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 preheaters 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 - Re-designing of critical cyclone components and areas
pressure drop

- Fluidic-optimized cyclone inlets and entrance bend units

17 mbar

-55%

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

p STAGE 1

7,6 mbar
after

before

MI-CFD BASED INLINE CALCINER OPTIMISATION

FOCUS ON SIMULATION - CFD-based burner positioning - Well chosen tertiary air inlets
Oxygen (%)

- Position of meal inlets - Staged meal chute systems

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 - Improved calcination: 90% 98% - Clinker production increase: +370 t/day - volumetric load of kiln: up to 5,4tpd/m
pressure drop Top stage clinker production

9,5mbar

21 mbar

-55%

+16% 2880 tpd

before

3350 tpd

p STAGE 1

before

9,5 mbar
after

after

OPTIMISATION OF KILN PLANTS

PH, calciner and cyclone optimisation, optimisation, reference and results

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
PM-TECHNOLOGIES

ultrafine classifier

impact hammer mill

product separation

Tapping into the full potential of grinding systems

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 (3,0m) 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 +58%
CEM I 52,5N
(4140 cm/g)

CEM I 42,5R

68 t/h

+18%
(3300 cm/g)

88 t/h

75 t/h

43 t/h
before after

before

after

CLASSIFYING AND GRINDING

activities and technical details

IMPACT HAMMER MILL

gas inlet

material charge

material + gas outlet

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

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 AND THE 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: office@pm-technologies.at, W: www.pm-technologies.at