Contact Info
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Sheng'an Building, No. 296 Xinhua Road, Shijiazhuang, Hebei Province
2x300 tpd traditional mixed fuel kilns upgraded to 400 tpd high‑quality positive pressure burner beam kilns, generating over $4 million in total profit
In 2022, our company successfully completed a comprehensive upgrade of two traditional mixed fuel lime kilns (300 tpd each) for a key client in Northwest China. By introducing positive pressure calcination technology with combustion beams, the original kilns were transformed into high‑quality positive pressure burner beam kilns with a capacity of 400 tpd each. The kilns ignited successfully on the first attempt and have consistently met design targets. As of 2026, four years of stable operation have generated approximately US$4 million in additional profit for the client. This project stands as a benchmark for the green and efficient retrofitting of existing lime production capacity.
| Parameter | Before Upgrade (Traditional Mixed Combustion Kiln) | After Upgrade (Positive Pressure Beam Kiln) | Change |
|---|---|---|---|
| Daily capacity per kiln (tpd) | 300 (for example) | 400 | +30-33% |
| Comprehensive heat consumption (kcal/kg lime) | 1,200 – 1,300 | 900 – 1000 | -25% to -30% |
| Loss on ignition (LOI) | 4% – 10% (highly variable) | 3% – 5% (with good operation) | Significant quality improvement |
| Fuel type | Expensive anthracite / coking coal | Low‑cost bituminous coal | Drastically reduced fuel cost |
| Dust emissions | High | Reduced | Noticeable environmental improvement |
Increased output revenue – The two kilns together produce an additional 200 tons of lime per day. Assuming 330 operating days per year and an average lime price of US$60/ton, the incremental output contributes approximately US$3.96 million in annual revenue. After deducting additional costs for ore and electricity, the direct profit from increased output over four years exceeds US$2 million.
Fuel cost savings – Heat consumption dropped. Each kiln saves roughly xx tons of standard coal equivalent per hour. With 330 operating days per year, the two kilns together save approximately US$xx0,000 annually in fuel costs, accumulating to over **US$x million** over four years.
Quality premium & market competitiveness – LOI reduced to below 5%, enabling the lime to be used in high‑end applications such as steelmaking and calcium carbide production. The selling price per ton can be increased by US$1.5-2, further boosting profit.
Comprehensive accounting – After deducting depreciation and maintenance costs for the retrofit equipment, the net additional profit over four years is firmly above US$4 million, with a payback period of less than six months for the client.
"Our two old kilns suffered from high energy consumption, low output, and unstable product quality. After the upgrade to positive pressure beam kilns, capacity jumped to over 400 tpd, heat consumption dropped by a quarter, and we can now use cheaper bituminous coal. Over four years, that adds up to an extra US$4 million in profit – real value from real technology."
— Production Manager of the client
Our positive pressure beam mixed combustion kiln technology has been successfully applied in multiple regions across China. It is particularly suitable for upgrading traditional mixed combustion kilns with a capacity greater than 100 tpd. The retrofit features a short construction period, rapid results, and a payback period typically under one year.
We cordially invite lime industry colleagues from around the world to visit the Northwest China project site for a firsthand look. We also welcome inquiries from clients currently operating traditional mixed combustion lime kilns who wish to significantly improve their economic returns.
