INDUSTRIAL ACCESSORIES COMPANY Industrial Accessories Company is an industrial design/build and original equipment manufacturer of baghouses, flue gas desulfurization, heavy metal mitigating sorbent injection systems, dry bulk materials handling, and pneumatic conveying systems Engineered Solutions for the Cement Industry PP030 1
INDUSTRIAL ACCESSORIES COMPANY Drake Cement, LLC, located in Drake, Arizona, is one of the Southwest U.S. newest cement plants. Drake focuses exclusively on the production of Type II/V (LA) Portland cement Medium to high volatile coal is used as primary fuel IAC provided 34 baghouses, air-to-air heater exchanger, screw conveyors, rotary valves, fans, dampers, and custom steel fabrication for the project Drake Cement IAC Provides APC compliment to newest USA plant 2
The plant includes a six stage precalciner/preheater kiln with a rated capacity of 660,000 tons of clinker per year or 2,000 tons per day Drake Cement IAC Provides APC compliment to newest USA plant 3
Drake Cement must conform to very stringent emission limits. IAC provided Drake with guarantees to meet these limits Drake Cement IAC Provides APC compliment to newest USA plant 4
Several operating and pollution controls incorporated into the plant are so advanced that they are found in only a few other facilities throughout the world Drake Cement IAC provided Clinker Cooler Baghouse and Stack 5
INDUSTRIAL ACCESSORIES COMPANY Three overland conveyors with a total length of 3500 ft. transport limestone from the quarry to the plant. IAC provided Jet Pulse Filters at the discharges of the Primary Crusher and each of the three overland conveyors Drake Cement Department 1: Overland Conveyors from Quarry to Plant 6
INDUSTRIAL ACCESSORIES COMPANY The raw material consists of 72% High Limestone and 26% Low Limestone materials mined from the Drake quarry. There is a 17 day covered storage reserve equivalent to approximately 51,000 tons Drake Cement Department 1: Overland Conveyor termination Baghouse 7
Drake Cement Department 2: Transportation to Raw Material Silos 8
INDUSTRIAL ACCESSORIES COMPANY IAC provided Jet Pulse fabric filters to control dust at belt conveyor discharges and raw material and coal silos. Eight 6 m bolted steel silos store High and Low limestone, iron ore, gypsum, clinker, Bauxite and raw coal Drake Cement Department 2: Transportation to Raw Material Silos 9
Drake Cement Department 3: Raw Material, Coal and Gypsum Silos 10
Drake Cement Department 3: Baghouses atop Raw Material Silos 11
INDUSTRIAL ACCESSORIES COMPANY IAC provided a total of 31 dust handling and nuisance dust filters on the project. Each had 8 ft. long bags All were designed with 70 degree hoppers and were factory insulated to promote discharge of material, avoiding condensation effects due to dramatic shifts in the nighttime and daytime desert temperatures Drake Cement Department 3: Baghouses atop Raw Material Silos 12
INDUSTRIAL ACCESSORIES COMPANY Drake Cement has a railroad and truck discharge system to unload limestone from outside sources, as well as other raw materials and coal sourced from Colorado and neighboring Western states The plant has a 32 day reserve of clinker storage which includes a covered clinker dome of 50,000 tons and an emergency stock silo of 13,800 tons Drake Cement Department 4: Railroad and Truck Discharge Installation 13
INDUSTRIAL ACCESSORIES COMPANY Shown are IAC Jet Pulse filters for collecting dust during transfer and discharge from the belt conveyors transporting raw coal, iron ore and Bauxite from Raw Material Receiving and for the discharge of Limestone and Raw Materials from covered stockpile to blending silos Drake Cement Department 4: Railroad and Truck Discharge Installation 14
Drake Cement Department 5: Raw Material Grinding 15
INDUSTRIAL ACCESSORIES COMPANY A Raw Meal Grinding System with an output of 171 ton/hr includes high-pressure Roller Press, combined with a High Efficiency Separator configuration. Hot gases used in the crusher for drying are taken from the six stage Preheater of the kiln IAC supplied the four 2.8 m de-dusting cyclones as primary dust collection for the Raw Mill and Crusher IAC supplied its M-Pulse Jet Pulse baghouse for the final collection from the Raw Mill and the Kiln Drake Cement Department 5: Raw Material Grinding 16
Major M-Pulse baghouse product features include: Low 50 psi pulse pressure for gentle bag cleaning Unique inlet gas baffle plate design, which aids in particle collection before filter media is encountered and in gas flow distribution in each module Simplified service through easily accessed cleaning valves and controls Penthouse enclosure provides weather protection for baghouse maintenance with overhead electric hoist on monorail for lifting insulated module roof doors for ease of bag removal Long bag design, (6 and 7 meter), reducing equipment footprint and capital investment for customer Steep pyramidal hopper design for each module, which aids material flow and simplifies material collection Individual and separated inlet and outlet gas manifolds to promote even gas flow distribution into and out of each cleaning module Automation integration into centralized plant system control Drake Cement Department 5: Raw Mill / Kiln Baghouse 17
