Saturator Integrated Lime Silo & Saturation Tank

## Product Overview
The Saturator Integrated Lime Silo is an all-in-one core equipment specially developed for hydrated lime storage and continuous saturated lime water preparation, widely deployed in water treatment and flue gas desulfurization systems. It integrates sealed lime powder storage, anti-bridging quantitative feeding, counter-current saturation dissolution, layered clarification and automatic sludge discharge into a single tank unit, replacing separate silos and mixing tanks to cut site footprint and construction costs drastically.

Conventional separate lime storage and mixing facilities suffer from severe dust leakage, frequent lime caking/bridging, unstable lime liquor concentration, heavy manual workload and messy sludge accumulation. Our Saturator tank adopts proprietary counter-current saturation technology to generate consistent clarified saturated calcium hydroxide solution round-the-clock for pH adjustment, water softening, heavy metal precipitation, phosphorus removal and flue gas neutralization. Horizontal and vertical configurations are available with customizable volumes ranging from 5m³ to 120m³ to fit various plant layouts.

## Working Principle
1. **Sealed Dust-Free Lime Storage**
Hydrated lime powder is delivered via pneumatic bulk truck conveying or manual bag feeding. The fully airtight tank body blocks external moisture to prevent lime damp agglomeration. A top pulse bag dust collector recycles all feeding dust, while radar level sensors monitor residual material and trigger low-lime auto-alarms. Vacuum relief valves balance internal pressure to avoid silo deformation.

2. **Anti-Bridging Uniform Discharging System**
The steep conical hopper at the tank bottom is equipped with aeration fluidization plates and high-frequency vibratory arch breakers to eliminate rat-holing and bridging. Variable-frequency star feeders deliver lime powder steadily and quantitatively to the saturation zone without blockages.

3. **Core Counter-Current Saturation Process**
Clean water flows upward through the lime bed from the tank bottom to achieve full dissolution under constant water head, forming stable saturated lime liquor. This design eliminates concentration fluctuations caused by unstable feeding rates, delivering uniform clarified lime water free of suspended solids.

4. **Layered Sedimentation & Automatic Sludge Removal**
Undissolved lime residues, sediment and impurities sink to the bottom sludge hopper. Automatic drain valves enable scheduled sludge discharge without frequent manual cleaning. Clear saturated lime water overflows from the middle clarification zone to downstream dosing pipelines, preventing pipeline clogging.

5. **Intelligent PLC Automatic Control**
The integrated control system interlocks water inlet valves, feeders, liquid level transmitters and online concentration monitors. It auto-regulates water supply and lime feeding to maintain saturated status, with automatic shutdown and fault alarms for low liquid level, material shortage and blockage. It supports seamless connection to plant DCS central control systems.

## Main Structural Components
1. **Integrated Tank Body**
- Standard material: Q235 carbon steel with internal epoxy anti-corrosion coating to resist alkaline corrosion; 304/316 stainless steel optional for highly corrosive working conditions
- Vertical / horizontal dual styles for low-height confined workshops
- Complete accessories: top manhole, safety platform, guardrails, vertical ladder and full sealing rubber gaskets

2. **Top Dust Removal Assembly**
Pulse bag dust collector with negative-pressure fan realizes zero dust emission during bulk feeding, fully complying with industrial environmental protection standards.

3. **Arch Breaking & Feeding Module**
Combined fluidization aeration + vibratory arch breaker + variable-frequency rotary feeder for stable, smooth lime discharging.

4. **Saturation Clarification & Sludge Discharge Zone**
Counter-current dissolution chamber, layered sedimentation area and centralized sludge hopper with automated drain outlets.

5. **Touch Screen PLC Control Cabinet**
Real-time monitoring of lime stock, water level, liquor concentration and equipment operating status; supports fault self-diagnosis, data logging and remote IoT monitoring.

## Core Competitive Advantages
1. **All-In-One Compact Layout, Small Footprint**
Combines storage, dissolution, clarification and sludge treatment in one tank, slashing civil engineering, pipeline and installation costs compared with split systems.
2. **Stable Saturated Lime Liquor Output**
Constant-head counter-current saturation guarantees consistent liquor concentration, avoiding unstable dosing results from manual mixing.
3. **Full Enclosed Dust-Free Operation**
Built-in dust recovery system eliminates lime dust pollution, improves workshop working conditions and meets strict emission regulations.
4. **Reliable Anti-Caking & Anti-Blocking Performance**
Multi-dimensional arch breaking and fluidization design thoroughly solves common silo bridging and discharge blockage issues.
5. **Low Maintenance & Unattended Continuous Operation**
Auto feeding, water replenishment and sludge draining minimize manual labor; centralized sludge hopper simplifies regular maintenance.
6. **High Customization Flexibility**
Customizable capacity, horizontal/vertical shape, electric heat tracing for cold anti-freezing, explosion-proof electrical parts and multi-silo parallel expansion solutions.

