Lime Kiln - Revision history

Marcin: /* About */

2026-01-30T02:34:02Z

About

← Older revision		Revision as of 02:34, 30 January 2026
Line 4:		Line 4:
	*Around 1.4 kwhr/kg of lime production - or 1400Mwhr for a ton		*Around 1.4 kwhr/kg of lime production - or 1400Mwhr for a ton
	Basic cost of open source - with [[1 Cent Solar]] - we have 1400 kWhr 1 cent/kWhr = $14 in electricity		Basic cost of open source - with [[1 Cent Solar]] - we have 1400 kWhr 1 cent/kWhr = $14 in electricity
	*Absolute base cost is $14 energy and $12 in [[Kanthal A1]] wear - making a 100 lb sack of concrete mix come out to $3 + rock, which is near zero marginal cost.		*Absolute base cost is $14 energy and $12 in [[Kanthal A1]] wear - making a 100 lb sack of concrete mix come out to $1.50 + rock, which is near zero marginal cost. Far below the $7.5/ 100 lb sack of industrial concrete.
	*It's worth doing. For 3000 psi concrete, need to use [[Metakaolin]] mixed during cement mix phase, Commercially, they fire with 20% clay-containing limestone at slightly higher temperature, 1200C. But can do pure limestone at 1100 and then add metakaolin.		*It's worth doing. For 3000 psi concrete, need to use [[Metakaolin]] mixed during cement mix phase, Commercially, they fire with 20% clay-containing limestone at slightly higher temperature, 1200C. But can do pure limestone at 1100 and then add metakaolin.
	*Otherwise, get lime concrete at 1500 PSI.		*Otherwise, get lime concrete at 1500 PSI.

Marcin: /* About */

2026-01-30T02:31:42Z

About

← Older revision		Revision as of 02:31, 30 January 2026
Line 4:		Line 4:
	*Around 1.4 kwhr/kg of lime production - or 1400Mwhr for a ton		*Around 1.4 kwhr/kg of lime production - or 1400Mwhr for a ton
	Basic cost of open source - with [[1 Cent Solar]] - we have 1400 kWhr 1 cent/kWhr = $14 in electricity		Basic cost of open source - with [[1 Cent Solar]] - we have 1400 kWhr 1 cent/kWhr = $14 in electricity
	*Absolute base cost is $14 energy and $12 in [[Kanthal A1]] wear - making a 100 lb sack of concrete mix come out to $3, which is near zero marginal cost.		*Absolute base cost is $14 energy and $12 in [[Kanthal A1]] wear - making a 100 lb sack of concrete mix come out to $3 + rock, which is near zero marginal cost.
	*It's worth doing. For 3000 psi concrete, need to use [[Metakaolin]] mixed during cement mix phase, Commercially, they fire with 20% clay-containing limestone at slightly higher temperature, 1200C. But can do pure limestone at 1100 and then add metakaolin.		*It's worth doing. For 3000 psi concrete, need to use [[Metakaolin]] mixed during cement mix phase, Commercially, they fire with 20% clay-containing limestone at slightly higher temperature, 1200C. But can do pure limestone at 1100 and then add metakaolin.
	*Otherwise, get lime concrete at 1500 PSI.		*Otherwise, get lime concrete at 1500 PSI.

Marcin at 02:31, 30 January 2026

2026-01-30T02:31:22Z

← Older revision		Revision as of 02:31, 30 January 2026
Line 1:		Line 1:
			=About=
	*Lime Kiln Calculations - $2400 for a minimum 100kW heater element for 1 ton batch kiln, lasts 150-300 heats.		*Lime Kiln Calculations - $2400 for a minimum 100kW heater element for 1 ton batch kiln, lasts 150-300 heats.
	*Bulk lime is $150-200 per ton - 10 cents per lb.		*Bulk lime is $150-200 per ton - 10 cents per lb.

