PYROSOLUTIONS

KHD's Pyro Process - Scope of Supply

KHD Preheater
- preheating of
raw meal
PYROTOP® mixing chamber
- mixing, CO reduction (complete burnout)

Further:
PYROSTEP® and
- Bypass PYROCLON
- Process fans PYROFLOOR® Cooler
- Process automation
LowNOx Calciner - clinker cooling
Combustion Chamber
- Calcination
- AF utilization
- NOx reduction
Tertiary Air Duct
- combustion air for calciner PYRORAPID® kiln
and 3-Tyre kiln
- sintering

PYROJET® Kiln Burner

PYROBOX® Calciner Burner
- combustion

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KHD`s PYRO SOLUTIONS

− Preheater
− PYROCLON® Calciner
− Rotary Kiln
− Clinker Cooler PYROFLOOR2® & PYROSTEP2®
− Firing Systems
− Bypass Systems
− Process Fans

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KHD Preheater - History
1952 1st Cyclone Preheater in the World Bomke & Bleckmann, Germany
1955 1st Bypass system Calera, Argentina
1965 1st PYROCLON® Calciner Rohrbach Zement, Germany
1980 1st PYRORAPID® Kiln Spenner, Germany
1980 1st PYRO-JET® Burner Bonner Zement, Germany
1988 1st PYROCLON® LowNOx calciner Norcem, Norway
1991 1st PYROTOP® Mixing chamber LAF Adriasebina, Italy
1992 1st PYROSTEP® Clinker cooler Maihar Cement, India
2002 1st PYROCLON® Calciner with Comb. Chamber Norcem, Norway
2002 1st Circulation of Bypass Gases (Emission Control) Norcem, Norway
2005 1st PYROFLOOR® Clinker cooler Mordow Zement, Russia
2012 1st PYROLOOP® LowNOx AF calciner Sönmez Cimento, Turkey

2015 PYROREDOX® NOx Control ...

2016 Clay Calciner ...
2016 PYROPUSH® Coarse AF burning ...
2016 AF Dryer systems ...

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KHD Preheater - Arrangements and Capacities
Single string PH Four string PH
Double string PH
with single Calciner with large single Calciner with twin Calciner
2.000 to 6000 t/d 6.000 to 12.000 t/d 10.000 t/d up to >12.000 t/d

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KHD Preheater - Customized Solutions
KHD Cross Flow Design Customer specific design
KHD Semi Wet System KHD Clay calcining
For max. production Many different
Up to 5000 t/d
increase modernization projects have
been done by KHD

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KHD`s PYRO SOLUTIONS

− Preheater
− PYROCLON® Calciner
− Rotary Kiln
− Clinker Cooler PYROFLOOR2® & PYROSTEP2®
− Firing Systems
− Bypass Systems
− Process Fans

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PYROCLON® Calciner - History
1965 1st PYROCLON® Calciner Rohrbach Zement, Germany

1980 1st PYRORAPID® Kiln Spenner, Germany

1980 1st PYRO-JET® Burner Bonner Zement, Germany

1988 1st PYROCLON® LowNOx calciner Norcem, Norway
1991 1st PYROTOP® Mixing chamber LAF Adriasebina, Italy
1992 1st PYROSTEP® Clinker cooler Maihar Cement, India
2002 1st PYROCLON® Calciner with Comb. Chamber Norcem, Norway
2002 1st Circulation of Bypass Gases (Emission Control) Norcem, Norway
2005 1st PYROFLOOR® Clinker cooler Mordow Zement, Russia
2012 1st PYROLOOP® LowNOx AF calciner Sönmez Cimento, Turkey

2015 PYROREDOX® NOx Control ...

2016 Clay Calciner ...
2016P
2017 ...

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PYROCLON® Calciner - Overview
Former Preheater/Calciner Arrangements Actual Modification Projects

w/o Calciner Pyroclon® S Pyroclon® RP crossflow

In Line Calciner Separate Line Calciner
w/o TAD

Actual KHD Calciner Technologies for new Projects

Pyroclon® R with Combustion
Pyroclon® R Pyroclon® R LowNOx Pyroclon® R LowNOx AF Chamber

