuel is fed from top andthe burnt product is drawn from bottom of shaft through openings.Initial firing is started by means of firewood at the bottom and due todraft the burning zone gradually travels upwards. Burning is restrictedto the central burning zone by regular withdrawals of burnt pioduct.The down-coming product COOIS off while heating the incoming air

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IS : 1861 ( Part II ) - 89774.2 Size of Fuel - As charcoal which has lower density and calorificvalue, 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 charginginto the kiln should be calculated with regard to the heat requirementsfor calcination and the calorific value of the fuel. On an averagecharcoal 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 beconverted into volumes and correct weight volume factors (relationship)be arrived at. When newly constructed kiln is ready for commissioningit 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 avoidcracking of kiln wall. While commissioning a new kiln or restarting anold one, sufficient ignition material, such as wood, may be placed andthus alternate layers of fuel and shell charged in. The,drawing of limeshould be done regularly at intervals that have been fixed with dueregard to retention time, which normally be 3 hours for limeshell. The.best practice should be to establish intermittent operations at as close aninterval as possible, so as to approach a continuous cycle. The interval

between two consecutive withdrawals of lime from the kiln may not belonger than 6 hours.4.4.3 Lime will be drawn equally from each of the drawn holesensuring that the charge comes down evenly in the kiln.

4.5 Temperature Cont;ol, - The temperature in the kiln should beregularly 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, andc) Temperature of drawn lime.

4.5.1 Temperufrcre of Calcinatior~ - In normal practice the temperature

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IS : 1861 ( Part II ) - 19774.5.2 Temperature of Drawn Lime - The temperature of drawn limeshould 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 preferablywithin 100C. This should be achieved by maintaining the properheight of pre-heating zone. For controlling the operations in the kiln,it wit1 be necessary to know the composition of the exhaust gas. Presenceof carbon monoxide will indicate incomplete combustion within the kiln.To ensure complete combustion of the fuel, certain quantity of excessair, say about 10 percent, will be necessary; larger quantities of excessair, however, will reduce the efficiency of the kiln. For conditions ofefficient operation, the carbon dioxide content in the exhaust gas shouldbe as high as possible and may range from 25 to 40 percent dependingupon the type of kiln and raw materials used; whereas the carbonmonoxide should not exceed 0.5 percent and that of oxygen not morethan 3 percent.4.6 Observation of Operation of Kiln - Kiln conditions can alsobe judged to some extent from visual observation of conditions at thetop of the kiln and guidance may be obtained from the condition of theflame as given below:

a) Heavy black smoke, or black smoke from the top of the kilnindicates 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 offeed 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 regularlyobserved 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 byincreasing or decreasing respectively the retention time in the calcinationzone and also by adjusting the limeshell/filel ratio.

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BUREAU OF INDIAN STANDARDSHeadqoaners:Manak Bhavan, 9 Bahadur Shah Zafar Marg, NEW DELHI 110002Telephones: 331 01 31, 331 13 75 Telegrams: Maneksanstha( Common to all Offices )Regional Off ices: TelephoneCentral Manak Bhavan, 9 Bahadur Shah Zafar Marg. I 331 01 31NEW DELHI 110002 331 13 75*Eastern : 1 /14 C. I. T. Scheme VII M, V. I. P. Road, 36 24 99

Maniktola, CALCUTTA 700054Northern : SC0 445-446, Sector 35-C, I 21843CHANDIGARH 160036 3 1641

41 24 42Southern : C. I. T. Campus, MADRAS 600113 ( t: 5: ::

1 tWestern : Manakalaya, E9 MIDC, Marol, Andheri ( East ), 6 32 92 95BOMBAY 400093Branch Off ices:Pushpak. Nurmohamed Shaikh Marg, Khanpur. I 2 63 48

AHMADABAD 380001 63 49+,Peenya Industrial Area 1st Stage, Bangalore Tumkur RoadI

38 49 55BANGALORE 560058 38 49 56Gangotri Complex, 5th Floor, Bhadbhada Road, T. T. Nagar, 667 16BHOPAL 462003Plot No. 82183, Lewis Road, BHUBANESHWAR 751002 5 36 2753i5. Ward No. 29, R.G. Barua Road, 5th Byelane, 3 31 77GUWAHATI 7810035-8-56C L. N. Gupta Marg ( Nampally Station Road ),HYDERABAD 500001 23 1083R14 Yudhister Marg. C Scheme, JAIPUR 302005 { 6 34 71

6 98 32117/418 B Sarvodaya Nagar, KANPUR 208005 { f: 8: ;;Patliputra Industrial Estate, PATNA 800013 6 23 05T.C. No. 14/1421. University P.O.. Palayam (6 21 04TRIVANDRUM 695035 16 21 17lnspecr ion Off ices With Sale Point ):

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AMENDMENT NO. 1 DECEMBER 1981TO

I S: 1861(Part I I ) - 1977 GUI DE FOR MANUFACTUREOF LI ME I N VERTI CAL M XED- FEED TYPE KI LNSPART I I FROMLI MESHELL

(Fi ret RuvisicmAl terati ona- - --

(Page 5, chue 4. 2) - Substltute the followingfor the existing clause:4. 2 Size of Fuel - The size of charcoal which is

normal-u-used -a fuel with limeshell because ofits lower density shall be about twice that of thelimeshell.'(BE 4)

Reprography Unit, BIS, New Delhi, India

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AMENDMENT NO. 2 APRIL 1999TOIS 1861( PART II ) : 1977 GUIDE FOR MANUFACTUREOF LIME IN VERTICAL MIXED-FEED TYPE KILNSPART II FROM LIMESHELL

First Revision)Page4, clause .1) -Substitute he following for the existing clause:

2.1 For the purpose of this standard, the definitions given in IS 6508 : 1988tshall apply.( Page 4, it-nofe marked t ) - Substitute the following for the existingfoot-note :

tGlossary of terms related to building lime (first re&iun ).(CED04)

Reprography Unit, BIS. New Delhi, India