Trends in cement kiln pyroprocessing

Source/Quelle: www.cemfocus.com

1 Kiln line size categories

Source/Quelle: www.cemfocus.com

2 Development of specific kiln throughputs

Source/Quelle: www.cemfocus.com

Source/Quelle: Polysius

3 ECC cement factory in Egypt

Source/Quelle: Polysius

Source/Quelle: OneStone

4 Schematic diagram of a kiln line

Source/Quelle: OneStone

Source/Quelle: FLSmidth

5 St. Genevieve cement works in the USA

Source/Quelle: FLSmidth

Source/Quelle: KHD

6 Preheater system options

Source/Quelle: KHD

Source/Quelle: FLSmidth

7 Hotdisc from FLS

Source/Quelle: FLSmidth

Source/Quelle: Polysius

8 Step Combustor from Polysius

Source/Quelle: Polysius

Source/Quelle: www.cemfocus.com

9 Schematic diagram of a multi-stage combustion system

Source/Quelle: www.cemfocus.com

10 Heat losses of a kiln line [1]

Source/Quelle: www.cemfocus.com

Source/Quelle: KHD

11 Regional distribution of kiln types

Source/Quelle: KHD

Source/Quelle: Pillard

12 Novaflam burner

Source/Quelle: Pillard

Source/Quelle: FLSmidth

PT Semen Gresik, Tonasa 5 plant, Indonesia

Source/Quelle: FLSmidth

Plant engineering companies supplying the cement industry have recently started talking about plants oriented to the needs of the customer. Attributes such as “tailor-made” or “standardized” seem to be a thing of the past.

1 Introduction

In recent years there have been no really new and profound technical developments in kiln technology and none are to be expected in the cement industry in the foreseeable future. Nevertheless, there are a number of trends that have a great influence on purchasing decisions and on current technology standards:

Dry process with preheater and calciner

Most usual plant sizes between 3000–6000 tpd

Specific heat consumptions of < 725 kcal/kg cl (5-stage preheater)

Specific electrical energy requirements < 90 kWh/t

Lowest possible emission rates (NO_x, SO_x, dust, noise)

Automatic plant...