Saturator Lime Silo
# Saturator Lime Silo Product Introduction
## 1. Product Overview
The Saturator Lime Silo is an integrated specialized storage and saturation system designed for hydrated lime powder, widely applied in water treatment, flue gas desulfurization, chemical industry and wastewater remediation. It integrates fully enclosed lime storage, anti-bridging feeding, continuous saturated lime liquor preparation, solid-liquid separation and sludge sedimentation into one unit. The equipment can stably produce saturated calcium hydroxide solution for pH adjustment, water softening, heavy metal precipitation, flue gas neutralization and other industrial processes.
Conventional manual lime mixing brings obvious drawbacks including severe dust pollution, lime agglomeration caused by moisture, unstable liquor concentration, high labor costs and troublesome sludge accumulation. Adopting an integrated silo-saturation tank structure, the Saturator Lime Silo is equipped with negative-pressure dust removal and intelligent quantitative feeding systems to realize 24-hour unattended continuous production of clarified saturated lime water. Two series are available: compact vertical integrated models and large split silo-linked models, with customizable volumes ranging from 5m³ to 120m³.
## 2. Working Principle
1. **Sealed Material Storage & Buffer**
Hydrated lime powder is delivered via tank truck pneumatic conveying or manual bag feeding. The fully sealed silo body isolates external moisture to avoid caking. A top dust collector recovers dust during feeding, while a vacuum relief valve balances internal pressure. A radar level sensor monitors residual lime volume and triggers an automatic low-material alarm.
2. **Anti-Bridging Uniform Discharging**
The silo bottom adopts a large conical hopper with an inclination angle over 60°. Equipped with aeration fluidization plates and high-frequency vibratory arch breakers, it effectively eliminates lime bridging and rat-holing. A variable-frequency star discharger quantitatively feeds lime powder to the saturation reaction zone.
3. **Counter-Current Saturation Process (Core Saturator Technology)**
Clean water flows upward from the silo bottom to pass through the lime powder layer for full dissolution, forming saturated lime liquor. A constant water level maintains a stable saturated layer, ensuring consistent output concentration without fluctuations from unstable feeding rates.
4. **Layered Clarification & Sludge Discharge**
Undissolved residues and impurities settle in the bottom sludge hopper. Automatic drain valves are installed on the side for regular sludge discharge. Clear saturated lime water overflows from the middle clarification zone, free of suspended solids to prevent blockage of downstream dosing pipelines.
5. **Automatic Circulation Control**
A PLC system links water inlet valves, feeders, liquid level transmitters and concentration monitors. It automatically replenishes water and adjusts lime feeding volume to maintain saturated conditions, with automatic shutdown and alarm functions for low liquid level, material shortage and blockage faults.
## 3. Main Structural Components
### 3.1 Main Storage Silo Body
- Material: Q235 carbon steel with internal epoxy anti-corrosion coating to resist alkaline lime corrosion; 304/316 stainless steel optional for harsh corrosive working conditions
- Structure: Vertical cylindrical tank with conical bottom hopper; top access manhole, operation platform, safety guardrails and vertical ladder provided
- Sealing: Perfluoroether rubber gaskets prevent moisture penetration and lime damp agglomeration
### 3.2 Top Environmental Dust Removal Unit
Pulse bag dust collector matched with negative-pressure fan completely recovers dust during pneumatic feeding, achieving zero external lime dust leakage and complying with industrial environmental protection standards.
### 3.3 Feeding & Arch Breaking Assembly
Aeration fluidization plates, vibratory arch breakers and variable-frequency rotary star feeders work together to guarantee stable, uniform lime discharging without blockage.
### 3.4 Saturation, Clarification & Sludge Discharge Zone
Counter-current dissolution chamber, layered sedimentation area and bottom sludge hopper with automatic drain valves for easy residue cleaning.
### 3.5 Intelligent Electrical Control System
Touch screen PLC control cabinet supports real-time monitoring of lime stock, water level, liquor concentration and equipment operation status. It realizes automatic interlock control, fault self-diagnosis, data recording and remote signal transmission to plant DCS central control systems.
## 4. Core Product Advantages
1. **Integrated Compact Design, Small Footprint**
Combines storage, dissolution and clarification functions in one single unit, cutting civil engineering and installation costs compared with separate silos and mixing tanks.
2. **Stable Saturated Lime Liquor Output**
Constant-head counter-current dissolution maintains steady liquor concentration, eliminating inconsistent mixing results from manual operation.
3. **Full Enclosed Dust-Free Operation**
Built-in dust recovery system avoids lime dust pollution, improving on-site working environment and meeting emission standards.
4. **Anti-Caking & Anti-Blocking Performance**
Multi-layer arch breaking and fluidization devices thoroughly solve common bridging and blockage issues of lime silos.
5. **Low Maintenance & Unattended Continuous Operation**
Automatic feeding, water replenishment and sludge draining reduce manual labor; centralized sludge hopper simplifies regular cleaning work.
6. **Wide Capacity Range & Customization Support**
Standard volumes cover 5m³ to 120m³; customized solutions including heat tracing for low-temperature anti-crystallization, explosion-proof design and parallel multi-silo expansion are available.
## 5. Application Scenarios
- Municipal tap water & sewage treatment (pH adjustment, water softening, heavy metal removal)
- Power plant flue gas desulfurization
- Chemical factory acidic wastewater neutralization
- Mine water purification
- Industrial circulating water conditioning
## 6. Optional Auxiliary Accessories
1. Online lime liquor concentration detector with automatic data logging
2. Electric heat tracing insulation system for anti-freezing in cold regions
3. IoT remote monitoring module for mobile/PC real-time equipment management
4. Automatic bulk lime conveying system matched with tank trucks
5. High-precision weighing module for real-time residual lime stock monitoring
6. Explosion-proof electrical components for hazardous working environments
## 7. Conclusion
As a standardized automatic storage and saturation equipment for hydrated lime, the Saturator Lime Silo replaces traditional scattered lime mixing tanks with integrated design. Featuring corrosion resistance, stable performance and easy maintenance, it is the ideal core equipment for lime dosing processes across multiple industries. Customized overall lime storage and saturation solutions can be provided according to site space, production capacity and material characteristics.
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:
| Material Category | Examples | Recommended Conveyor Type |
| Powder / Fine Granules | Fly ash, cement powder, lime powder | Screw Conveyor |
| Small Granules / Pellets | Biomass pellets, plastic granules, grain | Screw Conveyor / Belt Conveyor |
| Fragments / Chips | Wood chips, bark, agricultural residues | Chain Scraper Conveyor |
| Bulky / Abrasive | Bottom ash, slag, MSW, clinker | Chain En-Masse Conveyor |
| Vertical Lift | Any bulk material needs vertical transport | Bucket Elevator |
Step 2: Define Your Working Conditions
Please prepare the following parameters before contacting us:
| Parameter | Why It Matters | Example |
| Capacity (t/h) | Determines conveyor size and power | 10 t/h, 50 t/h, 100 t/h |
| Conveying Distance (m) | Determines machine length | 15m horizontal, 30m incline |
| Incline Angle (°) | Affects capacity and design | 0° horizontal, 30° incline |
| Material Temperature (°C) | Determines material grade | Ambient, 150°C, 300°C |
| Moisture Content (%) | Affects discharge design | Dry, damp, wet (needs dewatering) |
| Abrasiveness | Determines liner thickness | Low, medium, high |
| Application Industry | Determines certification needs | Power plant, cement, mining, recycling |
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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