Page 1 of 8 2014-CIC-0022

Pyro and Raw Mill Modifications to Achieve 2,200 STPD

Gerry McKervey Steven W. Miller Jared B. Weston

Plant Manager
Capitol Aggregates
11551 Nacogdoches Road
San Antonio, TX 78217, USA
Gerry.McKervey@capitolaggregates.com
Product Manager Pyro Technology
FLSmidth Inc.
2040 Avenue C
Bethlehem, PA 18017, USA
steven.miller@flsmidth.com
Sales Manager Customer Service
FLSmidth, Inc.
2040 Avenue C
Bethlehem, PA 18017, USA
Jared.Weston@flsmidth.com

Abstract The Company was left with more finish grinding capacity than the 4-stage preheater kiln could supply, emission credits set
to expire in 2011 and one of the healthier cement markets in the USA after shutting down a wet kiln in 2006. A strong, successful and
healthy relationship with the original equipment supplier (OEM) has allowed the Company to implement new technologies to drive
the operation of the equipment throughout the 30 year history of the production line.
Recently, the Company chose the OEM in undertaking a number of upgrades to achieve an increase in capacity and improved
efficiency. This paper highlights the steps taken during a 2-phase upgrade to achieve 2,200 STPD (2,000 MTPD) of clinker and allow
the Company to remain at the forefront in implementing new technologies in the industry.

I. INTRODUCTION

The dry process plant (Figure 1) was originally designed and supplied in 1982 with a guaranteed clinker production of 1,510
STPD (1,370 MTPD). For more than a decade the plant continued to operate at this rated capacity. The original dry process
plant consisted of a 4-stage preheater with flash calciner and bypass system, 12 ft x 165 ft (3.66 x 50.3 m) 3-support rotary kiln
and a reciprocating grate cooler. Raw meal for the process was supplied by a 2.4 m diameter vertical roller mill with 600 HP
(447 kW) motor.

Fig. 1. The Company's Cement Plant Located in San Antonio, Texas, USA.

978-1-4799-3294-8/14/$31.00 2014 IEEE

 2014-CIC-0022 Page 2 of 8

The company worked with the original equipment manufacturer (OEM) to increase capacity to 2,000 STPD (1,814 MTPD),
with these upgrades completed in 2001. Incorporated in these upgrades was an air beam cooler retrofit, addition of a separate
line calciner to the existing in-line calciner, and the addition of a calciner slip stream system to reduce SO2 emissions. The raw
meal grinding system was also modified to increase production to support the higher pyro system production. The
modifications included: increasing the mill motor size to 1,000 HP (746 kW), replacing the mill gear box to support the larger
mill motor, modifying the mill classifier to a modern high efficiency classifier and upgrading the mill fan with a larger 2,000
HP (1,491 kW) motor.
The company and the OEM decided to collaborate again in 2009 for modifications of the pyro-process and raw meal
production areas in order to achieve 2,200 STPD (2,000 MTPD). The desired upgrade represented a 10% production increase
over the current operation and a 46% increase over the original rated capacity of the plant.
Providing the best return on investment by reusing as much core equipment and minimizing downtime for new equipment
tie-in was the primary objective. To achieve this, the project consisted of two phases. Phase I included replacing the existing air
beam clinker cooler with a latest generation reciprocating bar cooler design, modifications to the kiln hood, a new kiln section
with air cowl and double spring plate kiln seal, a new high momentum kiln burner and modification to the tertiary air duct.
Extensive 3D modeling was used on the project in order to detect and minimize potential interferences. This provided the
company and OEM an additional tool in planning each step of the demolition and installation. It also allowed modifications to
be made to the equipment design in order to ease potential installation issues.

II. PHASE I MODIFICATIONS

1): Clinker Cooler

The highlight of the project was the replacement of the air beam cooler with the first installation of the latest generation
reciprocating bar cooler (Figure 2).
Similar to previous grate coolers, the new reciprocating bar cooler features a stationary grate line with no undergrate spillage
or conveying system, separation of the conveying and cooling systems, air distribution plates with mechanical flow regulators
and modular construction. All bars are movable and reciprocate allowing the optimization of transport efficiency and a
horizontal installation.

Fig. 2. Inside new clinker cooler

978-1-4799-3294-8/14/$31.00 2014 IEEE

Page 3 of 8 2014-CIC-0022

A fixed inlet section with controlled air blasters composed of eight grates wide by 5 rows long of stepped stationary plates
with mechanical flow regulators was installed at the feed end of the cooler. This design combines the advantages of a
stationary inlet section long service life and good cooling air distribution with the advantages off pneumatic clinker
clinke
conveying good clinker distribution and elimination of snowmen.
The inlet incorporates controlled air blasting technology as shown in Figure 3. Blast air is directed into the grate through the
same openings that the cooling air moves through. Air blasblasting
ting takes place on three levels of each grate. When the air blasters
engage, air flow from the undergrate is blocked off and the air blast is prevented ffrom
rom going into the undergrate. These blasts
reduce and/or eliminate snowmen formation.. After the inl inlet compartment, the rest of the cooler is comprised of an eight grate
wide by 56 row horizontal (equivalent grate length) grate line constructed by a series of standard units that are 4 grates wide by
7 grates long. These units come fully assembled to easease installation.

