Calciner

Pyroclon® R

We pioneered flash calciners in the cement industry and continue to lead innovation today. Based on the Pyroclon® R, our modular calciner systems are optimized to your process to guarantee best flow and reaction conditions for efficient, stable operation, and lowest fuel costs. Meanwhile, a range of specialized options enables us to tailor solutions to any specific application requirements.

Pyrotop® Mixing Chamber

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Special Connection Design

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Tailored Design

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Product Features

Calciners are critical to your process, your fuel efficiency and controlling your emissions. Which is why we make sure you get a solution that works for you.

Product Features

Tailored design as standard

All our calciner systems are based on our industry-standard Pyroclon® R calciner, ensuring proper mixing of raw material and fuels, as well as optimal residency times. But that does not mean all our calciners the same. In fact, we are not in the business of one-size fits all calciners.

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

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

Stop material fall through

One of the things you want to avoid is fall-through of coarse material to the kiln. The Pyroclon® R 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

A reliable and effective solution with flexible upgrade options: our calciner systems are built around you and your needs.

Key Benefits

Simple design, lowest maintenance

With its low building height and lowest pressure drop, the Pyroclon® R is a highly-attractive, low-investment, stand-alone system. Its simple design also keeps maintenance requirements low, helping to reduce operating costs.

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® R 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

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. Ooxidizing zone

References

Customer Country Year Capacity (tpd)
Shuva Laxmi Cement Nepal 2021 2500
Arun Cement Nepal 2021 1800
Baharden / Bilim Makina Turkmenistan 2021 3500
Samrat Cement Nepal 2018 4000
CG Cement  Nepal 2017 3900
Ghorahi Cement Industry Nepal 2017 2200
Biarjomand Cement Company Iran 2016 3300

Contact

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

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