{"id":470,"date":"2026-04-27T14:28:45","date_gmt":"2026-04-27T14:28:45","guid":{"rendered":"https:\/\/staging.advancedcyclonesystems.com\/?page_id=470"},"modified":"2026-05-08T11:08:25","modified_gmt":"2026-05-08T11:08:25","slug":"calcination-and-mineral-processing","status":"publish","type":"page","link":"https:\/\/staging.advancedcyclonesystems.com\/en\/calcination-and-mineral-processing\/","title":{"rendered":"Calcination and Mineral Processing"},"content":{"rendered":"<div class=\"et_pb_section_0 et_pb_section et_section_regular et_flex_section acs-page-hero\">\n<div class=\"et_pb_row_0 et_pb_row et_flex_row\">\n<div class=\"et_pb_column_0 et_pb_column et-last-child et_flex_column et_pb_css_mix_blend_mode_passthrough et_flex_column_24_24 et_flex_column_24_24_phone et_flex_column_24_24_phoneWide et_flex_column_24_24_tabletWide et_flex_column_24_24_ultraWide\">\n<div class=\"et_pb_text_0 et_pb_text et_pb_bg_layout_light et_pb_module et_flex_module\"><div class=\"et_pb_text_inner\"><p>Application Area<\/p>\n<\/div><\/div>\n\n<div class=\"et_pb_heading_0 et_pb_heading et_pb_module et_flex_module\"><div class=\"et_pb_heading_container\"><h1 class=\"et_pb_module_header\">Calcination and Mineral Processing<\/h1><\/div><\/div>\n<\/div>\n<\/div>\n<\/div>\n\n<div class=\"et_pb_section_1 et_pb_section et_section_regular et_flex_section acs-breadcrumb-section\">\n<div class=\"et_pb_row_1 et_pb_row et_flex_row\">\n<div class=\"et_pb_column_1 et_pb_column et-last-child et_flex_column et_pb_css_mix_blend_mode_passthrough et_flex_column_24_24 et_flex_column_24_24_phone et_flex_column_24_24_phoneWide et_flex_column_24_24_tabletWide et_flex_column_24_24_ultraWide\">\n<div class=\"et_pb_code_0 et_pb_code et_pb_module\"><div class=\"et_pb_code_inner\"><\/div><\/div>\n<\/div>\n<\/div>\n<\/div>\n\n<div class=\"et_pb_section_2 et_pb_section et_section_regular et_flex_section acs-content-section\" id=\"acs-application-area\">\n<div class=\"et_pb_row_2 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aria-expanded=\"false\">\n            <div>Emission Control<\/div>\n        <\/button>\n\n        <div class=\"acs-app-nav-overlay\" aria-hidden=\"true\">\n            <div class=\"acs-app-nav-panel\">\n                <div class=\"acs-app-nav-spacer\" aria-hidden=\"true\"><\/div>\n                <div class=\"acs-app-nav-links\">\n                    <ul>\n                                                    <li>\n                                <a href=\"https:\/\/staging.advancedcyclonesystems.com\/en\/biomass-and-coal-combustion\/\">Biomass and Coal Combustion<\/a>\n                            <\/li>\n                                                    <li>\n                                <a href=\"https:\/\/staging.advancedcyclonesystems.com\/en\/biomass-drying\/\">Biomass Drying<\/a>\n                            <\/li>\n                                                    <li>\n                                <a href=\"https:\/\/staging.advancedcyclonesystems.com\/en\/pyrolysis-gasification\/\">Pyrolysis & Gasification<\/a>\n                            <\/li>\n                                                    <li>\n                                <a href=\"https:\/\/staging.advancedcyclonesystems.com\/en\/high-temperature-separation-processes\/\">High Temperature Separation Processes<\/a>\n                            <\/li>\n                                                    <li class=\"current\">\n                                <a href=\"https:\/\/staging.advancedcyclonesystems.com\/en\/calcination-and-mineral-processing\/\">Calcination and Mineral Processing<\/a>\n                            <\/li>\n                                                    <li>\n                                <a href=\"https:\/\/staging.advancedcyclonesystems.com\/en\/steel-and-ferroalloys\/\">Steel and Ferroalloys<\/a>\n                            <\/li>\n                                                    <li>\n                                <a href=\"https:\/\/staging.advancedcyclonesystems.com\/en\/fuel-oil-combustion\/\">Fuel Oil Combustion<\/a>\n                            <\/li>\n                                                    <li>\n                                <a href=\"https:\/\/staging.advancedcyclonesystems.com\/en\/glass-and-ceramic\/\">Glass and Ceramic<\/a>\n                            <\/li>\n                                                    <li>\n                                <a href=\"https:\/\/staging.advancedcyclonesystems.com\/en\/oil-gas-and-high-pressure-applications\/\">Oil & Gas and High Pressure Applications<\/a>\n                            <\/li>\n                                            <\/ul>\n                <\/div>\n                <button class=\"acs-app-nav-close\" type=\"button\" aria-label=\"Close\">&times;<\/button>\n            <\/div>\n        <\/div>\n    <\/div>\n    <\/div><\/div>\n<\/div>\n\n<div class=\"et_pb_column_4 et_pb_column et-last-child et_flex_column et_pb_css_mix_blend_mode_passthrough et_flex_column_24_24 et_flex_column_24_24_phone et_flex_column_24_24_phoneWide et_flex_column_24_24_tabletWide et_flex_column_24_24_ultraWide\">\n<div class=\"et_pb_heading_1 et_pb_heading et_pb_module et_flex_module translation-block\"><div class=\"et_pb_heading_container\"><h2 class=\"et_pb_module_header\">Calcination and Mineral Processing<\/h2><\/div><\/div>\n\n<div class=\"et_pb_text_1 et_pb_text et_pb_bg_layout_light et_pb_module et_flex_module\"><div class=\"et_pb_text_inner\"><p><strong>Calcination<\/strong><span>\u00a0is a process that involves heating a substance, typically a solid material, at high temperature with limited supply of air or oxygen. The purpose of calcination is to remove volatile components and drive off impurities or to transform the material into a more desirable form for further processing.<\/span><\/p>\n<\/div><\/div>\n\n<div class=\"et_pb_heading_2 et_pb_heading et_pb_module et_flex_module\"><div class=\"et_pb_heading_container\"><h3 class=\"et_pb_module_header\">Cement Manufacturing<\/h3><\/div><\/div>\n\n<div class=\"et_pb_text_2 et_pb_text et_pb_bg_layout_light et_pb_module et_flex_module\"><div class=\"et_pb_text_inner\"><p><span>One of the most common processes is the manufacture of Portland cement where limestone (CaCO<\/span><sub>3<\/sub><span>) is fed into a large rotating kiln with clay. Hot air generated from coal, pet-coke or natural gas-fired burners raises the temperature to produce quicklime (CaO) which fuses minerals with the clay and cools down into clinker: pale, grayish nodules that are ground to make cement powder. In the process, large amounts of CO<\/span><sub>2<\/sub><span>\u00a0are released.<\/span><\/p>\n<p><span>A\u00a0<\/span><strong>pre-heater<\/strong><span>\u00a0made up by a series of cyclones is used to pre-heat limestone, clay and sand before these raw materials enter the rotary kiln. This process helps to reduce the amount of energy required to operate the kiln, as well as the amount of fuel needed to achieve the desired temperature.<\/span><\/p>\n<p><span>A\u00a0<\/span><strong>clinker cooler<\/strong><span>\u00a0cools and solidifies the hot clinker discharged from the rotary kiln, to facilitate handling and storage of the material.