Marcin at 02:31, 30 January 2026

2026-01-30T02:31:11Z

← Older revision		Revision as of 02:31, 30 January 2026
Line 6:		Line 6:
	*It's worth doing. For 3000 psi concrete, need to use [[Metakaolin]] mixed during cement mix phase, Commercially, they fire with 20% clay-containing limestone at slightly higher temperature, 1200C. But can do pure limestone at 1100 and then add metakaolin.		*It's worth doing. For 3000 psi concrete, need to use [[Metakaolin]] mixed during cement mix phase, Commercially, they fire with 20% clay-containing limestone at slightly higher temperature, 1200C. But can do pure limestone at 1100 and then add metakaolin.
	*Otherwise, get lime concrete at 1500 PSI.		*Otherwise, get lime concrete at 1500 PSI.

			=Free Pozzolan=
			== Economic Analysis: Pozzolan Production ==

			If you have '''$0.01/kWh''' electricity and '''$10/ton''' limestone, your energy and raw material costs are world-class. In this specific scenario, paying $60–$100/ton for Fly Ash does indeed double or triple your "binder" cost.

			To keep your economics in line with your ultra-cheap power, you should '''calcine your own local clay''' to create your pozzolan.

			=== The "Free" Pozzolan Strategy ===
			Since your power is essentially negligible, you can run a second "calcining" cycle in your 100kW kiln for the clay.

			* '''The Cost:''' At $0.01/kWh, firing 1 ton of clay to <math>750^{\circ}C</math> (roughly 600 kWh) costs only '''$6.00 in electricity'''.
			* '''The Yield:''' This transforms "free" site clay into a high-performance pozzolan for roughly '''$6.00/ton''', which is 10x cheaper than buying Fly Ash.

			=== Step 1: Dry Processing (Skip the Water) ===
			To make this practical for many houses, '''do not wash the dirt.''' Washing is for pottery-grade purity. For 3,000 psi concrete, "impurities" like fine silt and sand in the clay act as beneficial micro-aggregates.

			* '''Excavate:''' Dig up the clay-rich subsoil on your site.
			* '''Dry:''' Spread it out in the sun until it is bone-dry and brittle.
			* '''Crush:''' Use a simple jaw crusher or hammer mill to break it into 1-inch chunks.

			=== Step 2: The "Pozzolan Fire" ===
			# Load the crushed clay chunks into your 1-ton Kanthal kiln.
			# Heat to <math>750^{\circ}C</math> and hold for 2–3 hours.
			# '''Warning:''' Do not hit your <math>1,100^{\circ}C</math> lime temperature, or you will turn the clay into "grog" (hard ceramic), which is chemically dead and won't react with the lime.

			=== Step 3: Final Pulverization ===
			This is the only way to get 3,000 psi. You must grind the fired clay into a micro-fine flour.

			* '''The Tool:''' Since you are building many houses, buy or build a '''Continuous Ball Mill'''.
			* '''The Process:''' Tumble the fired clay with steel balls until it passes a 325-mesh screen. This increases the surface area so the lime can "grab" it instantly.

			=== Conclusion ===
			By using your cheap $0.01/kWh power to fire local clay at <math>750^{\circ}C</math>, you can produce a high-strength pozzolan for approximately '''$6–$10 per ton''' (electricity + labor). This matches your $10/ton lime cost and keeps your total binder cost around '''$20/ton''', which is roughly '''85% cheaper''' than buying Portland cement or Fly Ash.

