Reliable Wet Ball Mill Slurry Systems – Guaranteed 325 Mesh ≥90% Passing, Maximum SO₂ Removal Efficiency Complete turnkey limestone slurry preparation systems for wet flue gas desulfurization (WFGD) in coal-fired power plants, waste-to-energy plants, and industrial boilers. Our closed-circuit wet ball mill systems with hydrocyclone classification deliver consistent limestone slurry with ≥90% passing 325 mesh and 30-35 wt% solids, ensuring >95% SO₂ removal efficiency for your absorber. As a single-source EPC supplier from limestone receiving to slurry storage, we provide design, equipment, and commissioning
Our limestone slurry preparation system is a complete, integrated facility engineered to produce high-quality, consistent slurry for FGD absorbers. We deliver the system as an EPC project covering all mechanical, electrical, and control components.
System Scope of Supply
Core Process Equipment:
· Limestone receiving hopper with grid (truck discharge)
· Belt weigher and conveyor for precise limestone metering
· Wet limestone ball mill (rubber or high-chrome lined, continuous type)
· Mill water system with flow control valve and density meter
· Hydrocyclone cluster (polyurethane or ceramic lined) for classification
· Slurry sump tank with agitator and slurry pump
· Limestone slurry product storage tank (large volume, with agitators)
· Slurry transfer pumps (to FGD absorber area)
· Integrated electrical, instrumentation, and PLC/DCS control system
· Optional: Emergency by-pass system, limestone silo, grinding aid dosing
Input Material Specifications:
· Limestone (CaCO₃ ≥90%, typical 92-95%)
· Feed particle size: ≤20 mm (pre-crushed) or ≤50 mm (with dedicated crusher)
· Moisture content: <5% (surface moisture)
· Bond Work Index: 9-12 kWh/t (typical for limestone)
Slurry Product Guarantee:
· Fineness: ≥90% passing 325 mesh (44 µm)
· Solids content: 30-35 wt% (adjustable)
· Viscosity: <100 cP at 100 s⁻¹
· Density: 1.20-1.28 kg/L
From Limestone Chips to Consistent FGD Slurry: How Your Slurry Preparation System Works
Limestone Receiving & Weighing – Crushed limestone (≤20 mm) is delivered by truck and dumped into a receiving hopper. A belt weigher precisely meters the limestone feed rate into the wet ball mill, controlled by the central DCS.
Wet Ball Mill Grinding – The measured limestone enters the wet ball mill, where it mixes with a controlled flow of process water (typically from the gypsum dewatering system). The mill drum rotates, cascading steel or ceramic balls that crush and grind the limestone into a fine slurry through impact and attrition.
Hydrocyclone Classification – The mill discharge slurry flows by gravity or pump to a hydrocyclone cluster. The cyclones separate the slurry: the fine overflow (product slurry) goes to the product tank, while the coarse underflow returns to the mill inlet for regrinding. This closed-circuit ensures tight particle size control.
Slurry Storage & Agitation – The finished slurry, with density continuously monitored, is stored in a large agitated tank. Constant stirring prevents sedimentation and ensures homogeneity before pumping to the absorber.
Absorber Supply – Slurry transfer pumps, selected for high abrasion resistance, deliver the limestone slurry from the storage tank to the FGD absorber spray headers, precisely matching the SO₂ load demand.
Standard Wet Limestone Slurry System Configurations (Single Mill)
| Unit Capacity (kg/h limestone) | Wet Ball Mill Model | Mill Motor (kW) | Slurry Output (m³/h, 30% solids) | Product Fineness (%-325 mesh) | Typical Plant Size (MW) |
|---|---|---|---|---|---|
| 2,000 | Φ1.8×3.6m | 185 | 5-7 | ≥90% | 50-100 MW |
| 5,000 | Φ2.2×4.5m | 310 | 13-16 | ≥90% | 100-200 MW |
| 10,000 | Φ2.4×6.0m | 450 | 26-32 | ≥90% | 200-400 MW |
| 15,000 | Φ2.8×6.5m | 710 | 40-48 | ≥90% | 400-600 MW |
| 20,000 | Φ3.0×7.0m | 900 | 52-65 | ≥90% | 600-1000 MW |
For larger units (>1000 MW), multiple parallel slurry preparation trains are recommended for redundancy.
