INDUSTRIAL ACCESSORIES COMPANY · 2016-03-28 · Calciner (ILC) working together with selective non-catalytic reduction (SCNR) for NOx reduction The Preheater Tower takes most of

INDUSTRIAL ACCESSORIES COMPANY

Engineered Solutions for the Cement Industrywww.iac-intl.com

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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

PP030


Drake Cement – IAC Provides APC compliment to newest USA plantwww.iac-intl.com

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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


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The plant includes a six stage precalciner/preheaterkiln with a rated capacity of 660,000 tons of clinker per year or 2,000 tons per day


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Drake Cement must conform to very stringent emission limits. IAC provided Drake with guarantees to meet these limits

Drake Cement – IAC provided Clinker Cooler Baghouse and Stackwww.iac-intl.com

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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 – Department 1: Overland Conveyors from Quarry to Plantwww.iac-intl.com

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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 Conveyor termination Baghousewww.iac-intl.com

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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 2: Transportation to Raw Material Siloswww.iac-intl.com

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INDUSTRIAL ACCESSORIES

COMPANY

Drake Cement – Department 2: Transportation to Raw Material Siloswww.iac-intl.com

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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 3: Raw Material, Coal and Gypsum Siloswww.iac-intl.com

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Drake Cement – Department 3: Baghouses atop Raw Material Siloswww.iac-intl.com

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COMPANY

Drake Cement – Department 3: Baghouses atop Raw Material Siloswww.iac-intl.com

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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 4: Railroad and Truck Discharge Installationwww.iac-intl.com

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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


COMPANY

Drake Cement – Department 4: Railroad and Truck Discharge Installationwww.iac-intl.com

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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 5: Raw Material Grindingwww.iac-intl.com

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Drake Cement – Department 5: Raw Material Grindingwww.iac-intl.com

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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 Mill / Kiln Baghousewww.iac-intl.com

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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


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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



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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


COMPANY


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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 6: Blending Silowww.iac-intl.com

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COMPANY

Drake Cement – Department 6: Blending Silowww.iac-intl.com

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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


COMPANY

Drake Cement – Department 7: Kiln Feedwww.iac-intl.com

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The Raw Meal Feeding System for the Preheaterincludes 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 8: Six Stage Preheater with Calcinerwww.iac-intl.com

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COMPANY

Drake Cement – Department 8: Six Stage Preheater with Calcinerwww.iac-intl.com

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The kiln is connected to a six stage Preheater Tower including a “state-of-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


COMPANY

Drake Cement – Department 9: Rotary Kilnwww.iac-intl.com

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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


COMPANY

Drake Cement – Department 10: Cooler Heat Exchanger and Baghousewww.iac-intl.com

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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


COMPANY

Drake Cement – Department 10: Air-to-Air Heat Exchangerwww.iac-intl.com

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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


COMPANY

Drake Cement – Department 10: Air-to-Air Heat Exchangerwww.iac-intl.com

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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


COMPANY

Drake Cement – Department 10: Clinker Cooler Baghouse and Stackwww.iac-intl.com

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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 baghouseis effective for both high dust loading and high temperature service


COMPANY

Drake Cement – Department 10: Clinker Cooler Baghouse and Stackwww.iac-intl.com

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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


COMPANY

Drake Cement – Department 11: Cooler Discharge Baghousewww.iac-intl.com

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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: Clinker Transport to Clinker Domewww.iac-intl.com

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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 Storage Dome and Emergency Silowww.iac-intl.com

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Drake Cement – Department 11: Clinker Transport to Grindingwww.iac-intl.com

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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 12: Coal Grinding and Pneumatic Baghouseswww.iac-intl.com

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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 Baghousewww.iac-intl.com

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Drake Cement – Department 13: Cement Grindingwww.iac-intl.com

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COMPANY

Drake Cement – Department 13: Cement Grindingwww.iac-intl.com

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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 Baghouseswww.iac-intl.com

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COMPANY

Drake Cement – Department 14: Cement Transport to Cement Silowww.iac-intl.com

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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 baghouseprovides dust capture

from the silo mixing air introduced into the silo


Drake Cement – Department 14: Cement Silo and Baghousewww.iac-intl.com

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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


COMPANY

Drake Cement – Department 14: Cement Loading to Trucks and Railcarswww.iac-intl.com

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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

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

www.iac-intl.com44

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

www.iac-intl.com45

THANK YOUINDUSTRIAL ACCESSORIES COMPANY

4800 LAMAR AVENUE

MISSION, KANSAS 66202

800.334.7431 or 913.384.5511

Email: [email protected]

www.iac-intl.com46

Documents

INDUSTRIAL ACCESSORIES COMPANY · 2016-03-28 · Calciner (ILC) working together with selective non-catalytic reduction (SCNR) for NOx reduction The Preheater Tower takes most of