<\/span><\/p>\n<p><span>Both processes need\u00a0<\/span><strong>dedusting<\/strong><span>\u00a0before the hot gases are released to the stack or are used for\u00a0<\/span><strong>heat recovery<\/strong><span>.<\/span><\/p>\n<\/div><\/div>\n\n<div class=\"et_pb_image_0 et_pb_image et_pb_module et_flex_module\"><span class=\"et_pb_image_wrap\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/staging.advancedcyclonesystems.com\/wp-content\/uploads\/2026\/04\/calcination-and-mineral-processing-2025-01_1179.png\" title=\"calcination-and-mineral-processing-2025-01_1179\" width=\"600\" height=\"450\" srcset=\"https:\/\/staging.advancedcyclonesystems.com\/wp-content\/uploads\/2026\/04\/calcination-and-mineral-processing-2025-01_1179.png 600w, https:\/\/staging.advancedcyclonesystems.com\/wp-content\/uploads\/2026\/04\/calcination-and-mineral-processing-2025-01_1179-480x360.png 480w\" sizes=\"(min-width: 0px) and (max-width: 480px) 480px, (min-width: 481px) 600px, 100vw\" class=\"wp-image-566\" \/><\/span><\/div>\n\n<div class=\"et_pb_heading_3 et_pb_heading et_pb_module et_flex_module\"><div class=\"et_pb_heading_container\"><h3 class=\"et_pb_module_header\">Pre-heater dedusting for energy recovery<\/h3><\/div><\/div>\n\n<div class=\"et_pb_text_3 et_pb_text et_pb_bg_layout_light et_pb_module et_flex_module\"><div class=\"et_pb_text_inner\"><p><span>There is usually a large concentration of fines escaping with the last cyclone gas outlet of the pre-heater, typically composed of small particles of raw material and fly ash (D50~2.5\u03bcm).<\/span><\/p>\n<p><span>In new generation cement plants, the hot gases are used for heat recovery, such as\u00a0<\/span><strong>heating a mill for the grinding of pet coke, heating a limestone dryer<\/strong><span>\u00a0or to\u00a0<\/span><strong>enable heat recovery in exchangers or recovery boilers.<\/p>\n<p>ACS solutions<\/strong><span>\u00a0include\u00a0<\/span><strong>high efficiency cyclones<\/strong><span>\u00a0to heavily reduce the concentration of fines before\u00a0<\/span><strong>petcoke mills<\/strong><span>, low\u00a0<\/span><strong>pressure drop process cyclones for limestone dryers<span>\u00a0<\/span><\/strong><span>and<\/span><strong><span>\u00a0<\/span>pre-separator cyclones<\/strong><span>\u00a0for heat recovery.\u00a0<\/span><\/p>\n<\/div><\/div>\n\n<div class=\"et_pb_heading_4 et_pb_heading et_pb_module et_flex_module\"><div class=\"et_pb_heading_container\"><h3 class=\"et_pb_module_header\">Clinker cooler dedusting<\/h3><\/div><\/div>\n\n<div class=\"et_pb_text_4 et_pb_text et_pb_bg_layout_light et_pb_module et_flex_module\"><div class=\"et_pb_text_inner\"><p><span>The particles carried over in the exhaust gases of the clinker cooler are very abrasive due to their chemical composition and physical properties. The hardness of clinker particles, combined with their irregular shape, surface texture and large size (D50&gt;100\u03bcm), can cause them to wear down equipment and machinery, such as heat exchangers, waste recovery boilers and end stage bag filters.<\/span><\/p>\n<\/div><\/div>\n\n<div class=\"et_pb_image_1 et_pb_image et_pb_module et_flex_module\"><span class=\"et_pb_image_wrap\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/staging.advancedcyclonesystems.com\/wp-content\/uploads\/2026\/04\/calcination-and-mineral-processing-02_1180.png\" title=\"calcination-and-mineral-processing-02_1180\" width=\"601\" height=\"281\" srcset=\"https:\/\/staging.advancedcyclonesystems.com\/wp-content\/uploads\/2026\/04\/calcination-and-mineral-processing-02_1180.png 601w, https:\/\/staging.advancedcyclonesystems.com\/wp-content\/uploads\/2026\/04\/calcination-and-mineral-processing-02_1180-480x224.png 480w\" sizes=\"(min-width: 0px) and (max-width: 480px) 480px, (min-width: 481px) 601px, 100vw\" class=\"wp-image-564\" \/><\/span><\/div>\n\n<div class=\"et_pb_text_5 et_pb_text et_pb_bg_layout_light et_pb_module et_flex_module\"><div class=\"et_pb_text_inner\"><p><strong>ACS solutions<\/strong><span>\u00a0include\u00a0<\/span><strong>abrasive resistant cyclones with low pressure drop<\/strong><span>\u00a0to heavily reduce the concentration of clinker particles, thereby enabling energy recovery and increasing the lifetime of bag filters.