## Typical Application Scenarios
- Municipal tap water & wastewater treatment (pH adjustment, softening, heavy metal & phosphorus removal)
- Power plant flue gas desulfurization
- Chemical factory acidic wastewater neutralization
- Mine wastewater purification
- Industrial circulating water conditioning

## Optional Auxiliary Accessories
1. Online lime liquor concentration detector with automatic data recording
2. Electric heat tracing & insulation system for low-temperature anti-crystallization
3. IoT remote monitoring module for mobile/PC real-time equipment management
4. Automatic bulk lime pneumatic conveying system matching tank trucks
5. High-precision weighing module for real-time residual lime monitoring
6. Explosion-proof electrical components for hazardous production zones

## Conclusion
As a standardized automatic lime storage and saturation core unit, the Saturator Integrated Lime Silo replaces traditional scattered lime mixing pools with integrated, compact design. Featuring outstanding alkali corrosion resistance, stable operation and low maintenance costs, it serves as the optimal dosing front-end equipment for lime-based water treatment and desulfurization processes. We provide customized overall lime storage & saturation solutions tailored to site space, production capacity and raw material characteristics.

### Short Web Banner Version (for homepage banner)
# Saturator Integrated Lime Silo & Saturation Tank
All-in-one hydrated lime storage + saturated lime water preparation tank
Core equipment for water treatment & flue gas desulfurization
Dust-free, anti-blockage, fully automatic, stable saturated lime liquor output | Vertical & horizontal customizable

SELECTION & TECHNICAL QUESTIONS

Q1: How do I select the right conveyor model? What information should I provide?

> To recommend the most suitable solution, please provide the following details:

> 1. Material type: What material are you conveying? (e.g., fly ash, wood chips, biomass pellets, bottom ash, etc.)

> 2. Material properties: Particle size, temperature, moisture content, abrasiveness

> 3. Capacity requirement: How many tons per hour (t/h) do you need?

> 4. Installation conditions: Conveying distance, incline angle, space limitations

> 5. Application industry: Which industry is this for? (e.g., waste-to-energy plant, biomass power plant, cement plant)

> You can also email us or contact us via WhatsApp. Our engineers will get back to you within 24 hours.

Q2: What is the difference between screw conveyors and chain conveyors? Which one should I choose?

> Both types have different applications:

> – Screw Conveyors: Best for powdery and small-grain materials (e.g., fly ash, cement powder). Good sealing performance, simple structure, low maintenance cost.

> – Chain Scraper Conveyors: Best for bulky, highly abrasive materials (e.g., bottom ash, municipal solid waste, biomass fragments). Supports multiple inlet and outlet points.

> – Bucket Elevators: Ideal for vertical or steep-incline material lifting.

> If you are not sure, tell us your material and working conditions, and our engineers will help you choose.

Q3: Can your equipment handle high-temperature materials? What is the maximum temperature?

> We can customize equipment according to material temperature:

> – Standard type: 0~80°C, carbon steel

> – Medium temperature type: 80~200°C, thickened wear-resistant liner

> – High temperature type: 200~400°C, special heat-resistant steel, optional cooling jacket

> Please tell us your material temperature, and we will recommend the most suitable material solution.

Q4: Are there any limits on conveying distance and lifting height?

> Standard design range:

> – Screw conveyor: Single section up to 70 meters; multiple sections can be connected for longer distances

> – Chain conveyor: Single machine up to 60 meters

> – Bucket elevator: Lifting height up to 50 meters

> We can also customize for extra-long distances or special angles. Contact us for detailed solutions.

Q5: Do you provide explosion-proof design?

> Yes. For explosive and flammable conditions such as pulverized coal and biomass dust, we offer:

> – Explosion-proof motors (Ex d IIB T4 standard)

> – Reserved openings for explosion vents / rupture discs

> – Fully sealed structure to prevent dust leakage

> Please specify your explosion-proof rating requirements.

