2012-09-03 pm-technologies (tapping the full kiln ... · tapping into the full kiln potential ......
TRANSCRIPT
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: [email protected], W: www.pm-technologies.at
THANKS FOR YOUR ATTENTION!