5479_KilnPlant-Optimization_Activities.pdf

OPTIMIZATION OF KILN PLANTS ACTIVITIES AND TECHNICAL DETAILS

CYCLONE OPTIMIZATION

TECHNICAL FEATURES - flow-optimized entrance bend units - enlargement of cyclone sepa ration chambers - modification of cyclone entrances and spira ls - re-dimensioning of dip-tubes and riser ducts - installation of guide vanes HURRITEC GV

ADVANTAGES - reduction of pressure drop up to 50% - higher gas rate/performance at same pressu re drop - improved separation efficiency - increase of capacity up to 40% - best utilization of existing plant and buildings OPTIMIZATION OF KILN PLANTS

KEY COMPONENTS

GUIDE VANE (HURRITEC GV) - installation in topstage and 2 nd stage cyclone, directly on dip tubes - extreme pressure drop reductions up to 50% - energy savings, less fan power needed - easy installation of guide vanes - maximum production by minim um investment cost s

DIP TUBE - dip tube diameter and length are important design param eters for best separation efficiency - choice of material is of great importance due to the operating and chemical conditions - re-dimensioning and delivery of dip tubes acc. to the requirements

OPTIMIZATION OF KILN PLANTS

PREHEATER ACCESSORIES

SPLASH-BOX - splash-boxes for optimized meal dispersion and efficient heat exchange - special design with individual internal parts for each cyclone stage - turnable and adjustable splash-plates - easy exchange of splash-plate

PENDULUM FLAP - for efficient cyclone operation - less false air in the cyclone above - high operation reliability of equipment - easy installation and exchan ge in case of maintenan ce

OPTIMIZATION OF KILN PLANTS

UPGRADE OF EXISTING PRECALCINERS

TECHNICAL FEATURES - installation of customer-specific mixing chambers - prolongation of ascending and descending ducts - integration of burners for fir ing of secondary fired fuels - enlargement of existing combustion chambers - optimization and adjustment of meal feeding into precalciner - flow optimized entrance bend units for bottom-stage cyclones

ADVANTAGES - best operating and mixing condition s for good burnout and calcinati on - increase of retention time on targete d values - increase of secondary fired fuels and produ ction capacity - custom-made solutions due to the narrow space in existing buildings OPTIMIZATION OF KILN PLANTS

KILN INLET MODIFICATION

TECHNICAL FEATURES - optimized kiln inlet des ign by new housing - enlargement of critical kiln inlet cros s-section > 20% - enlargement of kiln screen and end-se ction of rotary kiln - kiln sealing pneumatically operated - integration of chlorine bypass system

ADVANTAGES - reduction of kiln gas veloc ity in critical areas - reduction of dust re-circulation rate - reduction of false air - removal of bottleneck

OPTIMIZATION OF KILN PLANTS

2-STEP MEAL CHUTE SYSTEM

TECHNICAL FEATURES - meal splitter with adjustable dividing plate - partial meal chute - main meal chute - splash-box for main meal feed incl. special splash-plate - splash-box for partial meal feed

ADVANTAGES - substantial reduction of build-ups at high SO 3-content - more stable and efficient kiln operation with alternative fuels - less maintenance required, easier manual cleaning - additional benefit: increase in alternative fuels fired in calciner without causing serious build-up problems in kiln riser duct OPTIMIZATION OF KILN PLANTS

CHLORINE-BYPASS SYSTEM

TECHNICAL FEATURES - feeding of cooling air - metered raw meal addition - multistream quenching chamber - large maintenance doors - bypass gas extraction unit

ADVANTAGES - compact design - cooling close to extraction point - high mixing quality by multistream quenching chamber - good access for cleaning - less maintenance required OPTIMIZATION OF KILN PLANTS

CLINKER COOLER DEDUSTING

TECHNICAL FEATURES - 1 HURRITEC DT instead of two conventio nal cyclones - guide vanes HURRITEC GV for lowest pressure drop - double dip tube cyclones lined with special wear resistant lining

RESULTS - highest separation efficiency > 98% - low pressure drop for energy saving operation - reduced system dimensions - no reasonable wear in HURRITEC DTs and fan after three years of operation OPTIMIZATION OF KILN PLANTS

t s u d l a u id s e r

550 mg/Nm³

-70%

150 mg/Nm³ before

after

p o r d e r u s s e r p

550 Pa

-18%

before

after

450 Pa

PM-TECHNOLOGIES GMBH

Neugasse 111, A-8200 Gleisdorf phone: +43 / 3112 / 41990-00 fax: +43 / 3112 / 41990-99 [email protected] www.pm-technologies.at

PM-TECHNOLOGIES GMBH