Beruflich Dokumente
Kultur Dokumente
By Wolfgang Pajonke and Matthias Mersmann, KHD Humboldt Wedag AG, Germany
A Flexible Strategy to Meet Market Demands Investment Limitations and Sales Opportunities
In a market situation like in Russia, it is not so easy to find the right balance between satisfying the market demands and overrunning the investment possibilities. Modification of kiln plants, rather than building new ones, is the more realistic way to match sales opportunities to investment limitations. A stepwise approach to increased production and plant availability levels out investment and pay back. The robust machinery utilised in the cement industry allows to keep older equipment in use, even within modified plants forming new process technology. Apart from process relevant modernisation aspects, there is, of course, always the need to check the structural condition of the plant. The following theoretical example illustrates from the process point of view, the sequential upgrading of a typical Russian kiln line, consisting of a long wet kiln (D=4,8 m, L/D= 36) and a grate cooler. The production of this exemplary plant shall be 2000 tclionker/d at a specific heat consumption of 5000 kJ/kgclinker (as can be seen in table 1).
Cooler Modification
The grate coolers of the 1970s were designed to be operated at a specific grate load of around or below 30 tons of clinker per day and square meter. Todays modern cooler technology allows to raise this parameter up to around 50 t/(dm2) at even higher availability and efficiency. Hence, the typical Russian grate coolers hold strong potential for a modernisation, because the existing grate area can handle a considerably larger production what makes expensive replacement of civil structures and transport devices unnecessary. Retrofitted with features like stationary inlet section and controlled aeration devices, part of the production increase can be generated by the modified cooler itself. By raising the recuperation efficiency from 60 to 75 %, as shown in this example, the fume gas flow the kiln can be reduced. This not only puts fan capacity on disposal for a higher production, but it also reduces the specific thermal heat consumption at the same time. As can be seen in table 1, the production of our exemplary plant has now been raised by 7 % to 3750 t/d, while the specific heat consumption has been lowered accordingly down to 3070 kJ/kg cli . Even stronger argumentation for a cooler retrofit comes at last when further production increase is targeted. In this case, additional grate surface comes together with higher efficiency and availability.
Benefit in Production
before Modification Preheater Cooler Tert. Air Duct after this step accumulated before
% + 75 +7 + 73
% + 75 + 88 + 225
% - 34 -8 -3
% - 34 - 39 - 41
picture 1: The PYROTOP compact swirl chamber serves for efficient mixing and burn-out
References
KHD Humboldt Wedag looks back at a history of more than 140 years delivering equipment and machinery to the process industry. Besides complete new plants, tailor-made plant modifications have always been integral part of the companys business. From the comprehensive reference-list, some of the latest examples shall be given below.
table 2: Comparison of efficiency data of the Rdersdorf lines 3 and 4 before and after retrofit of stationary inlet sections.
shell, the kiln was not just shortened, but actually re-engineered(see
picture 2). The mechanical strength properties of all tube sections have been checked for suitability not only in their present, but also in their possible future positions.
picture 2: schematic view of the kiln shortening of the Gorazdze plant. Roller stations have been kept in use
picture 3: View of the nye plant in Turkey with its new preheater