PM-TECHNOLOGIES FINEST SOLUTIONS Unique technologies for kiln plant, raw meal and cement grinding!
Josef Keuschnigg
RE-ENGINEERING THE KILN PLANT
BOTTLENECK ANALYSIS When re-engineering the kiln plant, all effects of the complete kiln system must be considered.
TAILOR-MADE OPTIMISATION CONCEPTS “A cyclone preheater’s basic equipment design is rarely a decisive factor for the functioning of the kiln plant, but rather the numerous details in the cyclone stages, the calciner and the lower preheater area.”
cyclone stage PM-TECHNOLOGIES Tapping into the full kiln potential
calciner
2-step meal chute system
chloride-bypass & kiln inlet
EFFECTS AND MEASURES WHEN UPGRADING THE PLANT INCREASED GAS FLOW RATES - Pressure drop reduction of cyclone stages to increase the level of clinker output - Improved cyclone efficiency and low pressure drop - Potential for increase in gas throughput of 30% to 40% by keeping the ∆p level EFFICIENT HEAT GENERATION AND HEAT TRANSFER - Good burnout with moderate of needed calciner residence time - Sufficient calcination at favourable calciner exit oxygen and temperature OPTIMISED OPERATING CONDITIONS IN LOWER PH AREA - Reduction of dust re-circulation rate and build-ups - Efficient chloride extraction via gas bypass system CLINKER QUALITY AND OUTPUT - Kiln burner and cooler assessment, etc. (in collaboration with external partners) PLANT UPGRADE Effects and measures
CYCLONE STAGE OPTIMISATION
PM-TECHNOLOGIES’ CYCLONE UPGRADE PACKAGE - To ensure high cyclone efficiency and low pressure drop - ∆p reduction potential of up to 50% when installing HURRITEC GV guide vanes
OPTIMISATION MEASURES - Cyclone solutions for maximum gas throughput - Special key parts installed on the inside for high efficiency at low ∆p - Fluidic-optimized cyclone inlets and entrance bend units
“Individual solutions and the attention to detail are prerequisites when making high quality technical modifications with a maximum rere-use of the existing equipment!” OPTIMISATION OF KILN PLANTS Activities and technical details
pressure drop
- Re-designing of critical cyclone components and areas 17 mbar
-55%
∆p STAGE 1
7,6 mbar
before
after
MI-CFD BASED INLINE CALCINER OPTIMISATION FOCUS ON SIMULATION - CFD-based burner positioning
- Position of meal inlets - Staged meal chute systems
- Well chosen tertiary air inlets Oxygen (%)
Temperature oC
OPTIMISATION OF KILN PLANTS Calciner optimisation
REFERENCE VENEZUELA PREHEATER MODIFICATION - Top stage: cyclones, guide vanes HURRITEC GV, entrance bend units - Calciner + 0,6 sec residence time, rearrangement of burners - 2step meal chute system with servo drive meal splitter - kiln riser duct with adjustable orifice and splash box RESULTS - pressure drop reduction at top stage: 21 9,5mbar - Improved calcination: 90% 98% - Clinker production increase: +370 t/day
21 mbar
∆p STAGE 1
before
-55%
9,5 mbar after
OPTIMISATION OF KILN PLANTS PH, calciner and cyclone optimisation, optimisation, reference and results
clinker production
pressure drop Top stage
- volumetric load of kiln: up to 5,4tpd/m³ +16% 2880 tpd before
3350 tpd
after
TAPPING INTO THE FULL POTENTIAL OF GRINDING SYSTEMS
BOTTLENECK ANALYSIS When re-engineering the separation system, all effects of the complete grinding system must be considered.
TAILOR-MADE OPTIMISATION CONCEPTS “the right ball charge in combination with a perfect separation is the most wanted target during an optimization phase.”
dynamic classifier
ultrafine classifier
PM-TECHNOLOGIES Tapping into the full potential of grinding systems
impact hammer mill
product separation
CLASSICLON ® - LEADING GENERATION OF CLASSIFIER
DESIGN CHARACTERISTICS - various housing types for up to 5.500Blaine - proven drive-unit for stable operation - patented technology for highest separation forces - “low-speed-rotor” technology = “low-wear-rotor” ADVANTAGES - highest classifying-efficiency - proven technology at several references - stable plant operation - low cost and easy maintenance
draft force Fd PM-TECHNOLOGIES activities and technical details
centrifugal force Fc
CLASSICLON® - RETRO-FIT
HIGHEST TECHNICAL STANDARD FOR EXISTING CLASSIFIERS custom made design - based on existing classifier-housing - 1st, 2nd or 3rd generation classifier upgrades are possible rere-use of existing equipment is possible - re-use of existing cyclone-separators - existing fan and filter can be used further
maximum economic upgrades due to low low modification costs for equipment and building! building! CLASSIFYING AND GRINDING activities and technical details
ENGINEERING FOR CLASSIFYING/GRINDING PLANTS REFERENCE GERMANY 2009: OPTIMIZATION OF CEMENT GRINDING SHOP - basic equipment: 1.700kW ball-mill (Ø3,0m) with 2nd generation classifier and 500kW roller-press - scope of project: project coordination, detail engineering and delivery of new classifying system MODIFICATIONS - new CLASSICLON DS classifier and HURRITEC ST for product separation - ball mill: enlargement of 2nd grinding chamber and adapted ball-charge - improved roller press efficiency due to better operation conditions PRODUCTION RATE AFTER SYSTEM UPGRADE
43 t/h before
after
+18%
CLASSIFYING AND GRINDING activities and technical details
(3300 cm²/g)
68 t/h
CEM I 42,5R
(4140 cm²/g)
CEM I 52,5N
+58%
88 t/h
75 t/h
before
after
IMPACT HAMMER MILL
TECHNICAL DETAILS patented design for highest prepre-grinding effect - flow-optimized housing-design - upper and lower deflector plates to reach internal material re-circulation for highest pre-grinding effect
individual solutions - for integration in existing ball-mill systems - retro-fit of existing hammer mills is possible - perfect for tandem drying-grinding systems
CLASSIFYING AND GRINDING activities and technical details
gas inlet
material charge
material + gas outlet
IMPACT HAMMER MILL NEW PROJECT VENEZUELA Clay drydry-grinding system -
Hot gas supply of preheater exhaust gas
-
Additional heat demand in wet season with a hot gas generator
-
Unique installation of impact hammer mill
-
HURRITEC double dip tube Cyclone technology for low pressure drop
-
Intermediate dry clay bin for easy handling of the system
-
Upgrade of complete raw grinding system +40% output of up to 320t/h
-
Planned start up: middle of 2012
CLASSIFYING AND GRINDING activities and technical details
ACTIVITIES TAPPING INTO ANDTHE PRODUCTS: FULL POTENTIAL OVERVIEW OF GRINDING SYSTEMS
GRINDING AND CLASSIFYING SYSTEMS
THANKS FOR YOUR ATTENTION! PM-TECHNOLOGIES Neugasse 111, 8200 Gleisdorf, Austria P: +43 / 3112 / 41990-00, M:
[email protected], W: www.pm-technologies.at