In Line Calciner with TAD In Line Calciner with TAD In Line Calciner with TAD In Line Calciner with TAD

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PYROCLON® Calciner - Technology
Pyroclon-R Pyroclon-R LowNOx Pyroclon-R LowNOx AF Pyroclon-R with
In-line calciner (ILC) ILC with staged combustion ILC with staged combustion Combustion Chamber
ILC with CC

Latest generation

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PYROREDOX Modul – NOx Reduction
Existing Pre-Calciner

PyroRedox

Additional Steel Structure

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Combustion Chamber Modul – AF Firing
Multi-Chanel Burner

- Highest flexibility
- Various fuel

Conical „Chinese“- Hat

- Heat radiation for better

fuel ignition

Hot Center Core

Tertiary air distribution
- Easy fuel ignition
- Easy Temperature
and Oxygen control

Video

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PYROROTOR Modul – AF Firing

PYROROTOR® Technical Data

Principle: Mechanic:
• Rotary drum reactor, similar to hazardous waste incineration. • Standardized set of reactor sizes for different clinker
productions.
Process Technology: • Direct drive of rotary drum. Revolution from 0,4 to 2,5 rpm.
• Temperature depending on tertiary air flow rate. Up to 1200°C.
• Residence time: Fuel Dosing:
• Gas: ~ 2 seconds. • Double screw conveyor for waste, coarse RDF….
• Material: ~ 10 minutes (depending on drum speed) • Flap gate for whole tires.

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KHD`s PYRO SOLUTIONS

− Preheater
− PYROCLON® Calciner
− Rotary Kiln
− Clinker Cooler PYROFLOOR2® & PYROSTEP2®
− Firing Systems
− Bypass Systems
− Process Fans

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Rotary Kiln - History
1980 1st PYRORAPID® Kiln Spenner, Germany

1980 1st PYRO-JET® Burner Bonner Zement, Germany

1988 1st PYROCLON® LowNOx calciner Norcem, Norway
1991 1st PYROTOP® Mixing chamber LAF Adriasebina, Italy
1992 1st PYROSTEP® Clinker cooler Maihar Cement, India
2002 1st PYROCLON® Calciner with Comb. Chamber Norcem, Norway
2002 1st Circulation of Bypass Gases (Emission Control) Norcem, Norway
2005 1st PYROFLOOR® Clinker cooler Mordow Zement, Russia
2012 1st PYROLOOP® LowNOx AF calciner Sönmez Cimento, Turkey

2015 PYROREDOX® NOx Control ...

2016 Clay Calciner ...
2016 PYROPUSH® Coarse AF burning ...
2016 AF D ...

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Rotary Kiln - Standard series
2-pier kiln (PYRORAPID®)

▪ Diameter from 3.6 m to 6.0 m in 0.2 m steps

▪ Length to diameter ratio ~ 13 (L/D ~ 13)

▪ Capacities up to 8000 – 10000 tpd

▪ Inclination 3.5%

3-pier kiln

▪ Diameter from 3.6 m to 6.0 m in 0.2 m steps

▪ Length to diameter ratio ~ 16 (L/D ~ 16)
▪ Capacities up to 10000 – 12000 tpd
▪ Inclination 3.5%

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Rotary Kiln - Standard series – main components

Inlet sealing
Girth gear

Tyre
Tyre section cooling

Hydraulic thrust roller Outlet

Bearing Roller sealing
Pinion

Drive
Sintering zone cooling
(optional)
Pinion
Auxiliary gear
Main motor
Auxiliary
motor Main gear
Oil cooler for
Diesel engine
main gear
(optional))
(optional)

