Headquarters
KHD Humboldt Wedag
International AG
Von-der-Wettern-Straße 4a
51149 Cologne
Germany
Preheaters
Preheater parts
Every preheater is different. But all contain some common key parts. From separators and cyclones to splash boxes, flap boxes and dip tubes, we supply all of the parts that go into a state-of-the-art preheater. All designed to achieve the optimal combination of heat transfer, pressure drop, separation efficiency and building height.
Double separator
Achieve industry-leading separation efficiency within a much lower height profile.
Splash boxes
An adjustable dispersion plate ensures controlled, uniform distribution of raw meal into the hot gas flow.
kTube
Exceptional chemical corrosion resistance combined with quick-and-easy installation. Our K-Tubes are a win-win.
High-efficiency cyclones
Downsize your cyclone – but still enjoy best-in-class heat transfer and pressure drop.
Air-cooled flap boxes
Reduce wear and improve the lifespan of your flap boxes with our air-cooled flaps.
Preheaters
Calciners
Calciners are the heart of the preheater. They also account for a significant proportion of total plant fuel consumption. Getting the right calciner is therefore vital for process stability and fuel costs (including alternative fuel substitution rates). We have two options. The Pyroclon® R is our robust and reliable workhorse: low height requirements and lowest pressure drop combine for a highly-attractive low-CAPEX option. Meanwhile, our Pyroclon® R Lownox AF calciner is our core solution for low emissions without additional end-of-pipe processes.
Pyroclon® R
Setting the industry-standard with best flow and reaction conditions for efficient, stable operation and lowest fuel costs.
Pyroclon® R Lownox AF
Perfecting the art of staged combustion to minimize NOx formation and reduce – or even eliminate – the need for additional systems, like SNCR or SCR.
Preheaters
Alternative fuel addons
We all know alternative fuels will play an increasingly important role in the cement industry. But how do you make sure you make the most out these variable and challenging materials? Our add-ons retrofit your calciner to boost your alternative fuel substitution rates – whether you are just starting out or are looking to achieve the very highest levels of performance. Meanwhile our industry-leading kiln bypass design capabilities ensure that any changes in your fuel use will have no detrimental impact on the reliability or availability of your pyroprocess.
Pyroincinerator
Our quick, simple and low-cost upgrade for coarse alternative fuel processing.
Combustion Chamber
Handle large quantities of coarse alternative fuels without impacting calciner performance or maintenance risks.
Pyrorotor®
Process even the most difficult of materials – even contaminated and hazardous wastes – for unmatched fuel flexibility and efficiency.
Kiln bypass
Designed for your specific process conditions, our bypasses provide optimal kiln gas cleaning, without impacting overall process efficiency.
Preheaters
Emission reduction addons
Long tolerated in the cement industry, there is now a noose tightening around NOx emissions, as governments wake up to the health and environmental risks and look to limit emissions. We wholeheartedly support the move to reduce NOx – but acknowledge the challenge for cement plants. Which is why we offer solutions that help limit NOx production at source in the calciner.
Pyroclon® R Lownox AF
Perfecting the art of staged combustion to minimize NOx formation and reduce – or even eliminate – the need for additional systems, like SNCR or SCR.
Pyroredox®
A one-time investment to permanently reduce NOx emissions without raising OPEX or impacting production capacity, fuel consumption or power demand.
Preheaters
Designing a high-performance preheater is sort of like doing a complicated, 3D jigsaw. But it’s a jigsaw without a picture that tells you what it should look like. Instead, you must design the picture yourself from a range of modular components, and taking into account a range of external factors. The goal is to achieve the best combination of heat transfer, pressure drop and separation efficiency, all in an optimized building structure.
The ultimate prize is a design that optimizes operating and installation costs, according to individual site priorities and targets. It gets a bit more complicated, though, because not every preheater will contain the same parts: some equipment is always there (although the exact design will vary) but other parts will be tailored to site requirements, e.g., to burn more alternative fuels or reduce NOx.
So, while the preheater may just be a big box, aligning the bits that go inside that box – doing the jigsaw, if you like – needs an experienced hand. One that intimately understands both the process and the equipment, as well as how the preheater fits into the overall pyroprocess. Which is what you get when you come to KHD.
As we said at the top of the page, we were the first company to introduce the preheater to the cement industry. We also introduced the calciner (one of those standard preheater parts). In doing so, we fundamentally changed the way the industry works. And we continue to build on those roots today, developing more efficient and cost-effective solutions that yield value for our customers.
All of our modern preheater parts are also designed with modularity in mind, meaning we straightforwardly fit the necessary pieces together to form an optimized preheater package that works for your unique site conditions – no matter the capacity, available fuels, local regulations or emissions requirements. We can also retrofit parts onto existing preheaters (whether KHD or third-party) to improve performance or adapt to changing requirements.
The bottom line: when you come to us, you get both the original experts and today’s leading innovators in preheater design. Why would you go anywhere else?