REITZ - Cement FIXED SIZES IN CEMENT PRODUCTION: FANS FROM REITZ.

Transcription

1 REITZ - Cement FIXED SIZES IN CEMENT PRODUCTION: FANS FROM REITZ.

2 REITZ ENHANCING PERFORMANCE IN EVERY RESPECT Dust, wear, extreme temperatures. 24-hour cement production makes maximum demands on the robustness and performance of ventilation components. REITZ fans have proven to be reliable solutions which maintain the production process, even under harsh operating conditions. This is why REITZ fans are the first choice throughout the entire process of notable plant and cement manufacturers around the world. MADE BY REITZ stands for consistent quality and maximum efficiency pursuant to the European Energy Efficiency Directive, regardless of the application and location of production A FULL RANGE MADE BY REITZ: FROM HIGH-PERFORMANCE PROCESS FANS TO STANDARD FANS FOR SIMPLE REQUIREMENTS FILTER FANS 1 RAW MILL FANS 3 PRIMARY AIR FANS 5 AIR SLIDE FANS 7 The basis for uniform air purification, use downstream of the filtering separator enables use of fans with high efficiency levels For reliable dust extraction during the milling process Optimised efficiency, single-stage design possible, for improvement of combustion processes in the kiln through optimum atomising of fuels For smooth conveyance of cement into the air slide KILN EXHAUST FANS, PREHEATERS 2 CLINKER COOLER FANS 4 SEPARATOR FANS 6 COOLER EXHAUST FANS 8 For continuous extraction of kiln and heat exchanger exhaust gases For cooling the clinker For uniform extraction during fine milling For cooler exhaust takeover following the cooling process

3 REITZ OPTIMISED FOR FUTURE CHALLENGES High levels of efficiency and long service life of ventilation components are an absolutely vital prerequisite for efficient 24h operation in the cement, lime and plaster industry. Downtimes due to unnecessary wear cost millions. Poor efficiency, inefficient control systems and poor aerodynamic design of gas-conveying system components leads to the unnecessary waste of energy. In cooperation with prestigious university institutes, technical colleges and external service providers, the REITZ development department focuses continually for this reason on the optimising of fans and their components, including with regard to their use in the system process. The assurance of a high degree of availability of fans and their components is reflected in the operational reliability and profitability of the entire process. INNOVATIVE WEAR PROTECTION MAXIMUM SERVICE LIFE IS ASSURED HIGH EFFICIENCY OVER 85%, THANKS TO OPTIMISED GEOMETRIES Modern process optimising and increasingly fine cement types have increased the importance of wear protection as a factor which impacts on the efficiency and reliability of overall production. REITZ has gained decades of experience with fans which convey solid matter, continually promoting development of special impeller geometries and effective coatings using high-performance materials for the most difficult operating conditions Advantage of REITZ: o Wear protection systems optimally adapted to process requirements o Innovative wear protection technology o High service life guarantee, reduced downtimes, minimised repair costs > Safe, efficient cement production Achieving the balance between the demands of wear protection and best-possible efficiency is the noble art of engineering. Meticulous monitoring of processes during individual production steps has enabled REITZ to adapt impeller geometries to suit process conditions. Efficiency levels of over 80% for solid matter conveying fans represent the rule rather than the exception. Efficiency levels which even exceed 85% can be realistically achieved, depending on the pressure and flow range. Advantage of REITZ: o Latest engineering plus innovative measurement techniques for process optimising of impeller geometries o High efficiency plus wear protection for efficient production procedures Special surface structures, materials and geometries minimise sticking of even abrasive solid matter and increase service lives. Basis for a high degree of efficiency: The impeller is adapted to the process and optimised right down to the last detail (high efficiency in partial load range through use of variable speed control)