INDUSTRIAL ACCESSORIES COMPANY Combined gas flow is 350,000 Actual cubic meter/hr at 250 F from the Raw Mill and the Kiln supplied to the IAC M- Pulse baghouse for final collection After passing through the baghouse I.D. fan, the gases are directed to a 2 m diameter x 65 m tall stack provided by IAC Drake Cement Department 5: Raw Mill / Kiln Baghouse 18
INDUSTRIAL ACCESSORIES COMPANY Steep pyramidal hopper design for each module aids material flow and simplifies material collection. Each hopper is equipped with a rotary airlock valve. Each hopper is insulated to prevent cooling and condensation of moisture inside the hopper Drake Cement Department 5: Raw Mill / Kiln Baghouse 19
INDUSTRIAL ACCESSORIES COMPANY Steep M-Pulse pyramidal hopper design for each module aids material flow and simplifies material collection Each is equipped with level detection, poke-hole, cut-off gate and rotary airlock valve suitable for high temperature service equipped with rotation detector Drake Cement Department 5: Raw Mill / Kiln Baghouse 20
Drake Cement Department 6: Blending Silo 21
INDUSTRIAL ACCESSORIES COMPANY There is a three day storage reserve of raw meal held in the 9,000 ton blending and storage silo The silo has a homogenizing chamber which permits a continuous blending of the raw meal simultaneously to the silo feeding and discharge Drake Cement Department 6: Blending Silo 22
INDUSTRIAL ACCESSORIES COMPANY The Raw Meal Feeding System for the Preheater includes airslides, weighing bin with load cells, flow meter and two high belt bucket elevators (one as a standby) with a design capacity of 170 ton/hr IAC provided much of the ductwork, access towers and support steel for the Preheater for the kiln Drake Cement Department 7: Kiln Feed 23
Drake Cement Department 8: Six Stage Preheater with Calciner 24
INDUSTRIAL ACCESSORIES COMPANY The kiln is connected to a six stage Preheater Tower including a stateof-the-art low NOx Internal Line Calciner (ILC) working together with selective non-catalytic reduction (SCNR) for NOx reduction The Preheater Tower takes most of its combustion air from the kiln hood through a tertiary air duct Fuel consumption is 50-55% in the calciner and 45-50% in the kiln burner Drake Cement Department 8: Six Stage Preheater with Calciner 25
INDUSTRIAL ACCESSORIES COMPANY The rotary kiln is 3.81 m dia. x 45.7 m long, supported on 2 bases A Clinker Cooler with air beam technology is employed for the 2000 ton/day production rate The gases leaving the Cooler, going to the baghouse first pass through an Air-to-Air Heat Exchanger provided by IAC Drake Cement Department 9: Rotary Kiln 26
INDUSTRIAL ACCESSORIES COMPANY The Air-to-Air Heat Exchanger cools the hot clinker cooler vent gas prior to entering the dust collector and the vent fan During upsets, the Air-to- Air Heat Exchanger aids to protect the downstream equipment so that it stays within design temperature limits Drake Cement Department 10: Cooler Heat Exchanger and Baghouse 27
INDUSTRIAL ACCESSORIES COMPANY The tubes are shop welded to upper and lower tube sheets, with intermediate tube guides located between fan levels to guide the tubes. The lower tube sheet is welded to the frame, while the inlets of the tubes float to allow for thermal expansion The dust that drops out of the gas stream passing through the Air-to-Air Heat Exchanger is collected in a bottom hopper and transported out by a screw conveyor. At the discharge of the screw conveyor, a rotary valve minimizes false air intake before passing the dust to the subsequent conveying system Drake Cement Department 10: Air-to-Air Heat Exchanger 28
INDUSTRIAL ACCESSORIES COMPANY The exhaust gas from the clinker cooler is vented to the Air-to-Air Heat Exchanger where it passes evenly through vertical parallel tubes. Cooling is accomplished by forced convection from cross-flow fans (not shown) moving ambient air over the outer surface of the tubes The Air-to-Air Heat Exchanger reduces the temperature of the clinker cooler gas venting to the dust collecting system, thereby lowering the gas volume to be handled and fan horsepower requirements Drake Cement Department 10: Air-to-Air Heat Exchanger 29
