PM-TECHNOLOGIES. FINEST SOLUTIONS Unique technologies for kiln plant, raw meal and cement grinding! Josef Keuschnigg

Transcription

1 PM-TECHNOLOGIES FINEST SOLUTIONS Unique technologies for kiln plant, raw meal and cement grinding! Josef Keuschnigg

2 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 calciner 2-step meal chute system chloride-bypass & kiln inlet PM-TECHNOLOGIES Tapping into the full kiln potential

3 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

4 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 - 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 re-use of the existing equipment! pressure drop 17 mbar p STAGE 1 before -55% 7,6 mbar after OPTIMISATION OF KILN PLANTS Activities and technical details

5 MI-CFD BASED INLINE CALCINER OPTIMISATION FOCUS ON SIMULATION - CFD-based burner positioning - Position of meal inlets - Well chosen tertiary air inlets - Staged meal chute systems Oxygen (%) Temperature o C OPTIMISATION OF KILN PLANTS Calciner optimisation

6 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 - volumetric load of kiln: up to 5,4tpd/m³ pressure drop Top stage 21 mbar p STAGE 1 before -55% 9,5 mbar after clinker production +16% 2880 tpd before 3350 tpd after OPTIMISATION OF KILN PLANTS PH, calciner and cyclone optimisation,, reference and results

7 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 impact hammer mill product separation PM-TECHNOLOGIES Tapping into the full potential of grinding systems

8 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 F d centrifugal force F c PM-TECHNOLOGIES activities and technical details

9 CLASSICLON - RETRO-FIT HIGHEST TECHNICAL STANDARD FOR EXISTING CLASSIFIERS custom made design - based on existing classifier-housing - 1 st, 2 nd or 3 rd generation classifier upgrades are possible re-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 modification costs for equipment and building! CLASSIFYING AND GRINDING activities and technical details

10 ENGINEERING FOR CLASSIFYING/GRINDING PLANTS REFERENCE GERMANY 2009: OPTIMIZATION OF CEMENT GRINDING SHOP - basic equipment: 1.700kW ball-mill (Ø3,0m) with 2 nd 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 2 nd grinding chamber and adapted ball-charge - improved roller press efficiency due to better operation conditions PRODUCTION RATE AFTER SYSTEM UPGRADE CEM I 52,5N (4140 cm²/g) +58% 43 t/h before 68 t/h after CEM I 42,5R (3300 cm²/g) +18% 75 t/h before 88 t/h after CLASSIFYING AND GRINDING activities and technical details

11 IMPACT HAMMER MILL gas inlet material charge material + gas outlet TECHNICAL DETAILS patented design for highest pre-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

12 IMPACT HAMMER MILL NEW PROJECT VENEZUELA Clay dry-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

13 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 / , M: office@pm-technologies.at, W: