Preheater calciner systems

Successful on every level 2 An optimal process Today’s modern plant preheats raw meal to calcination temperature in a multi-stage cyclone preheater. Most of the calcination process takes place in a separately fired, stationary calciner, while the remaining calcination and clinkerization process takes place in a rotary kiln. FLSmidth has precisely what cement producers need to make it an optimal process. With its low emissions, flexibility and ease of operation, the FLSmidth In-Line Calciner (ILC) preheater has been a success since its debut in 1976. And thanks to our continual development of...

3 section of the calciner. This creates a “hot zone” in the lower section of the calciner that is conducive to burning difficult fuels and further NOx reduction. Design characteristics • Full capacity range of today’s plants of 13,000 tpd or more • Built with single or multiple preheater strings with up to 6 cyclone stages • Ratio of firing in calciner: 55-65% • Calcination at kiln inlet: 92-95% • Allowable bypass of kiln gas: 0-60% • For bypass of kiln gas up to 100%, special ILC version applies • Optional “hot zone” in lower section of calciner • Available with or without the HOTDISC™ combustion...

Creating a system that meets unique needs 4 Burn coarse alternative fuels Increasingly, plants are burning solid waste fuels to achieve a variety of benefits. By integrating the ILC with our HOTDISC combustion device, it is possible to achieve unsurpassed fuel flexibility with minimal impact on process stability and performance. The HOTDISC is a safe, simple and effective combustion device that has proven to be the best available technology for substituting calciner fuel with coarse alternative fuels. With the HOTDISC, plants can burn all kinds of solid waste in sizes up to 1.2 metres. This eliminates...

5 Typical process flowsheet of an ILC kiln system -465 mm WG (4.5 kPa) 293° C 650° C 890° C 478° C 799° C 1000° C 280° C 100° C material gas fuel 1 Raw meal feed 2 Exhaust gas 3 Kiln gas bypass, if any 4 Clinker 5 Kiln burner 6 Calciner burners 7 Tertiary air duct 8 Tertiary air duct damper 9 Cooler excess air

Preheater components 6 Cyclones FLSmidth preheaters have been based on proven low pressure loss (LP) cyclones. The unique design of the LP cyclone ensures high thermal efficiency and low pressure drop while enabling a flexible and space-saving layout. LP cyclones have no horizontal surfaces on the inside for material to accumulate, thereby securing stable operation. The top stage has a special geometry to provide the lowest dust loss while maintaining low pressure drop. LP cyclones are not just for completely new preheaters but may be individually fitted to upgrade existing preheaters. Central...

Upgrades and special solutions 7 1 2 3 4 ILC upgrades It is possible to upgrade virtually any existing kiln system into the modern ILC – regardless of whether it comes from FLSmidth or another supplier. This includes not only conventional suspension preheaters (SP) and other calciner systems, but also complete transformations of long dry and wet kiln systems. SLC-D preheater calciner system As an optional preheater calciner system, FLSmidth also offers the SLC-D. With its high-temperature pre-combustion chamber, the SLC-D (Separate-Line with Downdraft Calciner) offers unique flexibility in fuel...

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