Preheaterupgradeandcalcineroptimizationin

combinationwithpetcokeatCementicillo
Fanna,Italy
FriedrichWillitsch

Loesche India Round Table 2012

by LOESCHE GmbH

ATECWORLDWIDE

Loesche India Round Table 2012

by LOESCHE GmbH

ATECMISSION

Loesche India Round Table 2012

by LOESCHE GmbH

ATECFOCUS

Increaseofclinkerproduction(kilncapacity)
Reductionofspecificheatconsumption
Reductionofspecificpowerconsumption
Reductionofemissions(NOx,CO,dust)

Improvedkilnefficiency
Lowerproductioncosts
Environmentalprotection

Loesche India Round Table 2012

by LOESCHE GmbH

TARGETS
OFPREHEATERMODIFICATION

PRODUCTS
FORPREHEATERIMPROVEMENT
clean gas duct

gas entry

Cyclone with
lowpressuredrop&
highseparationefficiency

dip tube

Decreasedpressuredrop
ofexistingcyclones
clean gas duct
dust extraction (meal pipe)

Loesche India Round Table 2012

by LOESCHE GmbH

PRODUCTS
FORPREHEATERIMPROVEMENT

REDUCHLOR

BYPASSSYSTEM

Improvestheoperatingconditions,
ifvolatilecomponentsare
inhotmeal

AIRSTOPKILNINLETSEAL

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by LOESCHE GmbH

Compensatesthesecondary
movementofthekilncompletely

EXAMPLESOF
INSTALLATION
Preheater
Date:15.06.2005
Author:AndreaTeichtmeister
Title:ATECInstallationExamplesPREHEATER

CEMEX ASSIUTKILN2+3,EGYPT

ProjectPeriod:8months
ShutDown:39days

ModificationonPreheater&Calciner
Disassemblyofpreheaterequipmentexcept
Cycloneconestage2&4
Mealpipesstage2&4
Installationofnewpreheaterequipment
Extensionexisting2stringcalciner
Newhotgasduct

Results:
Productionincreasefrom4000to4500t/d
withashutdownofonly39days!!!

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by LOESCHE GmbH

Loesche India Round Table 2012

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by LOESCHE GmbH

CEMEX ASSIUTKILN2+3,EGYPT

WIETERSDORFER&PEGGAUER

DESCRIPTION:
AIM:
DESCRIPTION:

W&P
WIETERSDORFER&PEGGAUER

Wietersdorf/Austria

A465.E.WUP.W1

STARTUP:
PRODUCTION:

projectstatus
1,400t/d

ConversionofaLEPOLkiln(Original:POLYSIUS)toanew
5stagecyclonepreheaterkilnwithprecalcination
IncreaseofProductionfrom1,000to1,400t/d
SignificantpartsoftheLEPOLkilnwillpersistandwillbeinvolvedfor
thesystemofthenew5stagecyclonepreheaterwithcalcinerand
tertiaryairduct.Theorderforthisproject designandafterreceipt
oflegalUVPapprovalalsoexecution hasbeenawardedtothe
companyintheframeofworksrenewalandcapacityextensionof
theW&Pplant.
Usingthenewpreheaterconcept,theproductioninthefirststep
willbeincreasedfrom1,000to1,400t/d.Thenewtechnicalconcept
alsoincludesamaximumflexibilityfortheuseofdifferentfuels.
Thestartupofthenewplantisscheduledforautumn2005.

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by LOESCHE GmbH

GROUP:
CLIENT:
PLANT/COUNTRY:

PRODUCTION:

2000t/d

USINGOFALTERNATIVEFUEL:

95%

Nox EMISSION:

450mg/Nm3

ALTERNATIVEFUELS:

TIRES,RUBBER,SEWAGESLUDGE(WET,DRY),
SORTEDDOMESTICWASTE,
REJECTFROMPAPER&PRODUCTION

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CURRENTSITUATION

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FINALINSTALLATION

HOLCIM UNTERVAZ/CH
GROUP:
CLIENT:
PLANT/COUNTRY:

HOLCIM
HOLCIM(Schweiz)AG
Untervaz/Switzerland

DESCRIPTION:

Completemodificationof4stagepreheatertower(Original:KHD) with
additionalNEWTOPSTAGE

AIM:

Increaseofclinkerproduction
Reductionofpreheaterexhaustgastemperature
Reductionofspecificheatconsumption
RetainingexistingpreheaterIDfan

A419.E.UNT.U1

STARTUP:
PRODUCTION:

2003
2,100t/d

topstage0

stage1

stage2
furtherupgrades

Loesche India Round Table 2012

Installationof2unitsHURRICLON 2800CTfornewtopstage0
Newriserducts,mealpipes,splashboxes,expansionjointsandpendulumflaps
Modificationofexistinghotgasductbetweennewtopstage0andcoolingtower
Modificationofexistingcyclones,newcyclonetopsections,the cylindricalSectionsand
extensionoftheconicalsections
Newriserductsandexpansionjoints
Increaseofdiptubes
Modificationofhotgasductingcoalmill
Modificationofrawmealfeed
Disassemblyofwasteheatboiler

14

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INSTALLATION/MODIFICATION:

PROJECTLAYOUT

Loesche India Round Table 2012

HOLCIM
HOLCIM(Schweiz)AG
Untervaz/Switzerland

A419.E.UNT.U1

STARTUP:
PRODUCTION:

2003
2,100t/d

15

by LOESCHE GmbH

GROUP:
CLIENT:
PLANT/COUNTRY:

RESULTS
HOLCIM
HOLCIM(Schweiz)AG
Untervaz/Switzerland

RESULTS/REALIZEDPARAMETERS

A419.E.UNT.U1

STARTUP:
PRODUCTION:

2003
2,100t/d

BEFORE
MODIFICATION

AFTER
MODIFICATION

4stagepreheater

5stagepreheater

GasQuantity:

380,000Am/h

380,000Am/h

RawMillFeed:

130t/h

140t/h

ClinkerProduction:
GasTemperature:
PressureDropbeforeCoolingTower:
Spec.HeatConsumption

Loesche India Round Table 2012

1,950t/d
410C
7,300Pa
790kcal/kgcl
(3,305kJ/kgcl)

2,000t/d
360C
7,300Pa
760kcal/kgcl
(3,180kJ/kgcl)

16

by LOESCHE GmbH

GROUP:
CLIENT:
PLANT/COUNTRY:

CEMEX SARABURI/THAILAND
GROUP:

CEMEX

CLIENT:
PLANT/COUNTRY:

CEMEX
Saraburi(kilnline1&2)/Thailand

RESULTS/REALIZEDPARAMETERS
GasQuantity:
RawMillFeed:
ClinkerProduction:
GasTemperature:
PressureDropofTopStageCyclone
Kilnline1:
Kilnline2:

A322.T.SAR.S2
A282.T.SAR.S3

STARTUP:
PRODUCTION:

BEFORE
MODIFICATION
175,000Am/h
56t/h
1,300t/d
360C
1,000Pa
1,000Pa

2000
1,300t/d
AFTER
MODIFICATION
175,000Am
56t/h
1,300t/d
360C
628Pa
610Pa

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InstallationofHurrivane

COLACEM RASSINA/ITALY
GROUP:
CLIENT:
PLANT/COUNTRY:

COLACEM
COLACEM
Rassina/Italy

A233.E.COL.R1

STARTUP:
PRODUCTION:

1999
2,750t/d

Modificationof4stagepreheatertower(Original:PSP)
DESCRIPTION:
Increaseofcapacity
AIM:
SITUATIONBEFOREMODIFICATION:
4stagepreheaterwith4cyclonesattopstage
Clinkerproduction:
2,450t/d
nd
Pressuredropoftopand2 stage:
3,700Pa
PowerconsumptionofIDfan:
1,200kWh

INSTALLATION/MODIFICATION:
2unitsHURRICLON 3700CTattopstage
2unitsHURRIVANE 2650mm&modificationofcyclonesat2nd stage

PARAMETERSGUARANTEED:
Pressuredropoftopand2nd stage:

2,100Pa

Pressuredropoftopand2nd stage:
PowerconsumptionofIDfan:
Energysaving
Increaseofclinkerproductionto
Loesche India Round Table 2012

1,600Pa
850kW
2,800,000kWh/yearor
2,750t/d(max.3,170t/d)
18

by LOESCHE GmbH

PARAMETERSREALIZED:

HOLCIM APAXCO/MEXICO
GROUP:
CLIENT:
PLANT/COUNTRY:

HOLCIM
CEMENTOSAPASCO
Apaxco(Kiln1)/Mexico

A437.E.APA.H1

STARTUP:
PRODUCTION:

2003
1,886t/d

Modificationof4stageDOPOLpreheater(Original:POLYSIUS)
withadditionalNEWTOPSTAGE(stage0)
AIM:
Increaseofclinkerproduction&separationefficiency
Reductionofpreheaterexhaustgastemperature
Reductionofspecificheatconsumption&exitgastemperature
SITUATIONBEFOREMODIFICATION:
4stagepreheater
Clinkerproduction:
1,610t/d
Heatconsumption:
881kcal/kgcl(3688kJ/kgcl)
Separationefficiency(topstage):
80.8%
Staticpressure:
9100Pa
Exitgastemperature:
390C
INSTALLATION/MODIFICATION:
2unitsHURRICLON atnewtopstage0
Modificationoflowerstagescyclonesinlet,involutesanddiptube
Modificationoflowstagesriserductanddowncomerduct
PARAMETERSGUARANTEED:
Clinkerproduction:1,710t/d(+6%)
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19

by LOESCHE GmbH

DESCRIPTION:

RESULTS
HOLCIM
CEMENTOSAPASCO
Apaxco(Kiln1)/Mexico

RESULTS/REALIZEDPARAMETERS

ClinkerProduction:

(+17%)

A437.E.APA.H1

STARTUP:
PRODUCTION:

2003
1,886t/d

BEFORE
MODIFICATION

AFTER
MODIFICATION

4stagepreheater

5stagepreheater

1,610t/d

1,886t/d

ExitGasTemperature:

390C

317C

Spec.HeatConsumption:

881kcal/kgcl

805kcal/kgcl

Separationefficiency(topstage):
StaticPressure:
StaticPressure(newtopstage0):

81%
9,100Pa

88% *)
8,200Pa*)
1,200Pa*)

*)at1,886t/dClinkerProduction

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by LOESCHE GmbH

GROUP:
CLIENT:
PLANT/COUNTRY:

FINALINSTALLATION

Loesche India Round Table 2012

HOLCIM
CEMENTOSAPASCO
Apaxco(Kiln1)/Mexico

A437.E.APA.H1

STARTUP:
PRODUCTION:

2003
1,886t/d

21

by LOESCHE GmbH

GROUP:
CLIENT:
PLANT/COUNTRY:

Cementizilloplant
upgradingfrom
1.700tpdto2.400
inFanna
Date:September2005
Author:DIWolfgangFreimann

TARGETS
OFTHEPROJECT

Increasedkilncapacity
Useof100%petcoke

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23

by LOESCHE GmbH

ReductionoftheNOx emission

SITUATION
BEFOREMODIFICATION

Limitationswerefound
Clinkercoolercapacity
Fuelgrindingplant
Thermalloadofkiln
Preheaterretentiontime
Rawgrindingplant
Exhaustgashandling
&dedustingplant

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by LOESCHE GmbH

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by LOESCHE GmbH

FINALINSTALLATION

GENERALDESCRIPTION

Clinkercoolermodification
Newcoalgrindingplant
Newtertiaryairduct
Kilnshortening
Newkilninletsealing
NewlowNOx calciner
Preheatermodification
Newhotgasduct
Newpreheaterfan
Newrawmill

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by LOESCHE GmbH

Newbagfilter

DETAILEDDESCRIPTION

Installationoftertiaryairducttoreducevelocityatkilninlet
Tertiaryairdividedinto3ducts

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Allducts separatetertiaryaircontrolgate

DETAILEDDESCRIPTION

3rd tertiaryairintake
2nd calcinerburner
2nd tertiaryairintake

tertiaryairintake

Loesche India Round Table 2012

1st calciner
burner

28

by LOESCHE GmbH

1st

DETAILEDDESCRIPTION

Cutofkilnbyapprox.1,5meter
Moveofexistingkilninletchamber

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InstallationofnewAIRSTOP kilninletsealing

DETAILEDDESCRIPTION

Installationofnewriserduct
Installationofnewhotgasduct

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Installationofnewpreheaterfan

ERECTION

Erectionofcompletely
galvanizedsteelstructure

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Mainpartserectedduring
normalkilnoperation!!!

ERECTION

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Duringkilnstopperiod
Connectionoftertiaryairducttocooler
Kilncutting&movingkilninletchamber
Connectionofcalcinertokilninletchamber
Modificationworksinpreheatertower
Connectionofpreheaterfantoexhaustgashandling
Refractoryliningofremainingparts

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CONCLUSION

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ATECWORLDWIDE

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ATECWORLDWIDE

THANKYOU
FORYOUR
ATTENTION!