Gas suspension calciner

Economic and productive gas suspension calciners

Having supplied gas suspension technologies since the 1970s, we understand the importance of affordability – without skimping on quality. Our GSCs offer just this. Low maintenance, easy to optimise, fuel efficient and flexible: we offer a highly productive experience for the thermal treatment of fine minerals.

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Key benefits of gas suspension calciners

  • Easier to optimise and automate

    As a stationary system, our gas suspension calciners are easily outfitted with instrumentation for enhanced operational feedback in a way rotary systems are not. This improves visibility of key operating parameters for straightforward and effective process control and optimisation. It also means the GSC is readily automated via conventional DCS, whereas rotary devices require much more advanced automation solutions. The bottom line is a system that is easier to maintain at optimum performance levels, delivering highly efficient and cost-effective productivity.

  • Lower maintenance than rotating systems

    The primary source of maintenance in thermal processing systems is the refractory lining. Rotating systems place significant mechanical stress on these linings, which simply aren’t present in stationary flash calcination systems like the GSC. Their refractory linings thus last longer between replacement or repair, cutting downtime and maintenance-related costs. There is also no need for the maintenance and periodic alignment of rotating components as is required with a rotary kiln.

  • Optimised heat recovery reduces fuel consumption

    Our gas suspension calciners are fully integrated systems designed to recuperate and return as much heat as possible to the process. Hot calciner off gas flows to multiple cyclone preheaters, which transfer the heat into incoming raw materials. Meanwhile, hot calcined materials flow to cyclone coolers, which capture the heat from these solids and transfer it to the incoming air stream. This dual heat recovery significantly reduces the fuel consumed in the flash calciner.

  • Fuel flexibility reduces fuel costs and emissions

    Our flash calciner can be fired with a wide range of solid, liquid, and gaseous fuels. It means fuel inputs can be optimised according to what is available and affordable locally, improving fuel security and costs. It also supports the transition to lower-carbon fuels such as natural gas, with the option to convert to carbon-neutral heating solutions, such as biomass, hydrogen, and electrified systems, in the future.

Our gas suspension calciners

Gas suspension calciners are used for the thermal treatment of fine materials, such as potash, phosphate, limestone, magnesite, gypsum, alumina, trona, clays, and talc. This may be an intermediate stage before subsequent smelting or other processing steps, or as an end-of-flowsheet solution to yield a final product. Each GSC is custom engineered to deliver optimum application-specific performance. Capacity potential, fuel and power consumption thus vary significantly between installations. For example, we have designed units with processing capacities as low as 1tph and as high as 800tph. Whatever the specifications, however, all GSCs are delivered as complete systems that make your job easier and more productive.

We have experience supplying gas suspension calciners in a wide range of sizes from very large installations (up to 10m dia.) to smaller-scale systems (1m dia.). When internal access is restricted such that maintenance cannot take place in situ, integral platforms support the safe dismantling and removal of components via mobile cranes for maintenance. We also supply limited-diameter components with pre-fitted refractory linings to ease onsite installation.

Gas suspension calciners features

  • Proprietary flash calciner

    Ensures proper solids entrainment, high heat transfer efficiency, and appropriate mixing to accommodate a wide range of fuels.

  • High efficiency preheating/cooling cyclones

    Optimise heat recovery from calciner off-gas and product streams for reduced fuel consumption.

  • Proprietary refractory specifications

    Minimise surface heat loss and support extended service life.

  • Full process automation

    Design incorporates features, instrumentation, and logic to facilitate full process automation.

Gas suspension calciners add-ons

  • Automation and control

    DCS control package to enable full automation of the GSC.

  • Fuel dosing

    Fuel dosing circuit to support solid fuel or biomass firing.

  • Gas treatment

    Off-gas treatment circuit for final emissions control.

  • SNCR

    Selective non-catalytic reduction to reduce NOx emissions.

  • Secondary product cooling

    Secondary product cooling to achieve lower final product temperatures.

Maintenance & service of gas suspension calciners

FLS is your single-source supplier of pyroprocessing equipment and systems. Our in-house test centre is home to a wide range of test and pilot-scale equipment, allowing us to simulate complete processes and ensure the best possible system design and equipment selection. Various analysis options are available at the test centre, providing rapid results to support your test campaign.

We provide commissioning/installation support and supervision to ensure optimal system start-up. A comprehensive range of aftermarket services continues to ensure your pyro-equipment maintains market-leading performance over its operating life. These include equipment inspections, troubleshooting and optimisation, high-quality spare parts, replacement of worn components, retrofits, modifications, and training. We also support conversions to alternative energy systems, such as hydrogen firing, oxyfuel combustion, and electing heating.

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Frequently asked questions

FAQs for gas suspension calciner

A flash calciner is a type of industrial furnace used for the thermal treatment (decomposition or heating) of fine mineral products.

Flash calcination works by suspending fine mineral particles in an upward flow of hot gases, allowing for rapid heating and calcination.

Our gas suspension calciners can process a wide range of fine products such as clays, limestones, metal ores and other minerals.

Our gas suspension calciners can process a wide range of fine products such as clays, limestones, metal ores and other minerals.