INDUSTRIAL ACCESSORIES COMPANY IAC's M-Pulse, long bag, medium pulse pressure baghouse is designed for efficient operation and effective cleaning for this large process gas flow application of 167,000 cubic meters per hour The M-Pulse baghouse is effective for both high dust loading and high temperature service Drake Cement Department 10: Clinker Cooler Baghouse and Stack 30
INDUSTRIAL ACCESSORIES COMPANY IAC supplied both the raw mill/kiln exhaust stack and the Clinker Cooler exhaust stack. Both were equipped with multiple access levels to allow ease of maintenance of the CEMS and for safety during stack testing Raw Mill/Kiln Stack: 2 m dia. X 65 m tall Clinker Cooler Stack: 1.9 m dia. X 65 m tall Drake Cement Department 10: Clinker Cooler Baghouse and Stack 31
INDUSTRIAL ACCESSORIES COMPANY IAC provided a total of 31 dust handling and nuisance dust filters on the project. Each had 8 ft. long bags All were designed with 70 degree hoppers and were factory insulated to promote discharge of material, avoiding condensation effects due to dramatic shifts in the nighttime and daytime desert temperatures Drake Cement Department 11: Cooler Discharge Baghouse 32
INDUSTRIAL ACCESSORIES COMPANY The clinker discharged from the Cooler is transported towards the clinker dome with a hot pan conveyor which discharges the clinker either to the dome central tower or to a side belt conveyor which travels towards the emergency clinker silo Drake Cement Department 11: Clinker Transport to Clinker Dome 33
Drake Cement Department 11: Clinker Storage Dome and Emergency Silo 34
INDUSTRIAL ACCESSORIES COMPANY In order to feed the cement grinding department with clinker, an underground belt conveyor collects the clinker from either the dome or from the clinker silo This belt feeds a second belt conveyor towards the clinker silos which supply clinker and gypsum to the cement grinding department Drake Cement Department 11: Clinker Transport to Grinding 35
INDUSTRIAL ACCESSORIES COMPANY Coal is pulverized by a Vertical Mill with a capacity of 15 tons per hour. The emissions control for the mill includes an IAC Jet Pulse filter equipped with explosion relief panels. The baghouse has a walk-in plenum, is structurally reinforced and insulated Drake Cement Department 12: Coal Grinding and Pneumatic Baghouses 36
Drake Cement Department 12: Coal Grinding Baghouse 37
Drake Cement Department 13: Cement Grinding 38
INDUSTRIAL ACCESSORIES COMPANY The plant includes a Combined Grinding system consisting of a Roller Press in close circuit with a High Efficiency Separator, Dissaglomerator and Bucket Elevator to produce 100 tons per hour before being fed to a 2500 hp Ball Mill Drake Cement Department 13: Cement Grinding 39
Drake Cement Department 13: Cement Grinding Baghouses 40
INDUSTRIAL ACCESSORIES COMPANY A bucket elevator feeds the Cement Silo at a design rate of 180 ton/hr The silo has a mixing silo process discharge An IAC baghouse provides dust capture from the silo mixing air introduced into the silo Drake Cement Department 14: Cement Transport to Cement Silo 41
INDUSTRIAL ACCESSORIES COMPANY A 10,000 ton storage Cement Silo provides a five day cement stock reserve for the plant A Pneumatic Parallel Distributor with four discharge spouts then feeds the Silo IAC provided the dust filter to collect the dust and discharges it into the Silo Drake Cement Department 14: Cement Silo and Baghouse 42
INDUSTRIAL ACCESSORIES COMPANY Cement dispatch can be done simultaneously to two bulk trucks and to one bulk railcar at the same time An IAC baghouse atop the structure provides dust capture from the bucket elevator, airslide conveyor and silo discharge spouts Drake Cement Department 14: Cement Loading to Trucks and Railcars 43
INDUSTRIAL ACCESSORIES COMPANY Products and Systems: OEM Baghouse and Pneumatic Conveyor Supplier Technology for SOx, HCl and Hg Removal Fly-ash & Dry Bulk Pneumatic Conveying Systems Dry Bulk and Liquid Storage Tanks Biomass Raw Material Storage and Distribution Facilities Coal and Biomass Steam Generation for Heat and Power Process Controls Field Construction and Project Management Engineering and Design Services Assistance for Air Quality Permitting On-site Sorbent Injection and Compliance Services Annual or Semi-annual Inspection Services 44
INDUSTRIAL ACCESSORIES COMPANY Project Execution: Plant General Equipment and Facility Arrangement Plant Process and Equipment Requirements Determination Emission Compliance Requirements Determination Project Scheduling, Procurement and Delivery Management Engineering and Design Fuel and Ash Handling Equipment Supply APC and Combustion Equipment Supply Construction Activities, Rentals and On-site Management Mechanical Millwrights Pipe Fitters ASME Welders Crane Operators OSHA and MSHA Trained Field Staff Engineering and Start-up Assistance 45
THANK YOU INDUSTRIAL ACCESSORIES COMPANY 4800 LAMAR AVENUE MISSION, KANSAS 66202 800.334.7431 or 913.384.5511 Email: iaccorp@iac-intl.com 46