FINEST SOLUTIONS FINEST SOLUTIONS FINEST SOLUTIONS FINEST SOLUTIONS

Unique technologies for kiln plant, raw meal

and cement grinding!

Josef KeuschniggJosef KeuschniggJosef KeuschniggJosef Keuschnigg

PM-TECHNOLOGIES

RE-ENGINEERING THE KILN PLANT

Tapping into the full kiln potentialTapping into the full kiln potentialTapping into the full kiln potentialTapping into the full kiln potential

PM-TECHNOLOGIES

cyclone stage calciner chloride-bypass & kiln inlet2-step meal chute system

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.”

BOTTLENECK ANALYSIS

When re-engineering the kiln plant, all effects of the complete kiln system must be considered.

EFFECTS AND MEASURES WHEN UPGRADING THE PLANT

Effects and measuresEffects and measuresEffects and measuresEffects and measures

PLANT UPGRADE

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

CLINKER QUALITY AND OUTPUT

- Kiln burner and cooler assessment, etc.

(in collaboration with external partners)

OPTIMISED OPERATING CONDITIONS IN LOWER PH AREA

- Reduction of dust re-circulation rate and build-ups

- Efficient chloride extraction via gas bypass system

EFFICIENT HEAT GENERATION AND HEAT TRANSFER

- Good burnout with moderate of needed calciner residence time

- Sufficient calcination at favourable calciner exit oxygen and temperature

CYCLONE STAGE OPTIMISATION

OPTIMISATION OF KILN PLANTS

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

ActivitiesActivitiesActivitiesActivities andandandand technicaltechnicaltechnicaltechnical detailsdetailsdetailsdetails

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

“Individual “Individual “Individual “Individual solutions and solutions and solutions and solutions and the attention to detail the attention to detail the attention to detail the attention to detail are are are are prerequisites prerequisites prerequisites prerequisites

when making high quality technical when making high quality technical when making high quality technical when making high quality technical modifications with a modifications with a modifications with a modifications with a

maximum remaximum remaximum remaximum re----use of the existing equipment!”use of the existing equipment!”use of the existing equipment!”use of the existing equipment!” pressure drop 17

mbar

7,6

mbar

-55%

after

∆p STAGE 1 before

MI-CFD BASED INLINE CALCINER OPTIMISATION

CalcinerCalcinerCalcinerCalciner optimisationoptimisationoptimisationoptimisation

OPTIMISATION OF KILN PLANTS

- CFD-based burner positioning

- Well chosen tertiary air inlets

Temperature oC

Oxygen (%)

FOCUS ON SIMULATION

- Position of meal inlets

- Staged meal chute systems

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

OPTIMISATION OF KILN PLANTS

REFERENCE VENEZUELA

clinker production

2880

tpd

3350

tpd

+16%

before after

PH, calciner and cyclone PH, calciner and cyclone PH, calciner and cyclone PH, calciner and cyclone optimisationoptimisationoptimisationoptimisation, reference , reference , reference , reference and resultsand resultsand resultsand results

pressure drop

Top stage

21

mbar

9,5

mbar

-55%

after

∆p STAGE 1 before

TAPPING INTO THE FULL POTENTIAL OF GRINDING SYSTEMS

Tapping into the full potential of grinding systemsTapping into the full potential of grinding systemsTapping into the full potential of grinding systemsTapping into the full potential of grinding systems

PM-TECHNOLOGIES

TAILOR-MADE OPTIMISATION CONCEPTS

“the right ball charge in combination with a perfect separation is the most wanted target during an

optimization phase.”

BOTTLENECK ANALYSIS

When re-engineering the separation system, all effects of the complete grinding system must be considered.

dynamic classifier product separationimpact hammer millultrafine classifier

CLASSICLON ® - LEADING GENERATION OF CLASSIFIER

activitiesactivitiesactivitiesactivities andandandand technicaltechnicaltechnicaltechnical detailsdetailsdetailsdetails

PM-TECHNOLOGIES

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 centrifugal force Fc

CLASSICLON® - RETRO-FIT

CLASSIFYING AND GRINDING

HIGHEST TECHNICAL STANDARD FOR EXISTING CLASSIFIERS

- based on existing classifier-housing

- 1st, 2nd or 3rd generation classifier upgrades are possible

custom made designcustom made designcustom made designcustom made design

- re-use of existing cyclone-separators

- existing fan and filter can be used further

rererere----use of existing equipment is possibleuse of existing equipment is possibleuse of existing equipment is possibleuse of existing equipment is possible

maximum economic upgrades due to maximum economic upgrades due to maximum economic upgrades due to maximum economic upgrades due to lolololowwww

modification costs for equipment and buildingmodification costs for equipment and buildingmodification costs for equipment and buildingmodification costs for equipment and building!!!!

activitiesactivitiesactivitiesactivities andandandand technicaltechnicaltechnicaltechnical detailsdetailsdetailsdetails

REFERENCE GERMANY 2009: OPTIMIZATION OF CEMENT GRINDING SHOP

- 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

ENGINEERING FOR CLASSIFYING/GRINDING PLANTS

CEM I 42,5R

(3300 cm²/g) 75 t/h

88 t/h+18%

before afterCEM I 52,5N

(4140 cm²/g)

43 t/h

68 t/h+58%

before after

CLASSIFYING AND GRINDING

activities and technical detailsactivities and technical detailsactivities and technical detailsactivities and technical details

- basic equipment: 1.700kW ball-mill (Ø3,0m) with 2nd generation classifier and 500kW roller-press

- scope of project: project coordination, detail engineering and delivery of new classifying system

MODIFICATIONS

PRODUCTION RATE AFTER SYSTEM UPGRADE

IMPACT HAMMER MILL

CLASSIFYING AND GRINDING

TECHNICAL DETAILS

- flow-optimized housing-design

- upper and lower deflector plates

to reach internal material re-circulation

for highest pre-grinding effect

patented design for highest prepatented design for highest prepatented design for highest prepatented design for highest pre----grinding effectgrinding effectgrinding effectgrinding effect

activitiesactivitiesactivitiesactivities andandandand technicaltechnicaltechnicaltechnical detailsdetailsdetailsdetails

gas inletmaterial

chargematerial + gas

outlet

- for integration in existing ball-mill systems

- retro-fit of existing hammer mills is possible

- perfect for tandem drying-grinding systems

individual solutionsindividual solutionsindividual solutionsindividual solutions

IMPACT HAMMER MILL NEW PROJECT VENEZUELA

CLASSIFYING AND GRINDING

activitiesactivitiesactivitiesactivities andandandand technicaltechnicaltechnicaltechnical detailsdetailsdetailsdetails

Clay dryClay dryClay dryClay dry----grinding systemgrinding systemgrinding systemgrinding 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

ACTIVITIES AND PRODUCTS: OVERVIEW

PM-TECHNOLOGIES

TAPPING INTO THE FULL POTENTIAL OF GRINDING SYSTEMS

GRINDING AND CLASSIFYING SYSTEMS

Neugasse 111, 8200 Gleisdorf, Austria

P: +43 / 3112 / 41990-00, M: office@pm-technologies.at, W: www.pm-technologies.at

THANKS FOR YOUR ATTENTION!