Calciner

Pyroclon® LowNOX AF

With governments continuously monitoring and tightening emissions regulations, combatting harmful gases is a vital part of standard operating procedures. The Pyroclon® LowNOX AF calciner is our core solution for lowering NOX emissions without additional end-of-the-pipe processes.

Tailored Design

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Pyrotop® Mixing Chamber

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Staged Combustion

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Special Connection Design

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Product Features

We introduced flash calciners into the cement industry and continue to pioneer innovation today. As we did with the Pyroclon® LowNOX AF.

Product Features

Perfecting staged combustion

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.

Product Features

Pyrotop® mixing chamber

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.

Upgrade competitor calciners with a Pyrotop®

Don’t have a KHD calciner? Pyrotop® mixing chambers can be retrofitted to third-party calciners with only minor changes to your existing equipment, usually as part of top-stage adjustment, dip-tube enhancement or other process upgrade.

Product Features

Tailored design as standard

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.

Product Features

Stop material fall through

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.

Key Benefits

Not only does it reduce NOX without end-of-pipe gas treatment, our Pyroclon® LowNOX AF is designed for easy upgrade and customization to your specific needs.

Key Benefits

Lower NOX emissions

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.

Key Benefits

Modularity and customization

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.

Performance Data

So, is the Pyroclon® LowNOX AF the calciner for you? Check out the production range below. Or contact us to talk to an expert.

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.

How it works

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.

Exhaust Gas (high NOx level)

Lean Gas (high CO level)

Tertiary Air (high O2 level)

Gas after combustion and calcination (low NOx, CO and O2 levels)

  1. Pyrotop®
  2. Penultimate cyclone
  3. Bottom cyclone
  4. Fuel feed
  5. Tertiary air duct
  6. Rotary kiln
  7. Meal to kiln
  8. Meal to calciner
  9. Meal to low NOX zone
  10. Low NOX zone
  11. Oxidizing zone

References

Customer Country Year Capacity (tpd)
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
Cimentfort Angola 2017 3500
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

Contact

Interested in our solutions? Get in touch! We are happy to help.

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