Optimisation of kiln plant
Transcription
Optimisation of kiln plant
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/Nm³ -70% 150 mg/Nm³ 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 [email protected] www.pm-technologies.at PM-TECHNOLOGIES GMBH www.pm-technologies.at