Lime — ZAP Engineering

Lime

ZAP engineers quicklime and hydrated lime facilities to meet demanding throughput, product quality, and safety targets.

Engineering Lime Facilities for Continuous Operation

ZAP delivers multidisciplinary engineering and construction services for greenfield lime plants, kiln retrofits, and complete quicklime or hydrated lime facilities. Our experience spans the complete production process, from raw material intake and kiln feed optimization to calcination, product finishing, storage, packaging, and high-speed loadout.

With direct lime industry expertise, we take projects from initial concept through successful commissioning. Whether executing a full EPC delivery or providing targeted engineering, procurement, and construction management (EPCM), we design around daily tonnage targets, product purity requirements, plant safety, and future capacity expansion.

Shane Wilson

Vice President of Business Development

Lime Facility Capabilities

Raw Material Receiving and Preparation
  • Truck and rail receiving systems
  • Limestone stockpiles and storage
  • Stockpile reclaim systems
  • Crushing and screening
  • Material sizing and classification
  • Mechanical conveying
  • Surge storage and kiln feed systems
Kiln and Balance-of-Plant Engineering
  • New lime kiln installations
  • Kiln retrofits, upgrades, and plant modifications
  • Vendor-supplied kiln equipment integration
  • Plant-wide mass and material balances
  • Balance-of-plant engineering
  • Kiln feed and product transfer systems
  • Process piping and utility connections
  • Equipment layouts and access requirements
  • Provisions for future expansion
Product Processing, Storage, and Loadout
  • Quicklime crushing and sizing
  • Lime storage silos
  • Lime slaking and hydration systems
  • Bulk product handling
  • Truck and rail loadout
  • Packaging systems
  • Dust collection and control
  • Finished-product storage and transfer
Facility Infrastructure
  • Plant and equipment layouts
  • Site development
  • Equipment foundations
  • Structural steel and equipment supports
  • Process and equipment buildings
  • Utility and electrical buildings
  • Access platforms and maintenance infrastructure
  • HVAC and supporting plant utilities
Electrical, Instrumentation, and Controls
  • Utility service and power distribution
  • Motor control and equipment power
  • Process instrumentation
  • PLC-based control systems
  • Automated plant operation
  • Remote monitoring
  • Vendor controls integration
  • Communications and network infrastructure
Facility Development and Modernization
  • Greenfield facility development
  • Capacity expansions and facility modernization
  • Equipment and system upgrades
  • 3D laser scanning and as-built verification
  • Existing facility tie-in design and system integration
Project Delivery
  • Conceptual engineering and feasibility studies
  • FEED
  • Multidiscipline detailed engineering
  • Equipment specifications and bid packages
  • Procurement support and bid evaluation
  • Project management and project controls
  • Onsite engineering during construction
  • Construction and construction management
  • Commissioning, startup management and project closeout
  • EPCM
  • Full-scope EPC delivery

Contact us

We partner with clients across the energy and industrial markets to solve complex technical challenges and deliver projects that perform.