Cement, Energy and Environment

38 OPERATIONAL UPSHOTS: - After successful implementation of new design static grate in several project the so called PYROSTATIC is now KHD´s standard in all their coolers. It is implemented not just in their PFC- products but also in their second generation PYROSTEP coolers. It also can be retrofitted to any cooler in the market. Case study; Plant With a focus on increased clinker cooling on the static grate, a modification on the static grate of PYROFLOOR® cooler installed in a Romanian plant owned by Holcim. A clear business case was: CONCLUSION Launching a new product is always an exciting challenge, especially in times where development cycles become increasingly shorter. With now more than 15 years of operation experience, the PFC cooler was improved continuously. Weak points have been critically analyzed and goal-directed solutions been introduced. With the new cooler cassettes and new static grate design KHD is answering the questions how to optimize a state-of-the-art cooler. The focus is not just mechanical but also process related. A • Reduce pressure drop across the static grate plates. • Optimize the design to allow clinker to ‘slide’ better from the static grate on to the moving lanes. • Increase of heat recuperation for higher thermal efficiency. • Increase of secondary air temperature for higher alternative fuel substitution (ignition temperature for main-burner and calciner fuel). PYROSTEP® Cooler Units of measure- ment Before Up- grade After Up- grade Comment Guarantees Zero Test Performance Test Type of upgrade Old Static Grate PYROSTATIC® Retrofit Clinker Throughput t/d 4674 4080 4704 +15% AF Rate % 60 50 64 +16% Cooling Air amount Nm³/kgcli < 2,00; > 1,75 1.56 1.85 OK Chamber Pressure Static Grate mbar 97 70 Power Consumption (static grate fans) kWh/tcli 1,85 0,90 -0.57 Clinker outlet temperature °C 130 169 76 OK Total heat consumption kcal/kg 884 876 - 8 kcal/kg As a result of this project the following table was conducted with process values. higher recuperation leading in a reduced thermal input of a plant. A reduced pressure loss for the cooling air fans leading in reduced electrical power consumption. By this KHD Humboldt Wedag with its strong entity Humboldt Wedag India as one of the major architects for engineering and machinery for the cement industry is participating actively in developing and providing solutions for sustainable growth of the industry with moving forward in green steps on the path of lower GHG emissions for low carbon roadmap initiative taken by all the major cement producers globally.