Fig. 3. Inlet provides cooling and blasting

The grate line is composed of stainless steel fabricated air distribution plates with replaceable components. The grate line is
completely stationary during operation, eliminating the need for spillage conveyors.
Each grate plate is equipped with a mechanical flow regulator (Figure 4), which is a weighted automatic air damper system
which opens and closes to adjust the cooling air pressure as the clinke
clinker bed depth changes (Figure 5). The drive plates penetrate
the grate line but are sealed by the use of profile plates which provide a labyrinth type seal to minimize air leakage around the
drive plates as well as material leakage to the undergrate compartments.

Fig. 4. Mechanical air flow regulator Fig. 5.. Constant airflow irrespective of overgrate conditions

978-1-4799-3294-8/14/$31.00 2014 IEEE

 2014-CIC-0022 Page 4 of 8

Drive plates are driven by hydraulic cylinders mounted in the under grate chambers. The conveyance of clinker is controlled
by the use of reciprocating bars which are mounted to the drive plates above the grate line. Reciprocating bars are mounted in i
place by a system of steel wedges held by pins, which will allo
allow
w for easy replacement when items wear.
The hydraulic drives are a closed-loop
loop hydraulic system. A cabinet mounted, programmable logic control system is provided
with each drive system. The power unit is preassembled on a skid including: reservoir with levlevel
el switches, temperature sensors,
oil heaters and oil filtration and cooling system. Each drive has a pump system. A standby pump was provided to allow
maintenance without shutting down any of the drive
drives.
The cooler is equipped with five cooling air fans pproviding
roviding an operational airflow of 2.3 kg air per kg clinker. Three new
fans were supplied with this project and two existing fans were reused with new ducts. Each fan supplies air to a specific under
un
grate compartment. Airflow is controlled with the use ooff an airflow device which measures, analyzes and adjusts the variable
inlet vane dampers.
The new cooler was designed to have a similar footprint to the existing cooler which allowed a majority of the cooler
support frame and cooler housing to be reused. The existing hammer breaker and vent air take-off off were also reused. Figure 6
highlights the areas of the new cooler housing.

2): Kiln Hood and Kiln Shell Section

The volume of the existing kiln hood was found to be inadequate for the new cooler and incr
increase
ease in capacity. A new,
enlarged kiln firing hood was included in the project which allowed the elimination of the separate tertiary air take-off
take from the
cooler. To allow for a larger hood to be used, th
the kiln was shortened by 2.5 ft (760 mm).

Fig. 6.. 3D Model of cooler and kiln hood modification

The last section of the kiln was replaced in order to minimize the work during the outage. The new kiln section was
predrilled for easy installation of a bolted-on
on nose ring of heat
heat-resistant,
istant, chrome nickel cast steel sections protected by a
castable refractory lining and included a new air cowl. The hood and shell sections were then fitted with a double spring-plate
kiln seal with a cloth of heat resistant material in between.

978-1-4799-3294-8/14/$31.00 2014 IEEE

Page 5 of 8 2014-CIC-0022

3): High Momentum Kiln Burner

The new hood and shell sections required a longer burner. In addition to the longer main burner pipe a new gas burner and
igniter were included in the project, as seen in Figure 7.
The OEM provided a high momentum burner with con consists
sists of a centrally located pipe in which the gas burner is placed. The
central
entral pipe is surrounded by two concentrically placed pipes forming two primary air channels, one for radial air and one for
axial air. These two primary air streams are mixed in tthe
he conical air nozzle at the end of the burner before they are injected into
the kiln.

Fig. 7. New high momentum kiln burner

The air nozzle exit area can be adjusted to alter the injection velocity of the primary air mix. Manual dampers located on the
branch pipes at the burner inlet allow an operator to adjust the distribution of axial and radial airflow in order to control the
degree of swirl for flame shaping. These adjustments may be made during burner operation.
The exposed burner
urner inserted into the kiln hood is constructed of stainless steel with the remaining length fabricated from
ASTM A36.
A new primary air fan sized for 10% of stoichiometric airflow was supplied to allow for the increased in capacity.
The existing trolley,
y, which allows adjustment of the burner nozzle in the axial, vertical and horizontal directions, and
support steel were reused.

