PYRO PROCESS UNIT Adnan Optimization & Capacity Upgrade Can · 2019-09-18 · 14- PREHEATER UNIT Lorem ipsum dolor sit amet, consectetur adipiscingelit. Gazakh CementPlant, Azerbaijan

PYRO PROCESS UNIT AdnanCan

Optimization & Capacity Upgrade

Evaluation of the Existing Conditions

Clinker Cooler Refrofit

Cooler Vent Fan Replacement

Preheater Cyclone Modifications

Kiln Feed System Modification

Capacity Upgrade of an Existing

Clinker Production Line, Nuh Cement

01-EVALUATING THE EXISTING CONDITIONS

Lorem ipsum dolor sit amet, consectetur adipiscingelit.

Nuh Cement Plant, TurkeyEvaluating the Existing Conditions of the 1st Line

Capacity : 2700-2800 tpd

Specific Heat Consumption : 850-870 kcal/kg clinker

Standard Cooler Loss : 140 kcal/kg clinker

Clinker Temperature : 170°C + ambient

Tertiary Air Temperature : 715°C


Nuh Cement Plant, TurkeyEvaluating the Existing Conditions of the 1st Line

Pressure Drop at PH-Tower Exit : 82-84 mbar

ID Fan Power Consumption : 12-13 kWh/t clinker

Cooler Vent Fan Power Consumption : 2,5 kWh/t clinker

Kiln Feeding System : Pneumatic

Total Power Consumption of Kiln : 31 kWh/t clinker

01-EVALUATING THE EXISTING CONDITIONS

02- CLINKER COOLER


Nuh Cement Plant, TurkeyPhase 1# Clinker Cooler Reftrofit Scope of Work

Complete Cooler Internals

Cooler Casing

Clinker Cooler (Roller Crusher to be installed)

New Cooler fans with Silencer, Motor and Drives

Dismantling and Erection Works

Supervision, Commissioning and Training

03- COOLER VENT FAN


Nuh Cement Plant, TurkeyPhase 2# Cooler Vent Fan Replacement

The fan rotor to be replaced with state-of-the-art design fan

Complete procurement, dismantling and erection is in the scope

1 kWh/t clinker to be reduced

03- PREHEATER CYCLONE MODIFICATION


Nuh Cement Plant, TurkeyPhase 3# Preheater Cyclone Modification Guaranteed Values

Capacity : 3200 tpd

Preheater Tower Pressure : 69 mbar at 3200 tpd

Energy Consumption Saving : 2 kWh/t clinker

Specific Heat Consumption : 790 kcal/kg clinker


Nuh Cement Plant, TurkeyPhase 3# Preheater Cyclone Modification Scope of Work

8 cyclones (O1A, O1B, O2, O3 & V1A, V1B, V2 and V3) to be

modified together with riser ducts

Dip tubes, splash boxes, meal flaps

Complete manufacture, dismantling and erection

Commissioning, Training and Optimization



Nuh Cement Plant, TurkeyPhase 3# Preheater Cyclone Modification / Existing Cyclones

Preheater String 1# O2 & O3 Cyclones




Nuh Cement Plant, TurkeyPhase 3# Preheater Cyclone Modification / Modified Cyclones

Preheater String 1# O2 & O3 Cyclones


04- CFD ANALYSIS OF THE MODIFIED CYCLONE

CFD Analysis of the Modified Cyclones

Before the modification After the modification

Static Pressure Distribution

Before Modification : 2436 Pa

After Modification : 1657 Pa



Tangential Velocity Distribution




Axial Velocity Distribution


05- CFD ANALYSES RESULTS FOR 2NDSTAGE


1657 Pa

2603 Pa

1788 Pa

Phase 3# Preheater Cyclone Modification / CFD Analyses Results for 2nd Stage

Nuh Cement Plant, Turkey

STATIC PRESSURE

TOTAL PRESSURE

Existing Cyclone

Simple Modification

Existing Cyclone

Simple Modification

2436 Pa

06- NUH CEMENT PLANT



07- KİLN FEED SYSTEM MODİFİCATİON


Nuh Cement Plant, TurkeyPhase 4# Kiln Feed System Modification Scope of Work

Pneumatic Feeding System to be replaced with mechanical

method (bucket elevator, airslide)