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Rotary Kiln - Standard series
Tyre
▪ Rectangular solid section tyres
▪ Low ovality (below 0.2% of nominal Kiln diameter)
▪ Low Hertz pressure between roller and tyre (< 430 N/mm²)
▪ Low bending stress (< 58 N/mm²)
▪ Designed according to the above mentioned values whilst
considering the weight

Tyre fastening
▪ Robust design without mechanical processing
▪ Replace the sliding plates for easy adjustments without
applying welding work on the rotary tube
▪ Laterally open locking, for faster discovery of
deformation and hot spots
▪ Unrestricted ability to lubricate the contact surfaces
▪ No restriction during measuring in the near of the tyre
▪ Guide blocks flush aligned for uniform distribution of the
axial forces and slight wear

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Rotary Kiln - Standard series
Bearing
▪ Kiln bearing assembly with heavy double bearing pedestals
▪ Water cooled
▪ Oil scoop lubrication
▪ The position of the supporting roller axes can be checked very
easily and exactly (vital for trouble-free operation)
▪ Bearings chosen according to the maximum pressure
▪ Adjustment of the position of DGL’s possible if needed (in axial
and transverse direction e.g. in case of changing thermal
expansion) due to a machined surface of the bearing base frame
▪ No need to align the bearings to each other, due to one solid
double bearing block unit

Roller with shaft

▪ Rectangular solid section rollers
▪ Solid shaft with very low bending stress

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Rotary Kiln - Standard series

Thrust Roller HDR

▪ Axial motion of rotary kiln is hydraulically controlled

(counteracts the motion forces of inclined kiln)
▪ Controls longitudinal kiln movement of +/- 25mm
▪ Automatically regulated by limit switches and timer delay

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Rotary Kiln - Standard series
Girth gear
▪ Form-fit for transmission of torque → separate transfer of drive
forces and static loads of kiln → high efficiency and low abrasion
(compared to friction drive)
▪ Girth gear fastening with tangential springs (resilient connection
elements balance the thermal expansion of the kiln tube and
avoid that girth gear or tooth engagement is affected)
▪ The width of the girth gear is a result of the motor power and
transmission ratio

Pinion
▪ Pinion gear with corrected toothing with large modulus → for a
good smooth running at high loads

→ Kiln can be restarted from any standstill! ([Link] case of excessively filled kiln or deformed kiln)
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Rotary Kiln - Standard series
Inlet
▪ The inlet is protected by a conical inlet ring of heat-resistant
segments
▪ Under upset conditions the rotating scoop ring with air-cooled
pockets safely returns overflowing hot meal, if any, to the inlet

Outlet
▪ Kiln outlet segments fastened to carrying arms
→ flaring of the tube shell is not needed
▪ Guided air cooling → more efficient cooling
▪ Uniform wall thickness of outlet segments for better cooling
efficiency into the forefront → reduction of tension
→ less wear

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Rotary Kiln - Standard series

Inlet and Outlet Sealing

▪ Prevent false air entry into kiln

▪ Spring-loaded type (standard)
or pneumatic type (option) available
▪ Designed for high temperatures in consideration of
longitudinal displacement, heat expansion and radial run-out
▪ Sealing with low wear
▪ Easy maintenance
▪ No lubrication of contact area of sealing needed
▪ Long term proven seals which have been successfully used
in plants all over the world

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KHD`s PYRO SOLUTIONS

− Preheater
− PYROCLON® Calciner
− Rotary Kiln
− Clinker Cooler PYROFLOOR2® & PYROSTEP2®
− Firing Systems
− Bypass Systems
− Process Fans

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PYROFLOOR2® Clinker Cooler
Overview
▪ First manufactured PYROFLOOR® displayed in KHD’s work shop in 2005

▪ First PFC commissioned in 2007

▪ Worldwide more than 50 PYROFLOOR ® sold for capacities ranging from 1,000 to 10,000
tpd

▪ 52 Pyrofloor ® units in operation till now.

