Rotary Equipment

machinery + plant
construction
Foundry
wind power
systems + Components
Rotary Equipment
We know our way around
Machinery + Plant construction
Rotary equipment has been manufactured on the
Stassfur t site since 1863. When potash mining
began – the first potash shaft in Stassfurt was sunk in
1852 – the company of Gustav Sauerbrey was
established to develop specialised equipment for the
processing and refinement of the crude salt, which was
then manufactured on its own production site.
Almost 150 years of expertise and upgrading have
since been invested in the design and manufacture of
Rotary Equipment
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Quality Assurance to DIN ISO EN 9001:2000
Approved Welding Company to EN 729 and
Pressure Equipment Directive Annex 1, Sect.
3 in conjunction with EN 729-2
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Comprehensive Certificate of Qualification
for Welding Jobs to DIN 18800 / Part 7
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Approved Company pursuant to the Federal
Water Management Act (WHG) Para. 19
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Approved Melting Shop to WH0
AD2000 – HP0 Bulletin
and many other types of process equipment.
Following an asset deal in 2005, EMDE IndustrieTechnik GmbH has been continuing operations at
the plant. We aim to strengthen this newly acquired
mainstay of our business through innovation, and look
forward to further expansion in the future.
The exacting quality specifications of the market
can only be met by highly-qualified and experienced
technical staff. We are well-placed in this respect,
thanks to our outgoing training and re-qualification
programme for our employees, who between them
have many years of service with the company.
Quality assurance complies with European standard
DIN ISO EN 9001:2000 as well as with many other
international standards.
The first salt-drying plant,
supplied to the Siegfried-Giesen
works, Hildesheim
Mobile grain and beet leaf dryer,
supplied to Lt. Müller at the
Neuglücker Werke and Rittergut
Klosteroda
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Rotary dryer,
1.6 m diameter, 8 m long,
for potash salts and
agricultural materials
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machinery + plant construction
Rotary Equipment
Rotary equipment is used in many industries and
processes:
can be used for a wide range of applications:
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Drying
Tempering
Cooling
Calcining
Tumbling
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Potash / Soda Production
Waste Incineration
Basic Chemistry
Non-Metallic Minerals
Cement Industry
Our extensive manufacturing capacity and largescale machinery mean that even very sizeable rotary
equipment can be manufactured:
Annealing
Your wishes and any special product requirements will
of course be reflected in the design of the equipment.
If no empirical values or existing designs are available, design tests will be carried out at institutes with
which we have enjoyed close ties for many years, thus
enabling us to try out new technology and develop
existing processes. Trials to develop new products are
carried out in test facilities.
Length:
up to 60 m
Diameter:
up to 5.5 m
Weight: up to 160 t
We are happy to organise heavy transportation as one
of our services.
Site erection and commissioning are carried out by our
own trained and experienced technical staff wherever
you are in the world.
Rotary equipment
ready for shipping
Loading rotary equipment
on board for an
export customer
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Road transportation of a
steam tube calciner
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Machinery + Plant construction
Rotary Dryers
Rotary dryers with various internals are used to dry
moist bulk solids (crystals, granules, powder, etc.).
These internals are designed specifically with the
chemical and physical characteristics of the product
in mind. The material used for the kiln shell can also be
adapted accordingly. This allows for great versatility.
When drying through indirect heat exchange, the dryer
is fitted with tubes or a double shell.
Drying Media:
– Hot water
– Thermo oil
– Hot gases
– Steam
– Air
Internals:
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Special Cruciform Arrangements mean High
Specific Evaporation
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The Solids are Distributed evenly throughout
the Dryer
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The Dryer has a Long Service Life,
because it Benefits from being Designed
and Assembled for its Specific Purpose
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Excellent Quiet Operation,
because Coordinated Materials are used
for the Drive
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High Throughput Rate
Folding Flights
Fixed Flights
Cruciform Arrangements
Baffles
Tubes
Optimum Availability
Gentle Treatment of the Product
Nominal Diameter: 1,200 – 5,000 mm
Length:
5,000 – 30,000 mm
Speed: 0,1 – 10 rpm
Material:
Chrome-nickel steels
Carbon steels
Cross-section of a
wood chip dryer
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Dispatching
wood chip dryers
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Dryer for
agricultural products
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machinery + plant construction
Rotary kilns are used for the heat treatment, pyrolisis,
combustion or incineration of a wide range of materials.
Where smouldering processes are used, the resulting
gases are recycled as fuel gas. We also supply the
peripheral technology.
The kiln shell is usually fabricated from high-temperature or heat-resistant steel, and is bricklined, but
stainless steel can also be used.
Rotary Kilns
Length: up to 60 m
Diameter:
up to 5.50 m
Temperature: Max. 1,000 °C / 1,832 °F
in the combustion
area
Options:
– Externally-heated kilns
– Speed regulation via
frequency controlled drives
– Internals which increase the
heat exchange area
are characterised by low wear, high corrosion
resistance, low servicing and maintenance costs, high
production rates and good reliability. They are highly
efficient as a result of high hot-gas input temperatures.
