Case Studies (4) – Plant Upgrade
Transcript of Case Studies (4) – Plant Upgrade
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KHD Humboldt Wedag Inc.
Personalized Choices -
Finding Solutions that fit
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KHD Humboldt Wedag Inc.
Solutions On Demand
Tuesday, September 14, 2010 2
Degrees of Modification/Upgrade –Degrees of Complexity
Equipment Level
System Level
Plant Level
Operational Level
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KHD Humboldt Wedag Inc.
Solutions On Demand
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Degrees of Modification/Upgrade –Degrees of Complexity
Plan & Budget
Implementation
Mechanical
Process
Environmental
Market
Impe
tus
Available Technology
Condition of Plant
Influ
ence
s
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KHD Humboldt Wedag Inc.
Solutions On Demand
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Outline
From Identification to Solution
Case Studies
Conclusion
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KHD Humboldt Wedag Inc.
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From Identification to Solution
Identify an Issue
Experience
Plant Audits
Best Practice Benchmarking
Define the Problem
Root Cause Analysis
Requirements for the Solution
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KHD Humboldt Wedag Inc.
Solutions On Demand
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From Identification to Solution
Collecting Ideas
Work with Suppliers
Compare Notes
Define Solution
Technical
Commercial
Market
Regulations
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Case Studies (1) – Equipment Upgrade
Expansion Joints:
Structural Issues
Leakage
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KHD Humboldt Wedag Inc.
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Case Studies (1) – Equipment Upgrade
Expansion Joints
Maintenance Friendly Replacement
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KHD Humboldt Wedag Inc.
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Case Studies (2) – Equipment Upgrade
Flap Valves & Inlet Boxes
Gas Bypassing
Meal Distribution
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Case Studies (2) – Equipment Upgrade
Flap Valves & Inlet Boxes
Adjustable Splash Box
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Case Studies (2) – Equipment Upgrade
Flap Valves & Inlet Boxes
Newly Designed Flap Valve Assembly
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Case Studies (2) – Equipment Upgrade
Flap Valves & Inlet Boxes
Newly Designed Flap Valve Assembly
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KHD Humboldt Wedag Inc.
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Case Studies (3) – Equipment Upgrade
Separator
Improve Quality
Increase Production
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Installation of dynamic Rotor
Cage Wheel and Seal
Central Tube
Case Studies (3) – Equipment Upgrade
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Case Studies (1) – System Upgrade
3rd Generation Separator
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KHD Humboldt Wedag Inc.
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Case Studies (2) – System Upgrade
Clinker Cooler
Reducing Heat Consumption
Production Increase
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Case Studies (2) – System Upgrade
Clinker Cooler Replacement
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Case Studies (2) – System Upgrade
Clinker Cooler
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Case Studies (3) – System Upgrade
Calciner:
Limitations on Using certain Fuels
Emissions
Production Increase
meal
fuel
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KHD Humboldt Wedag Inc.
Calciner:
Extension
Addition of TAD
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Case Studies (3) – System Upgrade
meal
fuel
PYROTOP
PYROCLON
PYRORAPID Kiln
TA Duct
Top Air Duct
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Case Studies (3) – System Upgrade
meal
fuel
Calciner:
PYROTOP Mixing Chamber
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Case Studies (3) – System Upgrade
Calciner
PYROBOX Burner
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Case Studies (3) – System Upgrade
Calciner
PYROBOX Burner
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Case Studies (4) – System Upgrade
Grinding:
Production Increase
Energy Reduction
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Case Studies (4) – System Upgrade
Grinding:
Rollerpress for Pre-Grinding
fresh feed
preground product
finishproduct
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Case Studies (4) – System Upgrade
fresh feed
finishproduct
Grinding:
Rollerpress for Finish Grinding
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Case Studies (4) – System Upgrade
Grinding:
COMFLEX
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Case Studies (4) – System Upgrade
Grinding:
COMFLEX
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Case Studies (4) – System Upgrade
Grinding:
Rollerpress
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Case Studies (1) – Plant Upgrade
Production Increase
ProductionBefore 1,900stpd
Illinois, USA - 2007
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Case Studies (1) – Plant Upgrade
Scope of Modification
h
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Case Studies (1) – Plant Upgrade
Scope of Modification
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Case Studies (1) – Plant Upgrade
ProductionBefore 1,900stpdAfter 3,000stpdIllinois, USA - 2007
Production Increase
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KHD Humboldt Wedag Inc.