▪ New series of Pyrofloor ® Cooler - PFC2 ® was introduced in 2012 for capacities up to
12,000 tpd

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PYROFLOOR2® Clinker Cooler - Advantages
Wear protection – in the clinker bed

▪ Pyrofloor® Coolers: no moving parts in the clinker bed = No wear!!!

▪ Aeration cassettes give ‘autogenous’ wear protection to metal

parts.

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PYROFLOOR2® Clinker Cooler - Advantages

▪ High recuperation efficiency

▪ Less wear
▪ Reduced spare inventory
▪ Less erection time

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PYROSTEP2® Clinker Cooler
Based on PYROSTEP® Cooler

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PYROSTEP2® Clinker Cooler - Advantages

Advantages of New PYROSTATIC® grate

• Aerodynamic design of aeration slots of the static grate plate & ‘chamber aeration’ in
place of ‘row aeration’ ensures reduced pressure drops ➔ optimized for increased
recuperation.

• ‘Horseshoe’ design enables quick distribution of clinker along the width. No air
‘escapes’ from sides and edges without cooling the hot bulk.

• Optimal pile formation in hot zone, that quickly transforms into ‘even’ clinker bed ➔
Homogenous cooling

Optimized operations!

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PYROSTEP2® Clinker Cooler

Advantages of New K-type grate plates

• Reduced pressure drop across standard grate plates ➔ saves electrical

power

• Pocketed design of new standard grate plates ➔ Longer lifetime, less

replacements ➔ lower maintenance costs

• Reduced shutdowns for maintenance and troubleshooting.

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PYROSTEP2® Clinker Cooler - Advantages

• High recuperation

• Reduced maintenance

• Low clinker outlet temperatures

• Low power demand and waste gas losses

• Highly reliable grate drive mechanism

(option of hydraulic or electromechanical drive
system)

Optimized operations!

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KHD`s PYRO SOLUTIONS

− Preheater
− PYROCLON® Calciner
− Rotary Kiln
− Clinker Cooler PYROFLOOR2® & PYROSTEP2®
− Firing Systems
− Bypass Systems
− Process Fans

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Firing Systems
KHD supplies a broad range of
burners for the entire clinker
burning process and all types of
fuels
Kiln burners
▪ PYROJET®
• Calciner burners
▪ HCB Combustion
Chamber Burner
▪ PYROBOX®
▪ HPYS Gas Ring
Burner System

Suitable for
▪ Conventional
Fuels
▪ Alternative Fuels

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PYROJET® Burner
▪ Efficient combustion due to sandwich flame concept
▪ Low primary air demand
▪ Low NOx emissions
▪ Sturdy design
▪ Burner momentum from 3.5 to 12.0 N/MW
▪ Suitable for following fuels:
▪ Coal / Petcoke / Lignite
▪ Heavy Fuel Oil
▪ Natural Gas / Lean Gas
▪ Animal Meal
▪ Sewage Sludge
▪ RDF
▪ Wood Chips
▪ Control Range 1:8 – 1:10

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PYROBOX® Calciner Burner

The PYROBOX® is a sturdy and

simple solution for the combustion of PYROBOX®
pulverized or granular fuels like coal
Burner
dust, petcoke or dried sewage
sludge. The PYROBOX® enables a
connection
pre-mixture of fuel and meal. This
ensures fast ignition on the hot flange
material, direct heat transfer and
therefore a more even heat profile in meal box
the calciner with benefits regarding
emissions and refractory service
time. poking hole
The special design of the
PYROBOX® burners works without riser duct
additional primary air.

splash plate

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PYROBOX® Calciner Burner
Fuel Distributor
The picture shows the installation of two
PYROBOX® systems for the combustion of
coal and petcoke in a PYROCLON®
LowNOx AF calciner. The upper box feeds PYROBOX®
meal and fuel into the upper part of the
riser, where kiln gases and tertiary air
Calciner Burner
merge, whereas the lower box supplies the
riser duct above the smoke chamber and
enables NOx abatement due to staged
combustion.
This technology ensures stable calciner
operation as well as low NOx emissions, as
a part of the kiln NOx is reduced to N2.