<\/span><br \/><span>\u00a0<\/span><\/p>\n<h3><strong>New materials to partially replace clinker<\/strong><\/h3>\n<p><strong>Calcined clay<\/strong><span>\u00a0(or metakaolin) can play a role in cement manufacturing by partially replacing clinker and thereby contribute to a reduction in CO<\/span><sub>2<\/sub><span>\u00a0emissions. When used in combination with other supplementary cementitious materials, such as fly ash or slag, calcined clay can help to reduce the overall clinker content of cement while maintaining or improving its mechanical and durability properties. As in other calcination processes, calcined clay is manufactured in kilns by heating natural clay materials to high temperatures (though lower than those of clinker) typically in the range of 650-800\u00b0C, to drive off water and other volatile components.<\/span><br \/><span>\u00a0<\/span><br \/><strong>ACS solutions<\/strong><span>\u00a0include\u00a0<\/span><strong>high efficiency cyclones to separate clay particles after kilns and flash dryers \/ calciners<\/strong><span>\u00a0upstream of final stage dedusters such as wet scrubbers.<\/span><br \/><span>\u00a0<\/span><\/p>\n<h3><strong>Calcination of Magnesium Oxide<\/strong><\/h3>\n<p><strong>Magnesium oxide (MgO)<\/strong><span>\u00a0has a wide range of applications due to its unique properties, such as high melting point, high thermal conductivity, high electrical resistivity, and good chemical stability. Applications include construction materials (MgO can be a binder to the construction of cement), refractory materials, fertilizer use and others.<\/span><\/p>\n<p><span>MgO is also obtained by a calcination process similar to that of quicklime. In this case, magnesium carbonate (MgCO<\/span><sub>3<\/sub><span>) is decomposed into MgO and CO<\/span><sub>2<\/sub><span>.<\/span><\/p>\n<p><strong>ACS solutions<\/strong><span>\u00a0include\u00a0<\/span><strong>cost efficient and abrasive resistant last stage cyclones in the pre-heater tower<\/strong><span>\u00a0to greatly reduce concentration before baghouses.<\/span><br \/><span>\u00a0<\/span><\/p>\n<h3><strong>Calcination of Dolomitic Lime<\/strong><\/h3>\n<p><strong>Dolomitic lime<\/strong>\u00a0is obtained by calcinating dolomite in a furnace or kiln with a high degree of limestone and magnesium CaMg(CO<sub>3<\/sub>)2, obtaining CaO\u00b0MgO. Applications include the steel industry, refractory materials, glass and agriculture.<\/p>\n<p><strong>Client needs<span>\u00a0<\/span><\/strong>for dedusting are very similar to those of Magnesium Oxide and<span>\u00a0<\/span><strong>include abrasive resistant cost-efficient cyclones<\/strong><span>\u00a0<\/span>to reduce concentration before baghouses.<\/p>\n<p><span>\u00a0<\/span><\/p>\n<h3><strong>Calcination of Calcium Aluminate<\/strong><\/h3>\n<p><span>Calcium aluminate (CaAl<\/span><sub>2<\/sub><span>O<\/span><sub>4<\/sub><span>) is a compound made up of calcium oxide (CaO) and aluminum oxide (Al<\/span><sub>2<\/sub><span>O<\/span><sub>3<\/sub><span>). One of the main applications of calcium aluminate is as a raw material in the production of refractory materials. Calcium aluminate can also be used as a binder in the manufacture of high-performance cement. which has superior strength, durability, and resistance to chemical attack compared to traditional concrete.