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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