4 REITZ PIONEERING FOR EFFICIENCY AND THE ENVIRONMENT Issues such as environmental protection and the reduction of emissions are growing in importance on an international level. REITZ variable speed control manages to kill several birds with a single stone as, in contrast to speed control using dampers and inlet guide vanes, the rated motor power is adapted to the respective demand to reduce energy costs and CO2 emissions by up to 30%. Pre-engineering through CFD and FEA aims to simulate operating conditions, tailor the design perfectly in advance to suit requirements and determine the potential for optimising gas-conveying system components. VARIABLE SPEED CONTROL PERFORMANCE ADJUSTMENT WITH ENORMOUS SAVINGS POTENTIAL The most convincing argument in favour of frequency converter technology is the fact that the additional expense pays off within the shortest time period. Following the amortisation phase, production plant operators persistently save up to 30% of the energy requirement for ventilation components through needs-oriented adaptation of the rated motor power. This simultaneously improves the environmental balance. (This is a particular advantage in the partial load range and is also positively reflected in the acoustic data.) Advantage of REITZ: o Needs-oriented consumption o Reduced wear o Lower noise development o Energy savings of up to 30% o Short-term amortisation of investment o Significant improvement in environmental balance (reduced CO2 emissions) PRE-ENGINEERING SETTING THE COURSE FOR SUCCESS During planning, flow simulation with CFD analyses indicates the improvement potential during plant design and the inflow and outflow situation of fans. On the one hand, improved efficiency enables the realisation of considerable energy saving potential and, on the other, even investment costs can frequently be lowered (e.g. through component reduction). Advantage of REITZ: o Optimum flow situations = energy savings o Enhancing of efficiency, also resulting in the optimising of acoustic data o Reduced investment costs Before After Ventilator Motor Frequenzumrichter + + = Max. Energieeffizienz Leistungsbedarfskurven C1 = Drosselregelung C2 = Drallregelung C3 = Drehzahlregelung PROCESS MONITORING FAULT-FREE OPERATION Measures to improve flow in the inlet duct and reduce pressure loss REITZ has developed future-oriented fan monitoring concepts to ensure smooth operation. These range from simple monitoring equipment with signalling to process control technology to online condition monitoring which enables timely initiation of maintenance measures. o Complete unbroken monitoring o Avoidance of downtimes o Above-average system availability

5 REITZ STRONG BUILDING MODELS FOR THE CEMENT INDUSTRY REITZ radial fans set standards. Designed for maximum performance, maximum availability and extreme conditions, they can reliably tackle any ventilation task in cement production. Whether primary air fans with total pressure increases of up to 4,000 dapa and air volumes of up to 75,000 m³/h for optimum atomising of fuels, or material-conveying fans with volume flows of up to 2,000,000 m³/h are involved, REITZ can supply everything from standard types to highly individual special design, providing exactly the fan types you need for smooth production. You can, of course, also obtain all necessary accessories and effective sound protection from REITZ. KXE KBA KBZ KBE MXE SPECIAL DESIGNS PERFECTLY NORMAL AT REITZ Each REITZ fan is designed to order and is, consequently, optimally adapted to suit your system. In addition, each model can be individually customised in any size and any design to meet customer requirements: o Special designs involving special steels and employing temperature-resistant and low-wear materials o Gastight designs o Shaft seal in special design o Equipping of fans with monitoring equipment o Explosion-protected design pursuant to ATEX o Pressure-resistant and pressure shockproof designs

6 REITZ MAJOR MODERNISING SUCCESS Overall, modernisation of individual components is frequently enough to make a reliable system more powerful, less susceptible to malfunction and more efficient and/or environmentally friendly. REITZ can provide support along the way, from needs analysis to planning and coordination, installation and commissioning. As an experienced specialist for system modernisation, we can assure you that all installation and repair work will be realised on schedule and with the least possible impairment of production. ADVANTAGE OF MODERNISATION GREATER POWER, FEWER FAULTS, GREATER EFFICIENCY MODERNISATION FROM A SINGLE SOURCE PLANNED AND REALISED BY REITZ o Improvements in production procedures through changing of operating parameters: fitting of additional filters, larger heat exchangers or rotary kilns, enlarging of raw mills or classifiers, expansion or modernisation of clinker coolers o Modification of system concept o Replacement of used fans or components o Energy saving through use of impellers with higher levels of efficiency o Energy saving through use of energy-efficient drive systems (variable speed control with frequency converters) MODERNISATION EXAMPLE MINOR MEASURES, MAJOR EFFECT: Each REITZ fan is designed to order and, consequently, optimally adapted to suit your system. In addition, each model can be individually customised in any size and any design to meet customer requirements: o Needs analysis through CFD, FEM and modal analysis o Planning o Dismantling o Installation o Commissioning o Monitoring o Maintenance o Impeller replacement with the blade design, impeller version and inflow nozzle appropriate for the application o Wear protection on the impeller and housing o Speed increase through frequency converters or belt drives by altering the transmission ratio, provided the dynamic limiting values of the machine are not exceeded o Replacement of fan components (e.g. bearing, shaft, coupling and belt drive) o Old fan replaced by new