<\/span><\/p>\n<p><span>Calcium aluminate can assume a\u00a0<\/span><strong>vitrified fiber form<\/strong><span>\u00a0similar to rock wool, which is very demanding to end stage dedusters, such as bag filters, causing frequent clogging.\u00a0<\/span><strong>ACS solutions<\/strong><span>\u00a0include\u00a0<\/span><strong>cost efficient cyclones to increase the collection of fibers<\/strong><span>\u00a0and\u00a0<\/span><strong>reduce maintenance<\/strong><span>\u00a0in the bag house.<\/span><\/p>\n<p>\u00a0<\/p>\n<h3><strong>Calcium Looping<\/strong><\/h3>\n<p><span>In\u00a0<\/span><strong>Calcium looping<span>\u00a0<\/span><\/strong><span>the sorbent\u00a0<\/span><strong>calcium oxide (CaO) reacts<\/strong><span>\u00a0with the\u00a0<\/span><strong>CO<sub>2<\/sub><\/strong><span>\u00a0in flue gas of an industrial process (such as cement manufacturing) to form calcium carbonate (<\/span><strong>CaCO<sub>3<\/sub><\/strong><span>).\u00a0<\/span><\/p>\n<p><strong>CaCO<sub>3<\/sub><\/strong><span>\u00a0is then broken down to capture the CO<\/span><sub>2<\/sub><span>\u00a0and regenerate the CaO for further use.<\/span><\/p>\n<ul class=\"bullets\">\n<li>The process relies on<span>\u00a0<\/span><strong>two reversible chemical reactions: carbonation and calcination.<\/strong><\/li>\n<li>During<span>\u00a0<\/span><strong>carbonation<\/strong>, the<span>\u00a0<\/span><strong>sorbent<\/strong><span>\u00a0<\/span>reacts with the<span>\u00a0<\/span><strong>CO<sub>2<\/sub><\/strong><span>\u00a0<\/span>in the flue gas to form calcium carbonate (CaCO<sub>3<\/sub>) - &gt;<span>\u00a0<\/span><strong>captured with cyclones.<\/strong><\/li>\n<li>The CaCO<sub>3<\/sub><span>\u00a0<\/span>is then fed into a<span>\u00a0<\/span><strong>calciner<\/strong>, where it is heated to about 850\u00b0C-950\u00b0C, causing it to decompose into an almost<span>\u00a0<\/span><strong><u>pure<\/u><span>\u00a0<\/span>CO<sub>2<\/sub><\/strong><span>\u00a0<\/span>gas stream and solid<span>\u00a0<\/span><strong>CaO<\/strong>. The CO<sub>2<\/sub><span>\u00a0<\/span>is removed and further purified, before being sent either for geological storage or onward use.<\/li>\n<li>The solid CaO can be sent back for reuse in the process to capture more CO<sub>2<\/sub>.<\/li>\n<\/ul>\n<\/div><\/div>\n\n<div class=\"et_pb_image_2 et_pb_image et_pb_module et_flex_module\"><span class=\"et_pb_image_wrap\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/staging.advancedcyclonesystems.com\/wp-content\/uploads\/2026\/04\/calcination-and-mineral-processing-03_1217.png\" title=\"calcination-and-mineral-processing-03_1217\" width=\"781\" height=\"600\" srcset=\"https:\/\/staging.advancedcyclonesystems.com\/wp-content\/uploads\/2026\/04\/calcination-and-mineral-processing-03_1217.png 781w, https:\/\/staging.advancedcyclonesystems.com\/wp-content\/uploads\/2026\/04\/calcination-and-mineral-processing-03_1217-480x369.png 480w\" sizes=\"(min-width: 0px) and (max-width: 480px) 480px, (min-width: 481px) 781px, 100vw\" class=\"wp-image-565\" \/><\/span><\/div>\n\n<div class=\"et_pb_text_6 et_pb_text et_pb_bg_layout_light et_pb_module et_flex_module\"><div class=\"et_pb_text_inner\"><p><strong>ACS solutions<\/strong><span>\u00a0include high efficiency\u00a0<\/span><strong>cyclones for the carbonator and for the calciner to increase the collection of both carbonator and calcined sorbents.