PYROBOX®
LowNOx Burner

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Ring burner system for gas-fired calciners

The gas ring burner system

from KHD enables fast ignition
of gas in the calciner duct,
even under complicated
conditions. It consists of 1 or 2
burners with ignition system
and up to 8 injection units
which are installed on the
circumference of the calciner
duct. The injectors require no
cooling air and can stay in
place even if not in operation.
The ignition system creates a
double-staged, strong ignition
flame to ignite the gas even at
low tertiary air/kiln gas
temperatures.

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HCB® Combustion Chamber Burner

Solid Alternative Fuels Primary Air

The HCB burner is Gas

sturdy and maintenance-
friendly designed. All
wear parts can be
exchanged. Pulverised Fuels

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KHD Hot Gas Generator

KHD has now also a simple hot gas generator

available. It is fired with an industrial monobloc
burner for oil or gas.
▪ Currently available for 1-100 MW
▪ Easy to scale for different requirements
▪ Industrial burner with integrated control
system or build burner for larger capacities
▪ Excellent mixture between tempering air
and flue gas due to heated tempering air
▪ Cold jacket
▪ Medium refractory inventory for good
protection and as a compromise between
fast reaction on load change and even gas
temperatures

39
KHD`s PYRO SOLUTIONS

− Preheater
− PYROCLON® Calciner
− Rotary Kiln
− Clinker Cooler PYROFLOOR2® & PYROSTEP2®
− Firing Systems
− Bypass Systems
− Process Fans

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KHD Bypass System- Mixing Chamber

Bypass Gas Duct

Mixing Chamber (Conical)

Cooling Air Inlet

Extraction point

Kiln Inlet

Tertiary Air Duct

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KHD Bypass System- Arrangement

• Extraction Point at Kiln Inlet

• Mixing-Chamber
• Cooling-Air Inlet with Fan
• Waste Gas Duct
• De-Dusting Equipment
• Bypass-Fan (Filter Fan)
• Bypass waste gas to Main Stack
• Dust Transport Devices and Silo

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KHD`s PYRO SOLUTIONS

− Preheater
− PYROCLON® Calciner
− Rotary Kiln
− Clinker Cooler PYROFLOOR2® & PYROSTEP2®
− Firing Systems
− Bypass Systems
− Process Fans

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Process Fans
• Raw Mill Fan
For high dusts loads and high
differential pressures.

• Preheater Waste Gas Fan

Suitable for peak temperatures up to
500 °C at high efficiency.

• Dedusting Fan
For kiln / mill waste gas, cooler- and
bypass de-dusting for large volumetric
flows at low pressure.

• Fans for cement grinding

With hard faced blades to decrease
wear.

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Process Fans

• Impeller diameter up to 4,5 m.

• Peripheral speed up to 200 m/s.
• Max. temperature up to 500 °C.
• Low vibration operation.
• Special design for abrasive gas flows.
• Simple bearing design – no external oil
cooling required.
• Available with fixed anchor or vibration
isolation base frame.
• Vibration monitoring system.

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Summary
▪ KHD delivers PYRO Technologies fitting for Future
Environmental Regulations

▪ Equipment Solutions for Standardized and Customized

Pyrolines up to 12.000 t/d

▪ Specific Requirements and Parameters for

Environmental Friendly and Energy Efficient Pyro Lines

▪ AFR Integration and Process Design

▪ Customized Plant Upgrade and Modernization

▪ Power Consumption Targets as well as NOx, SOx

Emisson Regulations Performable

▪ High Reliabilty of Equipment and Operational Safety by

various KHD References of “Medium - up to“High
Capacty -” PYRO Lines

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ZAB Zementanlagenbau GmbH Dessau
Brauereistrasse 13
06847 Dessau-Rosslau
Germany
* zab-info@[Link]
' +49 340 21965 213