7 REITZ GLOBALLY MORE SERVICE AND SUPPORT These figures demonstrate why the REITZ Group is regarded as a powerful and committed partner all around the world: more than 800 employees, 11 subsidiaries, 5 production facilities and group certificate DIN EN ISO 9001:2008 in Germany, China and India. The setup of our service network reflects this international mission. Wherever preventive servicing and maintenance is required and questions or problems arise, our service team is close at hand and can be with you at the shortest notice to provide you with advice and assistance. REITZ GROUP CONSISTENT QUALITY WORLDWIDE o 800 employees o 11 subsidiaries o 5 production facilities o Group certificate DIN EN ISO 9001:2008 REITZ SERVICES FOR YOUR OPERATIONAL RELIABILITY o planning o Installation and commissioning o Retrofitting, assembly, dismantling, repairs o Preventive maintenance and online condition monitoring o Documentation o Inspections o Advice on optimising of existing components o Measurements (flow, noise, vibration)

8 REITZ THE BENCHMARK IN STATE-OF-THE-ART SYSTEMS Because conditions encountered in cement production are harsh and make enormous demands on fans, we are proud that our products set standards in terms of efficiency, reliability and environmental protection in the latest cement, lime and earthworks. In cement production facilities from Brazil to Indochina, REITZ fans ensure smooth production and the long-term success of our customers. Exhaust fan Zementwerk, D KBZ Volume flow m 3 /h Pressure difference 841 dapa Temperature 300 ºC Design temperature 500 ºC Rated motor power kw Wellenleistung kw Housing made of S355J2G3 Impeller made of Shaft made of 42CrMo4 Cooler exhaust fan NatalCement, SA KBZ Volume flow m 3 /h Pressure difference 150 dapa Temperature 280 ºC Design temperature 350 ºC Rated motor power 200 kw Housing made of S355J2G3 Impeller made of Shaft made of 42CrMo4 Cooler ESP Fan CityCement, KSA KBZ Volume flow m 3 /h Pressure difference 230 dapa Temperature 280 ºC Design temperature 350 ºC Rated motor power 710 kw Raw mill fan Zementwerk, D KXA Volume flow m 3 /h Pressure difference 870 dapa Temperatuer 120 ºC Design temperature 180 ºC Rated motor power 500 kw Housing made of S355J2G3 Impeller made of inkl. Eurodur 3500 Verschleißauflage Shaft made of 42CrMo4 Housing made of Impeller made of Shaft made of S235JRG2 S355J2G3 inkl. Eurodur 3500 Verschleißauflage S355J2G3 EGR fan Raw mill fan Zementwerk, D KBA Volume flow m 3 /h Pressure difference 332 dapa Temperature 115 ºC Design temperature 180 ºC Rated motor power 315 kw Ambuja Cement, IN KBZ Volume flow m 3 /h Pressure difference 1200 dapa Temperature 20 ºC Design temperature 180 ºC Rated motor power 5600 kw Housing made of Impeller made of Shaft made of S355J2G3 S355J2G3 42CrMo4 Housing made of Shaft made of inkl. Eurodur 3500 Verschleißauflage 42CrMo4

9 Reitz Holding GmbH & Co. KG Konrad-Reitz-Straße 1 D Höxter-Albaxen Germany phone: +49 (5271) info@reitzgroup.com