<\/strong><span><\/span><\/p>\n<\/div><\/div>\n\n<div class=\"et_pb_text_7 et_pb_text et_pb_bg_layout_light et_pb_module et_flex_module translation-block\"><div class=\"et_pb_text_inner\"><h3><strong>Paper Mill Sludge Valorization: High-Temperature Mineral Recovery<\/strong><\/h3>\n<h4><strong>Transforming Paper Mill Sludge into Calcium Carbonate\u00a0<\/strong><\/h4>\n<p>Paper mill sludge contains a significant share of\u00a0<strong>valuable minerals<\/strong>, mainly\u00a0<strong>calcium carbonate (CaCO\u2083)<\/strong>, together with kaolin and other clays. Through advanced thermal processing routes, this waste stream can be converted into\u00a0<strong>high-value mineral products<\/strong>, supporting circular economy objectives. In both approaches,\u00a0<strong>ACS cyclone technology is essential for efficient mineral recovery at high temperatures.<\/strong><\/p>\n<h4><strong>Pyrolysis-based Mineral Recovery<\/strong><\/h4>\n<p>In pyrolysis processes, the organic fraction of the sludge is thermally removed, enabling the\u00a0<strong>concentration and recovery of calcium carbonate-rich minerals.<\/strong><\/p>\n<p><strong>ACS cyclones<\/strong>\u00a0ensure:<\/p>\n<ul class=\"bullets\">\n<li>Efficient separation of solids from hot process gases<\/li>\n<li>Reliable operation under high-temperature and abrasive conditions<\/li>\n<\/ul>\n<p>The recovered material can be reused as a\u00a0<strong>functional filler<\/strong>\u00a0in applications such as\u00a0<strong>paints, plastics and rubber,<\/strong><span>\u00a0<\/span>reducing disposal and associated CO\u2082 emissions.<\/p>\n<h3><strong>Thermal Calcination and Mineral Activation<\/strong><\/h3>\n<p>In calcination and activation routes, the sludge is dried and rapidly heated to produce\u00a0<strong>activated mineral materials<\/strong>. Depending on process conditions, the output may include:<\/p>\n<ul class=\"bullets\">\n<li>Activated calcium carbonate\u00a0for high-performance fillers<\/li>\n<li>Reactive mineral ash\u00a0for partial cement replacement<\/li>\n<li>Mineral materials with CO\u2082 adsorption potential, in selected cases<\/li>\n<\/ul>\n<p>Cyclones play a key role in the\u00a0<strong>high temperature Product Recovery.<\/strong><\/p>\n<h3><strong>Why ACS Cyclones?<\/strong><\/h3>\n<p>For high-temperature sludge valorization, ACS cyclones offer clear advantages:<\/p>\n<ul class=\"bullets\">\n<li>Operation up to\u00a0900 \u00b0C<\/li>\n<li>Low pressure drop\u00a0and high energy efficiency<\/li>\n<li>Robust, maintenance-free design\u00a0with no consumables<\/li>\n<li>Modular and scalable solutions\u00a0for easy plant integration<\/li>\n<\/ul>\n<p><strong>ACS cyclone technology enables efficient, reliable and sustainable recovery of valuable minerals from paper mill sludge processing technologies.<\/strong><\/p>\n<\/div><\/div>\n<\/div>\n<\/div>\n<\/div>\n\n<div class=\"et_pb_section_3 et_pb_section et_section_regular et_flex_section\" id=\"acs-cstudies\">\n<div class=\"et_pb_row_4 et_pb_row et_flex_row\">\n<div class=\"et_pb_column_5 et_pb_column et-last-child et_flex_column et_pb_css_mix_blend_mode_passthrough et_flex_column_24_24 et_flex_column_24_24_phone et_flex_column_24_24_phoneWide et_flex_column_24_24_tabletWide et_flex_column_24_24_ultraWide\">\n<div class=\"et_pb_code_2 et_pb_code et_pb_module\"><div class=\"et_pb_code_inner\">    <div class=\"acs-case-studies\" data-visible=\"3\">\n        <h2 class=\"acs-case-studies-title\">Case Studies<\/h2>\n        <div class=\"acs-cs-carousel-wrap\">\n            <button class=\"acs-cs-prev\" aria-label=\"Previous\">&#x2039;<\/button>\n            <div class=\"acs-cs-carousel-viewport\">\n                <div class=\"acs-cs-carousel-track\">\n                                            <div 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