Another major advantage is the gentle machanical
treatment of the bulk solids thanks to special
internals.
The kiln is fired with a gas or oil burner, which can be
supplied on request. Indirect heating by steam tubes
is also possible.
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Transporting a rotary kiln
Assembly on site of a
rotary kiln supplied in parts
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Delivery and installation
of an expanded clay kiln
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Machinery + Plant construction
Steam Tube Calciners
Steam calcination systems are generally manufactured
by EMDE to meet the specific needs of the project. All
of the process parameters, as well as the technical
dimensions of the equipment, are calculated to meet
the customer‘s requirements and designed individually
depending on use.
A customisation approach is the only way to ensure
cost-effecitve manufacture and optimum energy use
by the equipment.
Components of a Steam Tube Calciner:
– Steam tube calciner
– Conveyor diveces: Feed and discharge equipment
Flat belt conveyor, screws, star wheels
– Optional: Mixers
Single and twin-shaft mixers
– Optional: Cyclones
Dust removal from calcination gases
At EMDE, a half-century of experience in the manufacture of steam calciners goes hand in hand with the
latest in-house refinements.
The steam tube calciner is a rotary dryer in which there
is heat exchange between condensing water vapour
and moist bulk solids. Steam-heated finned tubes are
fitted internally for this purpose.
To save energy, the rotary dryer is completely heatinsulated.
EMDE can manufacture steam tube calciners to any
size the customer requests.
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High Capacity
Energy-Efficient
Optimum Availability
High Level of Automation
Rapid Start-Up and Shutdown
Dispatching a
steam tube calciner
Calciner with internal
soda recirculation
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Erection of five
tube calciners
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machinery + plant construction
The robust roller stations and the drive, which is
designed for continuous operation, provide the
necessary conditions for trouble-free operation.
Drive Stations and Riding Rings
All rotary equipment manufactured by EMDE has drives
consisting of girth gears and pinions or chain drives
and a suitably dimensioned motor/gear combination
with appropriate power reserves. The shell is fitted
with riding rings. The number of roller stations varies
between two and four, depending on the length of the
shell. The width of the riding ring and the combination
of materials used for riding ring and support roller are
also dependent on the length of the equipment and
its operating weight (weight of cylinder + contents).
Power is transmitted via claw, curved teeth or hydraulic
couplings.
The particularly wear-resistant riding rings of EMDE
rotary equipment are made steel castings that are
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Shrink-Fitted
Wedge-Mounted
Welded
Bolted
Affixed in a Floating Mount
to the shell.
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Machining of a
riding ring for a calciner
Roller station of a
steam tube calciner
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Shop trial assembly
of two calciners
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Machinery + Plant construction
Rotary Tube Coolers
are used to cool fine-grained, free flowing bulk solids.
A rotary cooler essentially comprises a cylinder with
an inbuilt cooling system consisting of either smooth
or finned tubes, depending on the amount of heat to
be discharged.
As the bulk solids travel through the rotating shell, their
heat is transferred to the cooling medium in the tubes.
This cooling medium may be in either liquid or gaseous
form. The medium can flow through the tube system in
either a parallel or a counter-current direction.
The cooling media enter and leave the tubes and cooling
jacket via cooling chambers or manifolds.
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Areas of Application:
– Chemical industry
– Fertiliser industry
– Potash industry
– Non-metallic minerals
Length: up to 60 m
Diameter:
up to 5.50 m
Cooling Media:
– Air
– Water
– Oil
High Cooling Effect
Large Heat-Exchange Surface
in a Confined Space
High Throughput Capacity
Gentle Treatment of the Product
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Rotary equipment
during manufacture
Cooling tubes are inserted in the
cylinder
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Transporting a rotary cooler
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machinery + plant construction
Fine to coarse-grained bulk solids are cooled using
sectional coolers.
Sectional Coolers
are particularly well-suited for bulk solids with low initial
temperatures which must be cooled intensively.
Sectional coolers comprise a welded cylinder with six
to eight sector-shaped chambers extending along its
entire length. The goods to be cooled flow through the
chambers in a counter-current direction, an lose heat
through contact with the water-cooled walls. As the
shell rotates, there is a constant exchange of coolant,
because the spaces between the chambers communicate via the central area.
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Energy-Efficient
Less Dust Collecting Capacity Required
High Cooling Effect
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Cooling data of selected products
Product
Temperature of bulk solids
Temperature of coolant
Grain size
Initial [°C / °F]
Final [°C / °F]
Initial [°C / °F]
Final [°C / °F]
Potash
125 / 257
55 / 131
14 / 57.2
32 / 89.6
fine
Soda ash
220 / 428
80 / 176
19 / 66.2
32 / 89.6
fine
Zinc blende
700 / 1,292
80 / 176
20 / 68
62 / 143.6
fine
Phosphate
600 / 1,112
100 / 212
20 / 68
60 / 140
coarse
Installing a
cooling section
Sectional cooler
during manufacture
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Sectional cooler
ready for delivery
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Machinery + Plant construction
During the slaking process, quicklime is dissolved in
water, forming lime hydrate. The lime remains in the
cylinder until slaking is complete.
