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At present, more than fifty industrial lime production units have been established in Iran, and although some of these units are successfully producing and supplying products, many of these factories do not have sufficient efficiency or are stopped due to different reasons. By conducting extensive research in the lime industry, Betsaco Company has identified the main and basic problems of this industry, some of these obstacles are as described below
With precision in the variety and extent of the mentioned obstacles and other cases, it is necessary for the respected owners and investors in this industry to take advantage of the knowledge and expertise of a capable group to facilitate the conditions of economic production. In this regard, Betsaco company, with the cooperation of experienced experts with deep knowledge of the processes and equipment of the lime industry and consumer industries, software systems and modeling, the use of targeted analysis methods and other capabilities, for technical advice and The useful following implementation will keep you up to date
Providing capable and expert human resources for operation and production is always one of the constant challenges of various industries, and this issue is more apparent at the expert and management levels. This company is ready to accept the responsibility of production (industrial lime, hydrated, micronized and other derivatives and products of this industry) with the cooperation of managers and experienced experts and by providing the required human resources in the operation, maintenance and repair departments. Complete mastery of acceptable product quality provides a worthy service to this industry.
Diagnosing and solving the problems of lime factories includes examining the complete chain from the mine to the market and providing practical solutions. The furnace as a lime production reactor plays the most important role in this industry. Most of the existing furnaces in the countries of the region, borrow the technology of the past decades from European or Japanese companies, and for various reasons, they do not have the enough efficiency, because the basic fuel, the chemical and mechanical properties of the limestone used, the type and the application of the product, the production capacity and other parameters governing the technology of these furnaces are different from the type of operation and also the current needs of the industry. This change, in addition to the complete evolution of the combustion system characteristics, has many effects on other parameters of operation, and with the change of fuel type, there should be comprehensive reforms in raw material grading, refractory type, cooling, discharge and charging systems, internal pressure, control systems, instrumentation, safety conditions and product type for each furnace, and Revamping needs to be done with minimum requirements. In order to achieve this goal, Lime Industries Development and Optimization Company examines the existing situation and corrective solutions by combining the use of simulation software, production data, laboratory results and process information for all types of furnaces and with the approach of cost reduction and prepares an optimal corrective plan.
Another part that determines the cost of production and its quality is the crushing and sorting system of raw materials for feeding the furnace, which for its optimality, such as type suitability, optimal capacity and arrangement of machines and the characteristics of limestone and dolomite which should be carefully checked.
Similar to the above issues, in the hydration units, the extraction of the product with the required chemical quality and fineness requires the review of the equipment and processes upgrading, as well as the updating of control system.
In general, diagnose studies, as well as optimization and modification of lime factories from the mine to the market in a practical way and in line with production excellence and cost reduction, based on continuous research of new technical knowledge and market needs, by the company Betsaco is done.
The use of the dedicated maintenance systems for factory, plays a very important role in reducing the products price, although its other important effects on personnel safety and disk reduction, increasing the life of equipment, improving the environmental situation, ease of sales planning and management, neatness of the work environment, organizational agility and proper product quality should be considered. Fortunately, investors and managers of lime industrial complexes have the necessity of determining the suitable strategy of maintenance in their agenda. Betsaco provides following services in this field
Implementation of maintenance structure in order to achieve lean production
Periodic or annual overhaul planning
Provision of resources and implementation of overhaul activities as well as continuous maintenance and repairs during operation
Creating and providing exclusive maintenance software for every factory
Sufficient technical and engineering documents are necessary in any factory to check production conditions, process settings, order spare parts, and prepare operating and maintenance instructions, even changes and check development plans. Also, due to various reasons such as the loss of drawings and technical documents over time, economic sanctions and lack of communication with foreign suppliers, usually there is not enough information and drawing to provide the required spare parts. In order to solve this problem and improve the situation, the engineering groups of Betsaco have made it possible to redesign all the parts, equipment and various units of the factory by using computing and 3D software, for the process, mechanical, electricity, control, instruments and facilities in a specialized way.
Supplying spare parts with acceptable quality and preventing the repetition of failures, has a key role in improving maintenance indicators. To ensure the quality of parts, the existence of engineering and functional requirements knowledge, Mastery of standard requirements, and also the ability to perform technical inspection are essential parameters. Having a wide group of reliable suppliers, we are ready to provide spare parts and consumables with competitive conditions in terms of quality and cost.
