Personalized Choices - Finding Solutions that fit

KHD Humboldt Wedag Inc.

Personalized Choices -

Finding Solutions that fit

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

KHD Humboldt Wedag Inc.

Solutions On Demand

Tuesday, September 14, 2010 3

Degrees of Modification/Upgrade –Degrees of Complexity

Plan & Budget

Implementation

Mechanical

Process

Environmental

Market

Impe

tus

Available Technology

Condition of Plant

Influ

ence

s

KHD Humboldt Wedag Inc.

Solutions On Demand

Tuesday, September 14, 2010 4

Outline

From Identification to Solution

Case Studies

Conclusion

KHD Humboldt Wedag Inc.

Solutions On Demand

Tuesday, September 14, 2010 5

From Identification to Solution

Identify an Issue

Experience

Plant Audits

Best Practice Benchmarking

Define the Problem

Root Cause Analysis

Requirements for the Solution

KHD Humboldt Wedag Inc.

Solutions On Demand

Tuesday, September 14, 2010 6

From Identification to Solution

Collecting Ideas

Work with Suppliers

Compare Notes

Define Solution

Technical

Commercial

Market

Regulations

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 7

Case Studies (1) – Equipment Upgrade

Expansion Joints:

Structural Issues

Leakage

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 8

Case Studies (1) – Equipment Upgrade

Expansion Joints

Maintenance Friendly Replacement

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 9

Case Studies (2) – Equipment Upgrade

Flap Valves & Inlet Boxes

Gas Bypassing

Meal Distribution

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 10

Case Studies (2) – Equipment Upgrade

Flap Valves & Inlet Boxes

Adjustable Splash Box

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 11

Case Studies (2) – Equipment Upgrade

Flap Valves & Inlet Boxes

Newly Designed Flap Valve Assembly

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 12

Case Studies (2) – Equipment Upgrade

Flap Valves & Inlet Boxes

Newly Designed Flap Valve Assembly

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 13

Case Studies (3) – Equipment Upgrade

Separator

Improve Quality

Increase Production

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 14

Installation of dynamic Rotor

Cage Wheel and Seal

Central Tube

Case Studies (3) – Equipment Upgrade

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 15

Case Studies (1) – System Upgrade

3rd Generation Separator

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 16

Case Studies (2) – System Upgrade

Clinker Cooler

Reducing Heat Consumption

Production Increase

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 17

Case Studies (2) – System Upgrade

Clinker Cooler Replacement

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 18

Case Studies (2) – System Upgrade

Clinker Cooler

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 19

Case Studies (3) – System Upgrade

Calciner:

Limitations on Using certain Fuels

Emissions

Production Increase

meal

fuel

KHD Humboldt Wedag Inc.

Calciner:

Extension

Addition of TAD

Tuesday, September 14, 2010 20

Case Studies (3) – System Upgrade

meal

fuel

PYROTOP

PYROCLON

PYRORAPID Kiln

TA Duct

Top Air Duct

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 21

Case Studies (3) – System Upgrade

meal

fuel

Calciner:

PYROTOP Mixing Chamber

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 22

Case Studies (3) – System Upgrade

Calciner

PYROBOX Burner

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 23

Case Studies (3) – System Upgrade

Calciner

PYROBOX Burner

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 24

Case Studies (4) – System Upgrade

Grinding:

Production Increase

Energy Reduction

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 25

Case Studies (4) – System Upgrade

Grinding:

Rollerpress for Pre-Grinding

fresh feed

preground product

finishproduct

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 26

Case Studies (4) – System Upgrade

fresh feed

finishproduct

Grinding:

Rollerpress for Finish Grinding

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 27

Case Studies (4) – System Upgrade

Grinding:

COMFLEX

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 28

Case Studies (4) – System Upgrade

Grinding:

COMFLEX

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 29

Case Studies (4) – System Upgrade

Grinding:

Rollerpress

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 30

Case Studies (1) – Plant Upgrade

Production Increase

ProductionBefore 1,900stpd

Illinois, USA - 2007

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 31

Case Studies (1) – Plant Upgrade

Scope of Modification

h

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 32

Case Studies (1) – Plant Upgrade

Scope of Modification

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 33

Case Studies (1) – Plant Upgrade

ProductionBefore 1,900stpdAfter 3,000stpdIllinois, USA - 2007

Production Increase

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 34

Case Studies (2) – Plant Upgrade

Production Increase

Reduction of Heat Consumption

ProductionBefore 2,400stpd

Kentucky, USA - 2002

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 35

Case Studies (2) – Plant Upgrade

Scope of Modification

PH w/Calciner

Clinker Cooler

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 36

Case Studies (2) – Plant Upgrade

Scope of Modification

PH w/Calciner

Clinker Cooler

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 37

Production Increase

Case Studies (2) – Plant Upgrade

ProductionBefore 2,400stpdAfter 4,700stpdKentucky, USA - 2002

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 38

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

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 39

Scope of Modification

Case Studies (3) – Plant Upgrade

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 40

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

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 41

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

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 42

Case Studies (4) – Plant Upgrade

Production Increase

Increase use of Secondary Fuels

Production Use of Altern. Fuels

Before 4,000tpd 25%

Brazil - 2010

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 43

Scope of Modification

Combustion Chamber

New Calciner

Calciner Extension

Case Studies (4) – Plant Upgrade

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 44

fresh materialabrasivesand

hot gashot gas

Case Studies (4) – Plant Upgrade

Existing Raw Grinding System

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 45

Case Studies (4) – Plant Upgrades

Modified Raw Grinding System

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 46

Case Studies (4) – Plant Upgrades

New Raw Grinding System

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 47

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

KHD Humboldt Wedag Inc.

Solutions On Demand

Tuesday, September 14, 2010 48

Operational Upgrades

Training for Maintenance & Process

Hands-on

Simulator

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 49

Operational Upgrades

SIMULEX®

LessonServer

SIMULEX®

SimulationServer

SpecialistWorkstationGenerating

Lesson

TraineeWorkstation

Training INTERNET

Rating & Certificate

SIMULEX – Cement Plant Simulator

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 50

Operational Upgrades

SIMULEX – Cement Plant Simulator

KHD Humboldt Wedag Inc.

Solutions On Demand

Tuesday, September 14, 2010 51

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

KHD Humboldt Wedag Inc.

Solutions On Demand

Tuesday, September 14, 2010 52

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

KHD Humboldt Wedag Inc.

Tuesday, September 14, 2010 53

Solutions On Demand