Expedited Screw is Delivered Ahead of Schedule for Lime Producer Calera, AL

General Description of the Application

A worldwide manufacturer of lime operates a quarry and processing facility in Calera, AL to manufacture various types of lime. Lime is made from limestone that has been calcined or heated to extreme temperatures to create quicklime. Water is then be added to convert quicklime to slaked or hydrated lime. Various forms of lime are used extensively to adjust the pH in applications ranging from soil to wastewater treatment.

A critical operation at the Calera plant involved conveying quicklime to a hydrator using a screw conveyor. Prior to a planned shutdown, the existing screw failed and could not be repaired. Downtime is valued at thousands of dollars per hour and the plant needed help. Without a replacement screw, hydrated lime could not be produced since there was no redundancy built into the system. The lime producer needed a special screw manufactured immediately and KWS responded by exceeding expectations.

Design Parameters of Application

1. Product Type: Lime
2. Material Density: 45 to 60 Lbs. per Cubic Foot
3. Capacity: 2,000 Cubic Feet per Hour
4. Duty: 24 Hours per Day, 7 Days per Week

Advantages Provided by KWS

With a commitment to continuous improvements, KWS has streamlined every manufacturing procedure and now, provides the shortest lead times in the industry. Lean manufacturing processes have reduced queue times, allowing for efficient production and improved deliveries. Standard lead time to build the new screw was fifteen working days, but our goal was to get the plant up and running as soon as possible.

After being notified of the screw failure on Wednesday afternoon, KWS manufactured and delivered the replacement screw within three days. The new KWS screw was installed and the plant was running at full production on Saturday morning. KWS reduced the lead time from fifteen to three working days and satisfied another valued Customer.

The replacement screw was very special in design with heavy-duty flights, 3-bolt shaft connections, and continuously welded flights on schedule 80 pipe. The drive end of the screw was reinforced with an external collar that fit on the pipe OD and reinforced the area around the coupling bolt holes.