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Case Studies (2) – Plant Upgrade
Production Increase
Reduction of Heat Consumption
ProductionBefore 2,400stpd
Kentucky, USA - 2002
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KHD Humboldt Wedag Inc.
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Case Studies (2) – Plant Upgrade
Scope of Modification
PH w/Calciner
Clinker Cooler
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Case Studies (2) – Plant Upgrade
Scope of Modification
PH w/Calciner
Clinker Cooler
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Production Increase
Case Studies (2) – Plant Upgrade
ProductionBefore 2,400stpdAfter 4,700stpdKentucky, USA - 2002
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KHD Humboldt Wedag Inc.
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Case Studies (3) – Plant Upgrade
Conversion from Wet to Semi-Wet
Production Increase
Reduction of Heat ConsumptionProduction Heat
ConsumptionBefore 1,400stpd 1,500kcal/kg
Russia - 2008
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Scope of Modification
Case Studies (3) – Plant Upgrade
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KHD Humboldt Wedag Inc.
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g/Nm³80dustmbar41p°C545tNm³/h146 000V
%18H2Ot/h180m wett/h148m dry
kg/h7520m
g/Nm³35dustmbar75p°C150tNm³/h214 800V
mbar28,5p°C740t
mbar19p°C870t
mbar9,0p°C880t
g/Nm³15dustmbar-3p°C890tNm³/h56 600V
g/Nm³10dustmbar-2p°C227tNm³/h79 000V
kg/h790m
Nm³/h172 500V kg/h95 830m
Nm³/h3900gas
PYROCLONNm³/h5900gas
Case Studies (3) – Plant Upgrade
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KHD Humboldt Wedag Inc.
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Case Studies (3) – Plant Upgrade
Production Heat Consumption
Before 1,400tpd 1,500kcal/kgAfter 2,300tpd 850kcal/kgRussia - 2008
Conversion from Wet to Semi-Wet
Production Increase
Reduction of Heat Consumption
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KHD Humboldt Wedag Inc.
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Case Studies (4) – Plant Upgrade
Production Increase
Increase use of Secondary Fuels
Production Use of Altern. Fuels
Before 4,000tpd 25%
Brazil - 2010
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Scope of Modification
Combustion Chamber
New Calciner
Calciner Extension
Case Studies (4) – Plant Upgrade
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fresh materialabrasivesand
hot gashot gas
Case Studies (4) – Plant Upgrade
Existing Raw Grinding System
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Case Studies (4) – Plant Upgrades
Modified Raw Grinding System
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Case Studies (4) – Plant Upgrades
New Raw Grinding System
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KHD Humboldt Wedag Inc.
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Case Studies (4) – Plant Upgrades
Production Use of Altern. Fuels
Before 4,000tpd ~5%After 4,825tpd 25%Brazil - 2010
Production Increase
Increase use of Secondary Fuels
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Solutions On Demand
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Operational Upgrades
Training for Maintenance & Process
Hands-on
Simulator
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Operational Upgrades
SIMULEX®
LessonServer
SIMULEX®
SimulationServer
SpecialistWorkstationGenerating
Lesson
TraineeWorkstation
Training INTERNET
Rating & Certificate
SIMULEX – Cement Plant Simulator
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Operational Upgrades
SIMULEX – Cement Plant Simulator
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Conclusions (1)
Modifications come in all Sizes and
Shapes, for a variety of Reasons and
from different starting Points
Consider all Factors for a Solution
Accept Compromises
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KHD Humboldt Wedag Inc.
Solutions On Demand
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Conclusions (2)
Problem and Solution can become
very complex
Customized Concepts will be needed
Experience in Modification Projects
and Understanding of the entire Process
is valuable
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Solutions On Demand