Marcin at 02:20, 30 January 2026

2026-01-30T02:20:26Z

← Older revision		Revision as of 02:20, 30 January 2026
Line 1:		Line 1:
	*Lime Kiln Calculations - $2400 for a minimum 100kW heater element for 1 ton batch kiln, lasts 50-300 heats.		*Lime Kiln Calculations - $2400 for a minimum 100kW heater element for 1 ton batch kiln, lasts 150-300 heats.
	*Bulk lime is $150-200 per ton - 10 cents per lb.		*Bulk lime is $150-200 per ton - 10 cents per lb.
	*Around 1.4 kwhr/kg of lime production - or 1400Mwhr for a ton		*Around 1.4 kwhr/kg of lime production - or 1400Mwhr for a ton
	Basic cost of open source - with [[1 Cent Solar]] - we have 1400 kWhr 1 cent/kWhr = $14 in electricity		Basic cost of open source - with [[1 Cent Solar]] - we have 1400 kWhr 1 cent/kWhr = $14 in electricity
	*Absolute base cost is $14 energy and $24 in [[Kanthal A1]] wear - making a 100 lb sack of concrete mix come out to $4, which is near zero marginal cost.		*Absolute base cost is $14 energy and $12 in [[Kanthal A1]] wear - making a 100 lb sack of concrete mix come out to $3, which is near zero marginal cost.
			*It's worth doing. For 3000 psi concrete, need to use [[Metakaolin]] mixed during cement mix phase, Commercially, they fire with 20% clay-containing limestone at slightly higher temperature, 1200C. But can do pure limestone at 1100 and then add metakaolin.
			*Otherwise, get lime concrete at 1500 PSI.

Marcin at 01:41, 30 January 2026

2026-01-30T01:41:13Z

← Older revision		Revision as of 01:41, 30 January 2026
Line 3:		Line 3:
	*Around 1.4 kwhr/kg of lime production - or 1400Mwhr for a ton		*Around 1.4 kwhr/kg of lime production - or 1400Mwhr for a ton
	Basic cost of open source - with [[1 Cent Solar]] - we have 1400 kWhr 1 cent/kWhr = $14 in electricity		Basic cost of open source - with [[1 Cent Solar]] - we have 1400 kWhr 1 cent/kWhr = $14 in electricity
	*Absolute base cost is $14 energy and $24 in [[Kanthal A1]] wear		*Absolute base cost is $14 energy and $24 in [[Kanthal A1]] wear - making a 100 lb sack of concrete mix come out to $4, which is near zero marginal cost.

Marcin at 01:39, 30 January 2026

2026-01-30T01:39:59Z

← Older revision		Revision as of 01:39, 30 January 2026
Line 1:		Line 1:
	*Lime Kiln Calculations - $~~2000~~ for a minimum 100kW heater element for 1 ton batch kiln, lasts 50-300 heats.		*Lime Kiln Calculations - $2400 for a minimum 100kW heater element for 1 ton batch kiln, lasts 50-300 heats.
	*Bulk lime is $150-200 per ton - 10 cents per lb.		*Bulk lime is $150-200 per ton - 10 cents per lb.
	*Around 1.4 kwhr/kg of lime production - or 1400Mwhr for a ton		*Around 1.4 kwhr/kg of lime production - or 1400Mwhr for a ton
	*Basic cost of open source - with [[1 Cent Solar]] -		Basic cost of open source - with [[1 Cent Solar]] - we have 1400 kWhr 1 cent/kWhr = $14 in electricity
			*Absolute base cost is $14 energy and $24 in [[Kanthal A1]] wear

Marcin at 01:37, 30 January 2026

2026-01-30T01:37:03Z

← Older revision		Revision as of 01:37, 30 January 2026
Line 1:		Line 1:
	*Lime Kiln Calculations - $2000 for a minimum 100kW heater element for 1 ton batch kiln, lasts 50-300 heats.		*Lime Kiln Calculations - $2000 for a minimum 100kW heater element for 1 ton batch kiln, lasts 50-300 heats.
			*Bulk lime is $150-200 per ton - 10 cents per lb.
			*Around 1.4 kwhr/kg of lime production - or 1400Mwhr for a ton
			*Basic cost of open source - with [[1 Cent Solar]] -

Marcin at 01:33, 30 January 2026

2026-01-30T01:33:56Z

← Older revision		Revision as of 01:33, 30 January 2026
Line 1:		Line 1:
	*Lime Kiln Calculations - $~~1000~~ for a minimum 100kW heater element for 1 ton batch kiln		*Lime Kiln Calculations - $2000 for a minimum 100kW heater element for 1 ton batch kiln, lasts 50-300 heats.

Marcin: Created page with "*Lime Kiln Calculations - $1000 for a minimum 100kW heater element for 1 ton batch kiln"

2026-01-30T01:22:22Z

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*Lime Kiln Calculations - $1000 for a minimum 100kW heater element for 1 ton batch kiln