In December 2011, ZAB Zementanlagenbau GmbH Dessau, a subsidiary of KHD Humboldt Wedag GmbH, carried out a successful performance test of the rotary kiln plant that was recently constructed on a green field in Novotroizk/Russia, at the JUGPK company. The plant’s capacity is 3000 t/d (Fig. 1). The remarkable thing about this kiln plant, equipped with KHD technology, is that, for environmental reasons, in addition to the raw materials usually used for producing clinker, limestone and clay, a large percentage of blast furnace slag is processed. The slag is accumulated as residual in the nearby steel complex, where it is piled up in huge quantities. Although this slag has already undergone thermal treatment, it still contains residual organic and combustible components. The presence of the organic and combustible residue in the slag, results in a lower demand for purchased fuel during the clinker production process.
The guaranteed values of the throughput rate for the cement grinding system (Fig. 2) have, also, already been verified for the customer, JUGPK. In the performance test was 168 t/h reached. A throughput rate of 155 t/h had been guaranteed. The measured clean gas particle concentration in the exhaust air was significantly lower than the standard values applicable in Russia for new plants. The data of the test is shown in Table 1.
The scope of delivery, with regard to KHD products and services, extends from raw material storage and preparation, to clinker production, cement production and storage, cement loading, including packing services, all associated dust removal systems, as well as the automation and control station technology. The 3000 t/d kiln line is provided with the following core equipment of KHD design:
Roller Press RP 13 – 170/140 with V- separator and static LS- separator
5-stage preheater with PYROCLON® R-calciner and tertiary air duct
Two-tyre PYRORAPID® rotary kiln Ø 4.4 m x 52 m long, with PYROJET® burner
PYROFLOOR® clinker cooler with 73 m2 cooling surface and clinker crusher
All system fans
The cement grinding system is provided with the following core equipment of KHD design:
Ball mill Ø 5.0 m x 14.5 m, power capacity 6,000 kW
High efficiency separator SKS-Z 3250
System fan
The successful realization of this kiln line provides yet another confirmation of the outstanding products and services provided by KHD as a supplier of cement kiln lines, not just all over the world, but particularly in the significantly growing Russian market. In an expression of approval, JUGPK has commissioned a second kiln line from KHD/ZAB that is identical to the first and will run in parallel. This second kiln line is currently being assembled, and is expected to be brought into service in the second half of this year.
