Hydration Plant

Product Description

Hydration Plant Description and Operation

A Hydration Plant is used for the production of Hydrated Lime (Calcium Hydroxide Ca(OH)) by reacting Quicklime (Calcium Oxide CaO) with water in a controlled process called hydration or slaking. Hydrated lime is widely used in industries such as water treatment, flue gas desulfurization, chemical manufacturing, steel plants, sugar plants, construction, and environmental applications.

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1. Working Principle of Hydration Plant

The hydration process involves a chemical reaction between quicklime and water. When water is added to quicklime, it produces hydrated lime along with heat.

Chemical Reaction

CaO + HO Ca(OH) + Heat

This reaction is exothermic, meaning it releases a significant amount of heat. Therefore, the process must be carefully controlled to maintain proper temperature, moisture content, and particle size to produce high-quality hydrated lime powder.

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2. Main Components of a Hydration Plant

A typical hydration plant consists of the following major equipment:

1. Quicklime Storage Hopper

• Used for storing quicklime lumps or powder.
• Equipped with vibrators and feeders for controlled feeding.

2. Lime Feeder System

• A screw feeder or belt feeder regulates the flow of quicklime into the hydrator.

3. Hydrator (Slaker Reactor)

• The main equipment where quicklime reacts with water.
• Water is sprayed in a controlled quantity.
• The reaction converts quicklime into hydrated lime powder.

4. Hydrated Lime Separator

• A classifier or separator separates fine hydrated lime from coarse particles.

5. Grinding / Pulverizing System

• Coarse particles may pass through a grinding mill to achieve the required fineness.

6. Dust Collection System

• Bag filters or cyclones collect fine dust and maintain environmental safety.

7. Storage Silo

• Final hydrated lime powder is stored in silos before packing or further use.

8. Packing System

• Hydrated lime is packed in 25 kg / 50 kg bags or stored in bulk silos.

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3. Operation of Hydration Plant

Step 1 Feeding of Quicklime

Quicklime (CaO) is fed from the storage hopper into the hydrator using a feeder system.

Step 2 Water Injection

Measured water is injected into the hydrator. The amount of water is carefully controlled to ensure proper hydration.

Step 3 Hydration Reaction

Inside the hydrator, quicklime reacts with water to form hydrated lime (Ca(OH)). The reaction generates heat and breaks the lime particles into fine powder.

Step 4 Material Mixing and Residence Time

The material is continuously mixed inside the hydrator to ensure uniform reaction and proper particle size formation.

Step 5 Classification

The hydrated lime passes through a separator where fine particles are separated from coarse materials.

Step 6 Dust Collection

Fine dust generated during the process is collected through bag filters and recycled into the system.

Step 7 Storage and Packing

The final hydrated lime product is stored in silos and then packed in bags or supplied in bulk.

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4. Types of Hydration Plants

Common types include:

1. Batch Type Hydrator
   • Suitable for small capacity plants.
   • Operation done in batches.
2. Continuous Hydration Plant
   • Suitable for large industrial capacities.
   • Continuous feeding and discharge.

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5. Typical Operating Parameters

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6. Advantages of Hydration Plant

• High quality fine hydrated lime production
• Continuous and automated operation
• Low manpower requirement
• Efficient dust control system
• High production efficiency

Advanced Computerized Operation

Our Hydration Plant features seamless automation through a sophisticated PLC control system. This ensures precise process management, minimizes manual intervention, and enhances production consistency. Operators benefit from intuitive controls and efficient monitoring, maximizing uptime and productivity.


High Capacity and Sturdy Design

Processing up to 10 tons per day, this plant meets the demands of large-scale operations. Crafted from durable steel and weighing 15,000 kg, it promises long-term stability and resilience. Its robust construction supports rigorous industrial use while maintaining optimal safety standards.


Comprehensive Industrial Support

As a reputable supplier and manufacturer in India, we offer complete pre-sales guidance, professional installation, and after-sales service. Our team ensures seamless integration of the hydration plant into your system, with export and distribution support for clients worldwide.