OPTIMIZATION OF KILN PLANTS

ACTIVITIES AND TECHNICAL DETAILS

CYCLONE OPTIMIZATION

TECHNICAL FEATURES
- flow-optimized entrance bend units
- enlargement of cyclone separation chambers
- modification of cyclone entrances and spirals
- re-dimensioning of dip-tubes and riser ducts
- installation of guide vanes HURRITEC GV

ADVANTAGES
- reduction of pressure drop up to 50%
- higher gas rate/performance at same pressure drop
- improved separation efficiency
- increase of capacity up to 40%
- best utilization of existing plant and buildings
OPTIMIZATION OF KILN PLANTS
activities and technical details

KEY COMPONENTS

GUIDE VANE (HURRITEC GV)

- installation in topstage and 2nd stage cyclone, directly on dip tubes
- extreme pressure drop reductions up to 50%
- energy savings, less fan power needed
- easy installation of guide vanes
- maximum production by minimum investment costs

DIP TUBE
- dip tube diameter and length are important design parameters
for best separation efficiency
- choice of material is of great importance due to the operating
and chemical conditions
- re-dimensioning and delivery of dip tubes acc. to the requirements
OPTIMIZATION OF KILN PLANTS
activities and technical details

PREHEATER ACCESSORIES

SPLASH-BOX
- splash-boxes for optimized meal dispersion and efficient heat exchange
- special design with individual internal parts for each cyclone stage
- turnable and adjustable splash-plates
- easy exchange of splash-plate

PENDULUM FLAP
- for efficient cyclone operation
- less false air in the cyclone above
- high operation reliability of equipment
- easy installation and exchange in case of maintenance

OPTIMIZATION OF KILN PLANTS

activities and technical details

UPGRADE OF EXISTING PRECALCINERS

TECHNICAL FEATURES
- installation of customer-specific mixing chambers
- prolongation of ascending and descending ducts
- integration of burners for firing of secondary fired fuels
- enlargement of existing combustion chambers
- optimization and adjustment of meal feeding into precalciner
- flow optimized entrance bend units for bottom-stage cyclones

ADVANTAGES
- best operating and mixing conditions for good burnout and calcination
- increase of retention time on targeted values
- increase of secondary fired fuels and production capacity
- custom-made solutions due to the narrow space in existing buildings
OPTIMIZATION OF KILN PLANTS
activities and technical details

KILN INLET MODIFICATION

TECHNICAL FEATURES
- optimized kiln inlet design by new housing
- enlargement of critical kiln inlet cross-section > 20%
- enlargement of kiln screen and end-section of rotary kiln
- kiln sealing pneumatically operated
- integration of chlorine bypass system
ADVANTAGES
- reduction of kiln gas velocity in critical areas
- reduction of dust re-circulation rate
- reduction of false air
- removal of bottleneck
reliable key part for stable and efficient kiln operation!
OPTIMIZATION OF KILN PLANTS
activities and technical details

2-STEP MEAL CHUTE SYSTEM

TECHNICAL FEATURES
- meal splitter with adjustable dividing plate
- partial meal chute
- main meal chute
- splash-box for main meal feed incl. special splash-plate
- splash-box for partial meal feed

ADVANTAGES
- substantial reduction of build-ups at high SO3-content
- more stable and efficient kiln operation with alternative fuels
- less maintenance required, easier manual cleaning
- additional benefit: increase in alternative fuels fired in calciner
without causing serious build-up problems in kiln riser duct
OPTIMIZATION OF KILN PLANTS
activities and technical details

CHLORINE-BYPASS SYSTEM

TECHNICAL FEATURES
- feeding of cooling air
- metered raw meal addition
- multistream quenching chamber
- large maintenance doors
- bypass gas extraction unit

ADVANTAGES
- compact design
- cooling close to extraction point
- high mixing quality by multistream quenching chamber
- good access for cleaning
- less maintenance required
OPTIMIZATION OF KILN PLANTS
activities and technical details

CLINKER COOLER DEDUSTING

TECHNICAL FEATURES
- 1 HURRITEC DT instead of two conventional cyclones
- guide vanes HURRITEC GV for lowest pressure drop
- double dip tube cyclones lined with special wear
resistant lining

RESULTS

- reduced system dimensions

- no reasonable wear in HURRITEC DTs
and fan after three years of operation
OPTIMIZATION OF KILN PLANTS
activities and technical details

550
mg/Nm

-70%
150
mg/Nm

before

after

pressure drop

- low pressure drop for energy saving

operation

residual dust

- highest separation efficiency > 98%

550
Pa

-18%

before

after

450
Pa

THANKS
FOR YOUR ATTENTION!

PM-TECHNOLOGIES GMBH
Neugasse 111, A-8200 Gleisdorf
phone: +43 / 3112 / 41990-00
fax:
+43 / 3112 / 41990-99
office@pm-technologies.at
www.pm-technologies.at

PM-TECHNOLOGIES GMBH
www.pm-technologies.at