Rotary lime slakers comprise a rotary cylinder with
staggered conveyor flights. The discharge unit is a
trommel screen, which separates out solids from the
lime milk.
Rotary Lime Slakers
ensure continuous slaking of quicklime.
Areas of Application for Lime Hydrate:
– Deacidification of drinking water
– Neutralisation of acidic waste water
– Raw juice separation in the
sugar industry
– The soda industry
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Technical data of selected cylinders
Length
[mm]
Slaked lime [t/h]
Lime milk [m3/h]
1,000
4,000
0.8
4
1,200
5,000
1.4
7
1,400
6,000
2.0
10
1,600
6,000
3.0
15
1,600
8,000
4.0
20
1,800
8,000
5.0
25
2,000
10,000
7.0
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Rotary lime slaker
for the soda industry
Rotary lime slaker
ready assembled
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10
Capacity
Nominal diameter
[mm]
Rotary lime slaker
ready for commissioning
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machinery + plant construction
Everything from a
Single Source
Depending on the particular operating conditions,
Rotary Equipment
EMDE Industrie-Technik GmbH can work together
with a test labortory and a process research and test
centre using pilot size equipment to supply a complete
process design and calculation package for your plant,
if so required.
EMDE can also perform final tests such as weld seam
inspections, pressure tests, true-running tests or
acceptance inspections.
can be fabricated from either cast iron or steel.
Design:
Mild steel
Stainless steel
1.4301 / 1.4571 / 1.4878 / 1.4539
Combinations of steel and stainless steel
Option with refractory lining
Sectors for which rotary equipment is manufactured:
Highly wear-resistant or
corrosion-resistant steels
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EMDE Services
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Alignment Surveying
Support Roller Alignment
Repairs
Regular Servicing
Transportation Planning
Soda Industry
Potash Industry
Chemical Industry
Petrochemical Industry
Fertiliser Production
Refining Technology
Waste Disposal
Agriculture
Timber Industry
Pigment Industry
Limestone Industry
Sugar Industry
Loading a
wood chip dryer
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Ultrasonic test
on a riding ring
Erection by
trained personnel
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Lifting a cylinder onto the
preassembled roller stations
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machinery + plant construction
The Complete Range
Filling and Emptying
EMDE FIBC and IBC Systems
EMDE Sack Emptying Systems
EMDE Star Wheels
EMDE Barrel Handling Systems
Machinery and Plant Construction
EMDE High-Performance Filters
EMDE Rotary Kilns
EMDE Steam Tube Calciners
EMDE Rotary Dryers
EMDE Rotary Coolers
EMDE Lime Shaft Kilns
EMDE Thickeners
Special Steel Equipment
Foundry
STASSFURT Iron Castings
Cast Iron Columns
Dosing and Mixing
EMDE Dosing Screws
EMDE Dosing Troughs
EMDE Batch Mixers and Mixing Screws
Systems and Components
Multi-Components Dosing Systems,
Batching and Weighing Systems,
Empty Sack and FIBC Compactors,
Lump Breakers, Vibrating Trays,
Expansion Joints, Inflating Hoses,
Flat Slide Valves
Windpower Plants
Towers
Cast Iron Components (hubs, shafts)
Systems and Components
Repulpers and Dissolvers, Liquor Preheaters,
Vacuum Coolers, Surface Condensers,
Vacuum Filters, Potash Filters, Sugar Filters,
Pressure Filters,
Containers and Tanks of Special Materials,
Heat Transmission Equipment, Agitators,
Equipment for the Soda, Potash and Sugar
Industry
D806.0015
We will be happy to send you detailed information on request.
The information in this brochure is not binding. Technical modifications are possible.
Conveying
EMDE Screw Conveyors
WUTRA Bucket Elevators
Flexible Screw Conveyors EMDE-LIFT
EMDE Vibratory Conveying Troughs
EMDE Industrie-Technik
Gesellschaft für Rationalisierung und Verfahrenstechnik mbH
Chemical plant construction ◆ Foundry
www.emde.de ◆ [email protected] ◆ www.chemieanlagenbau.de
Main Factory Nassau
Koppelheck ◆ D-56377 Nassau/Lahn
Phone: +49 (0) 26 04 - 97 03 - 0 ◆ Fax: +49 (0) 26 04 - 97 03 - 33
Plant Stassfurt
Atzendorfer Straße 19 ◆ D-39418 Staßfurt
Phone: +49 (0) 39 25 - 985 - 0 ◆ Fax: +49 (0) 39 25 - 985 - 700