Key Performance Guarantees
| Parameter | Guaranteed Value |
|---|---|
| Slurry fineness (%-325 mesh passing) | ≥90% (adjustable 85-95%) |
| Slurry solids concentration | 30-35 wt% (controlled ±1%) |
| Product slurry density | 1.20-1.28 kg/L |
| System availability | >95% (excluding scheduled maintenance) |
| Mill liner life (rubber) | >20,000 hours (5-8 years) |
| Grinding ball consumption | <100 g/t of limestone |
| Noise level at 1m | <85 dB(A) |
EPC Project Scope Options:
· Full System EPC: Complete slurry preparation building from limestone hopper to storage tank and transfer pumps, including civil, structure, mechanical, electrical, and control.
· Equipment Supply + Design: Supply of ball mill, hydrocyclone, pumps, tanks, and electrical/automation. Civil works and erection by client with our technical advisory.
· Core Mill & Cyclone Package: Supply of the wet ball mill, hydrocyclone cluster, and mill-related instrumentation only.
Tell us your unit capacity (MW), limestone source analysis, and SO₂ removal target. We will size the optimal slurry preparation system and provide a guaranteed performance proposal.
Proven Performance: Global FGD Slurry System Installations
Case 1: 2×600 MW Coal-Fired Power Plant FGD, Southeast Asia
· System: 4 trains × Φ2.8×6.5m wet ball mill slurry preparation system (2 duty + 2 standby)
· Limestone: CaCO₃ 94%, Bond Wi 10.5 kWh/t, feed ≤20 mm
· Performance: Each mill produces 15 TPH of slurry (30% solids), 93% passing 325 mesh. 3 years continuous operation without unplanned downtime. Specific power 22 kWh/t limestone.
· Outcome: SO₂ emissions consistently <35 mg/Nm³, surpassing the local 50 mg/Nm³ standard.
Case 2: Waste-to-Energy Plant FGD, Europe
· System: 1 × Φ2.2×4.5m wet ball mill (duty) + 1 × same (standby)
· Challenge: Variable limestone quality from different quarries; tight city noise limits.
· Solution: Rubber liners for noise reduction (<80 dB at 1m) and an automatic grindability adaptation program in the DCS.
· Result: Slurry fineness maintained at 91% -325 mesh despite fluctuating feed. Plant operated at full capacity meeting EU emission directive 2019.
Case 3: Industrial Boiler FGD Retrofit, Middle East
· System: 1 × Φ1.8×3.6m mill, replacing an old open-circuit system
· Original: 1.5 TPH slurry at 80% -325 mesh, 28% solids, high maintenance
· New: 2.0 TPH slurry at 92% -325 mesh, 32% solids
· Outcome: Absorber efficiency increased from 92% to 96%. Maintenance hours reduced by 40%.
FGD System Reliability & Performance Assurance
· Material Compatibility Guarantee: All wetted parts (pumps, pipes, hydrocyclones) are selected for limestone slurry abrasion resistance: natural rubber, high-chrome alloy, or ceramic. We provide a material selection report certified for your slurry conditions.
· Fineness & Density Performance Test: A 24-hour continuous performance test is conducted after commissioning. Slurry samples are taken every 2 hours to verify 325-mesh passing rate (≥90%) and solids content (30-35%). System handover only upon passing.
· Redundancy & High Availability: Critical equipment (mill, pumps) is configured for N+1 redundancy. We guarantee >95% system availability, excluding scheduled maintenance.
· Remote Diagnostics & Support: The control system can be linked to our after-sales server for real-time monitoring and troubleshooting. 24/7 remote technical support and annual on-site service visits are included in the warranty period.
Ready to Secure Your FGD Slurry Preparation with a Guaranteed Solution?
Send an inquiry. You will receive:
A complete slurry preparation system proposal matched to your unit size (MW) and limestone source.
A P&ID flow diagram, general arrangement drawing, and equipment list.
Reference cases from similar FGD projects.
Optional: Free limestone grinding test with fineness analysis and recommended mill configuration.
Your project data and limestone specifications are kept strictly confidential.
Kolev Equipment Technology Co., Ltd. is a large-scale private technology enterprise specializing in the research, development, production, and sales of mining and metal ore processing equipment. With over 20 years of experience in ultra-fine grinding, industrial drying, and crushing sand making industries, we provide intelligent solutions and mature supporting products worldwide.
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