KHD Humboldt Wedag
Staged combustion may sound complicated but it essentially means that the calciner is designed to facilitate the chemical reduction of NOX to nitrogen. To achieve this, the Pyroclon® LowNOX AF calciner features an additional reduction zone compared to our Pyroclon® R calciner, effectively lowering NOX production at source.
Proper mixing of material and gas flows is important to ensure complete combustion. Which is why we developed the Pyrotop® mixing chamber. Fitted to all KHD calciners, it enhances mixing at the gas turning point at the top of the calciner to ensure combustion is complete before the gas stream enters the lowest cyclone stage of the preheater.
What does that deliver in practice? It ensures complete burn-out of CO, minimizing emissions. This gives you the confidence to burn a range of primary and alternative fuels. And it does this while achieving the lowest possible pressure loss. In other words, it is a useful box of tricks to sit atop your calciner.
All our calciner systems designed to ensure proper mixing of raw material and fuels, as well as optimal residency times. To achieve this, our process experts calculate the optimal retention time for your specific process using a range of factors, and then tailor your calciner design accordingly.
For example, the calciner length will be individually calculated to guarantee complete fuel burn out, minimized CO emissions and uniform operating temperature. The internal geometry is also optimized to ensure raw meal and fuel are safely entrained in the air stream, avoiding material accumulation and drop out.
One of the things you want to avoid is fall-through of coarse material to the kiln. The Pyroclon® LowNOX AF features a specially-designed restricted connection (or orifice) between the kiln inlet chamber and the riser duct that prevents large particles, such as coarse alternative fuels, from entering the kiln inlet chamber.
This restricted orifice also helps maintain the gas balance, not only in the calciner, but across the kiln, tertiary air duct and calciner.
Depending on your current emissions limits, the Pyroclon® LowNOX AF may actually eliminate the need for further gas treatment, such as SNCR or SCR. And when such systems are still required, their operating costs will be much lower than in plants without the NOX-reducing potential of the Pyroclon® LowNOX AF.
Discover more about how KHD technologies are reducing the environmental impact of cement on our Clean Solutions page.
But what makes it a really smart choice is its modular design, which makes upgrading an easy process – like adding a Pyroredox® low-NOX reactor module for reduced emissions.
Or you might want to improve your thermal substitution rates or the flexibility of your alternative fuel use. In which case, check out our Pyroincinerator, Combustion Chamber and Pyrorotor® calciner add-ons.
It’s a simple and cost-effective way to build a full calciner system that meets your specific needs. And with our process experts to assist you to make the best decisions along the way, you can be sure of a positive result.
Calciner layout depends, amongst others, on used fuels, raw materials and targeted pressure loss and is always tailored to the individual requirements of a specific project.
An additional low-oxygen reduction zone facilitates the chemical reaction of NOX to nitrogen, lowering NOX production and thus the need for end-of-pipe gas treatment.
|UTCL Dhar Line 2||India||2021||8000|
|UTCL Hirmi Line 2||India||2021||8000|
|UTCL Coral, Pali||India||2021||8000|
|Deccan Cement Line 3||India||2021||3500|
|Asia Cement Corporation, Korea Jecheon||South Korea||2021||1800|
|Lehigh Heidelberger Mitchell Plant||USA||2019||7000|
|Dincer Cimento Madencilik Bilecik||Turkey||2018||5000|
|Shree Cement Raipur Line 2||India||2016||6000|
|Shree Cement Gulbarga||India||2016||6750|
|The KCP Ltd.||India||2016||4500|
|SOMA Cimento Madencilik||Turkey||2016||4000|
|YD Madencilik A.S.||Turkey||2016||5000|
|Links & Downloads|
Article in International Cement Review (January 2018) – Not Simply Calcining