Phase I: Erection and Commissioning Timeline

26 January 2010 Kiln shutdown for cooler modification and planned maintenan
maintenance.
1 February 2010 Contractor work begins
begins.
8 March 2010 Cold commissioning and signal testing began
began.
17 March 2010 Cooler hydraulicc system test run without load for 40 hrs
hrs.
19 March 2010 Refractory work started in cooler and kiln hood
29 March 2010 Refractory dry-out out ~ 70 hours
hours.
1 April 2010 Kiln preheat began..
2 April 2010 Cooler operation with load and stabilized at 80% production.
26 April 2010 Operating at 2,000
000 STPD (1,814 MTPD) (considered full production
uction of plant).
plant)

Phase I Results
Standard Cooler Loss 96 kcal/kg
al/kg Clinker
Cooler Efficiency 80.8 %
Cooler Fans Power Consumption Savings 20%

978-1-4799-3294-8/14/$31.00 2014 IEEE

 2014-CIC-0022 Page 6 of 8

II. PHASE II MODIFICATIONS

1): Preheater

The twin top-stage

stage cyclones of the existing plant were replaced with a 5,200 mm single cyclonee of the latest design to
achieve efficiencies in excess of 95%. The vessel is designed with a tangential inlet and carbon steel outlet thimble.
A new riser duct was required to deliver pr
process gases to the
single Stage-I cyclone. The Stage-II feed pipe was replaced with a
larger size and included a sluice flap and expansion joint.
Distribution boxes were modified or reused. Ducting from the tower
to the ID fan was also replaced. Figure 8 highlights the changes
required to the tower.
Components of the preheater were fabricated in sections for ease
of shipping, shop-assembled and match-marked
marked to ease field
assembly and erection. Structural modifications of the tower were
required on two levels to allow for the new cyclo
cyclone.
The increased collection efficiency resulted in a lower dust loss
from the tower, which lead to a slight increase in fuel efficiency and
decrease in gross feed-to-clinker
clinker ratio. This was found to be
especially advantageous as the kiln feed system was a limiting
factor in production. The new cyclone also provided a lower
pressure drop (<7 in WG) adding to power savings of the ID fan. It
also eliminated concern with balancing gas flows between the
existing twin cyclones.

2): Water Spray

With higher gas flows, a new down comer duct and water spray
system were supplied in order to ensure proper velocities and
cooling.

3): Preheater ID Fan

A new ID fan was sized to support a production increase to 22,200

STPD (2,000 MTPD)) along with the potential for future alternative
fuel firing in the calciner. The existing preheater ID fan was a
single-inlet
inlet radial fan with speed control from a fluid coupling
which provided a relatively low overall efficiency. A high
high-
efficiency, double inlet, backward inclined curcurved fan with variable
frequency drive and 2,250 HP (1,678 678 kW) motor was chosen as the
replacement.
While original plans were to use the foundation of the existing
fan, the plant personnel decided to install the new fan on a new
foundation in order to minimize ize the required work needed during
the plant shutdown.
Fig. 8.. Graphic showing changes made to preheater tower.

4): Cooler Vent Fan

The cooler vent fan was upgraded with a complete VFD package allowing for greater control of the kiln hood pressure,
leading to a more stable burning zone.

5): Material Handling

Upgrades were made to components for the kiln feed system and clinker transport in order to support the higher capacities.

978-1-4799-3294-8/14/$31.00 2014 IEEE

Page 7 of 8 2014-CIC-0022

6): Raw Mill System Modifications

In order to allow the raw mill to support the increased plant production, modifications were made to optimize the existing
mill components and bring it into good mechanical condition.
The pressure drop of the mill was minimized by increasing the louver ring area as seen in Figure 9..

Fig. 9. Raw mill louver ring modification

Roller seals were replaced with a newer design in order to decrease the false air entering the mill. Additional upgrades for
the raw mill are being investigated as it is now the bottleneck for plant capacity.

Phase II Timeline

24 March 2010 Plant meeting held to discuss permit for capacity increase.
29 April 2010 Engaged Environmental consultant to assist with Permit application
application.
4 August 2010 Submitted
ubmitted initial permit application
application.
20 May 2011 Permit approved..
27 February 2013 Shutdown of kiln
kiln.
31 March 2013 Dry-out/heat-up.
3 April 2013 Feed on kiln brought up to 22,100 STPD (1,905 MTPD)
8 November 2013 Clinker weigh test demonstrated 22,255 STPD (2,045 MTPD)

Phase II Results

Production Achieved (confirmed by drop test) 2,255 STPD

Raw Mill, Blending and Pyro Areas Average Power Savings
10.6%
(Based on 6 month periods before and after Phase II)
Fuel Consumption Savings
75 kcal/kg
al/kg Clinker
(Based on 6 month periods before and after Phase II)

978-1-4799-3294-8/14/$31.00 2014 IEEE

 2014-CIC-0022 Page 8 of 8

IV. CONCLUSION

Building on a long, successful and healthy relationship with the original equipment supplier, the Company upgraded their dry pyro process
line in San Antonio Texas. The two-phase installation of a new reciprocating bar cooler, kiln hood, kiln outlet section, high momentum
burner, top-stage cyclone, kiln ID fan, gas conditioning system and VFD added to the cooler vent fan has allowed the Company to increase
production 10% to 2,200 STPD (2,000 MTPD) and reduce fuel and power consumption.
Trust and a healthy working relationship between Supplier, Installer and Owner was the main driver for the success of this project. Other
lessons learned from the owner/operator perspective are:
Any time and effort spent in the planning stage is paid back many times over during the construction stage.
Understanding the critical path and dedicating resources accordingly will pay dividends.
Be prepared for the unexpected. Some surprises are good.

978-1-4799-3294-8/14/$31.00 2014 IEEE