16 Josef Keuschnigg

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FINEST SOLUTIONS FINEST SOLUTIONS FINEST SOLUTIONS FINEST SOLUTIONS

Unique technologies for kiln plant, raw meal and cement grinding!

Josef Keuschnigg Josef Keuschnigg Josef Keuschnigg Josef Keuschnigg

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RE-ENGINEERING THE KILN PLANT

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

PM-TECHNOLOGIES

cyclone stage calciner 2-step meal chute system chloride-bypass & kiln inlet

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

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EFFECTS AND MEASURES WHEN UPGRADING THE PLANT

Effects and measures Effects and measures Effects and measures Effects 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

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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

Activities Activities Activities

Activities andandandand technicaltechnicaltechnical detailstechnicaldetailsdetailsdetails

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 the attention to detail solutions and the attention to detail the attention to detail the attention to detail are are are prerequisites are 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 re

maximum re maximum re

maximum re----use of the existing equipment!”use of the existing equipment!”use of the existing equipment!”use of the existing equipment!” pre

s s u re d ro p 17 mbar 7,6 mbar -55% after ∆p STAGE 1 before

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MI-CFD BASED INLINE CALCINER OPTIMISATION

Calciner Calciner Calciner

Calciner optimisationoptimisationoptimisationoptimisation

- CFD-based burner positioning - Well chosen tertiary air inlets

Temperature o_C

Oxygen (%)

FOCUS ON SIMULATION

- Position of meal inlets

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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

REFERENCE VENEZUELA

c lin k e r p ro d u c ti o n 2880 tpd 3350 tpd +16% before after

PH, calciner and cyclone PH, calciner and cyclone PH, calciner and cyclone

PH, calciner and cyclone optimisationoptimisationoptimisation, reference optimisation, reference , reference and results, reference and resultsand resultsand results

p re s s u re d ro p T o p s ta g e 21 mbar 9,5 mbar -55% after ∆p STAGE 1 before

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TAPPING INTO THE FULL POTENTIAL OF GRINDING SYSTEMS

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

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CLASSICLON

®

_{- LEADING GENERATION OF CLASSIFIER}

activities activities activities

activities 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

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CLASSICLON

®

_{- RETRO-FIT}

CLASSIFYING AND GRINDING

HIGHEST TECHNICAL STANDARD FOR EXISTING CLASSIFIERS

- based on existing classifier-housing

- 1st_{, 2}nd _{or 3}rd _{generation classifier upgrades are possible}

custom made design custom made designcustom made design custom made design

- re-use of existing cyclone-separators - existing fan and filter can be used further re

rere

re----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 lololowlowww modification costs for equipment and building modification costs for equipment and buildingmodification costs for equipment and building modification costs for equipment and building!!!!

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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

C E M I 4 2 ,5 R (3 3 0 0 c m² /g ) _{75 t/h} 88 t/h +18% before after C E M I 5 2 ,5 N (4 14 0 c m² /g ) 43 t/h 68 t/h +58% before after

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

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IMPACT HAMMER MILL

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 pre patented design for highest prepatented design for highest pre

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

activities andandandand technicaltechnicaltechnicaltechnical detailsdetailsdetailsdetails

gas inlet

material

charge

material + gas

outlet

- for integration in existing ball-mill systems - retro-fit of existing hammer mills is possible - perfect for tandem drying-grinding systems individual solutions

individual solutionsindividual solutions individual solutions

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IMPACT HAMMER MILL NEW PROJECT VENEZUELA

activities andandandand technicaltechnicaltechnicaltechnical detailsdetailsdetailsdetails Clay dry

Clay dryClay dry

Clay 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

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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: [email protected], W: www.pm-technologies.at