CUSTOMIZATION & MANUFACTURING

Q6: Do you support customization? What is the lead time?

> Over 90% of our equipment is customized according to customer working conditions. Standard models take about 90–120days. Special customizations take 120–180 days, depending on configuration complexity.

Q7: What material options do you offer?

> Common materials include:

> – Carbon steel (Q235B): Standard working conditions

> – Wear-resistant steel (NM400/NM500): Highly abrasive materials

> – Stainless steel 304/316L: Food, chemical, corrosion-resistant requirements

> – Bi-metal wear-resistant composite plate: Extreme abrasion conditions

> We will recommend the most cost-effective material solution based on your material properties.

Q8: What certifications do you have?

> We hold the following certifications:

> – ISO 9001:2015 Quality Management System

> – ISO 14001 Environmental Management System

> – ISO 45001 Occupational Health & Safety Management

> – CE Certification (EN 1090 Steel Structure)

> If you need scanned copies of specific certificates, please contact us.

DELIVERY & LOGISTICS

Q9: Which countries do you export to? Do you have export experience?

> Our equipment has been exported to more than 20 countries worldwide, including:

> – Europe: Germany, France, Poland, Turkey, etc.

> – Southeast Asia: Singapore, Thailand, Indonesia, Vietnam, etc.

> – Middle East: Saudi Arabia, UAE, etc.

> – South America**: Brazil, Chile, etc.

> We are familiar with the full export process: packaging, customs declaration, and ocean freight. We can provide FOB, CIF, and other trade terms.

Q10: What is your packaging method? Is it suitable for long-distance ocean shipping?

> Export-standard packaging:

> – Large items / complete machines**: Rust prevention + waterproof film + fumigated solid wood pallet

> – Precision components: Wooden case with shock-absorbing filling

> – Random accessories: Categorized packing with detailed packing list

> All wooden packaging meets IPPC fumigation standards for direct customs clearance.

Q11: What is your minimum order quantity?

> We do not have a strict minimum order quantity. Single-unit orders are welcome. Bulk orders can enjoy more favorable pricing.

INSTALLATION & AFTER-SALES

Q12: Do you provide installation guidance? Do engineers need to come to site?

> We offer two service options:

> 1. Remote guidance: Detailed installation drawings and operation manuals, video guidance for installation (free of charge)

> 2. On-site service: Dispatch engineers to site for installation and commissioning (travel costs are additional)

> Most customers choose remote guidance. Our equipment is designed as a modular structure for easy installation.

Q13: What is the warranty period? What are the wearing parts?

> Standard warranty period is 12 months (from the date of arrival at port).

> Wearing parts list:

> – Chain / screw flights: Approximately 1–3 years, depending on material abrasiveness

> – Liners: Approximately 2–4 years

> – Bearings: Approximately 2–3 years

> We recommend ordering a wearing-parts spare kit together with your first order.

Q14: How do you solve problems during operation?

> We provide 7×24 technical support:>

> – Response within 24 hours for technical issues

> – Remote video troubleshooting guidance

> – Engineer on-site service when necessary

> – Common spare parts in stock for fast delivery

QUOTATION & COOPERATION

**Q15: How can I get a quote? How long does it take?

> Quotation process:

> 1. You provide material parameters, capacity, installation conditions, and other requirements

> 2. Our engineers evaluate and select the appropriate model

> 3. Formal quotation and technical proposal provided within 7 working days

> You can contact us via email, or the online inquiry form.

Q16: What are your payment terms?

> Standard payment terms:

> – 30% advance payment: After contract signing, to start production

> – 70% balance: Before shipment, or against copy of Bill of Lading

For long-term cooperative customers, more flexible payment terms can be negotiated.

Follow these 3 steps to find your ideal conveyor solution

Step 1: Identify Your Material Type

Different materials require different conveyor designs. Tell us what you are conveying:

Step 2: Define Your Working Conditions

Please prepare the following parameters before contacting us:

Step 3: Choose Configuration Options

Based on your answers above, our engineers will recommend:

Material grade — carbon steel / wear-resistant steel / stainless steel

Sealing type — open trough / fully enclosed / gas-tight

Drive system — motor power, gearbox brand, speed range

Auxiliary options — explosion-proof motor, cooling jacket, cleaning device, level sensors

 Not Sure Where to Start?

Send us your basic requirements, and our engineers will design a customized solution for you — completely free.

Email: bootec@bootecgroup.com  Response time: Within 24 hours

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