Basic and Detailed Engineering

Complete set of equipment

Steel structure and manufacture

All erection, commissioning, supervision and training

08- MODIFICATIONS AT NUH CEMENT



09- OVERALL GUARANTEES OF ALL PROJECT


Nuh Cement Plant, TurkeyOverall Guarantees of All Project

Capacity : 3200 tpd


Energy Consumption : 26 kWh/t clinker



10- ACHIEVED VALUES


Nuh Cement Plant, TurkeyAchieved Values

Capacity : 3400 tpd


Energy Consumption : 24 kWh/t clinker



11- BEFORE AND AFTER



Evaluation of the Existing Conditions

Raw Meal Drying and Grinding Unit

Kiln De-Dusting Unit

Pyro Process Unit

Ongoing Capacity Upgrade Project of an Existing

Clinker Production Line, Gazakh Cement Plant

11- GAZAKH CEMENT PLANT


Gazakh Cement Plant, AzerbaijanEvaluating the Existing Conditions

Capacity : 2500-2700 tpd


Raw Mill Capacity : 205 tph

Fineness of the Mill Product :≥15.5% R90µm

Separator Efficiency : 75%

12- RAW MEAL DRYING AND GRINDING UNIT


Gazakh Cement Plant, AzerbaijanRaw Meal Drying and Grinding Unit Scope of Work

New drying equipment for the raw meal

Complete replacement of the separator and cyclones

New Raw Mill Fan complete with motor and drive

New raw meal transport unit

Raw meal weighing unit modifications

Complete procurement, dismantling and erection

Supervision, commissioning and training

13- KILN DE-DUSTING UNIT


Gazakh Cement Plant, AzerbaijanKiln De-Dusting Unit Scope of Work

Bag Filter modifications

New Bag Filter Fan with motor and drive

Complete procurement, dismantling and erection works


14- PREHEATER UNIT


Gazakh Cement Plant, AzerbaijanPreheater Unit Scope of Work

Preheater cyclone modifications

TA Duct and Calciner connection modification

New dip tubes, riser ducts and splash boxes

New ID Fan, complete with motor and drive

Complete manufacture, dismantling and erection


15- GUARANTEES


Gazakh Cement Plant, AzerbaijanOverall Guarantees of All Project

Production Capacity : ≥240 tph

Mixed Raw Material Moisture : Max 8%

Mixed Raw Material Feed Size : 90% <25 mm

Raw Meal Moisture Content : ≤1%

Separator Efficiency : ≥85%

Raw Mill Unit

15- GUARANTEES



Clinker Production Capacity : ≥3300 tpd

Heat Consumption : ≤765 kcal/kg clinker

Preheater Pressure Drop : ≤60 mbar

ID Fan Power Consumption : 9 kWh/t clinker

Top Stage Cyclone Efficiency : 93%

Rotary Kiln Unit

15- GUARANTEES



Free Lime : ≤1.5% (daily avg.)

C3S : ≥55 (Std. Bogue formula)

LSF : 93-97

Silica Ratio : 2.0 - 2.8

Al2O3 : 1.0 – 1.8

New Process Fans’ Efficiency : ≥80%

Quality Parameters

16- HIGHLIGHTS OF THE PROJECT


Gazakh Cement Plant, Azerbaijan

Supply of the equipment will be at 6 months

Flame-off flame-off period is planned to be 35 days

Highlights of the Project

GRACIAS

Documents

PYRO PROCESS UNIT Adnan Optimization & Capacity Upgrade Can · 2019-09-18 · 14- PREHEATER UNIT Lorem ipsum dolor sit amet, consectetur adipiscingelit. Gazakh CementPlant, Azerbaijan