Production of mineralised clinker
Mineralisation is achieved by controlled introduction of sulphate and fluoride into the kiln system. The mineralised clinker has higher strength potential and is an excellent material for producing high strength cement or blended cements. Additional benefits of mineralisation are: lower burning zone temperature, lower NOx emission, easier grindability of clinker and the possibility of using fuels with high sulphur content.
Customer Services provides services ranging from feasibility studies to the implementation of a mineralisation technology project. To determine whether a plant is able to adopt production of mineralised clinker, the raw materials are analysed and mineralised samples are produced and tested in the Customer Services laboratory to evaluate the potential benefits. If the laboratory tests prove positive, the next step is to plan and perform a full-scale industrial test at the plant. Customer Services specialists will assist in monitoring the production of the mineralised clinker and the subsequent grinding of the clinker in a cement mill.
The results of the test and the cement qualities attained are then described in a report which will state an opinion on whether mineralisation is technically feasible for the plant in question. Your final decision whether to adopt mineralisation technology will also depend on the benefits of lower production costs vs. market attitude towards the produced cement, environmental aspects, and the initial costs of installing the mineraliser feed equipment.
To implement production of mineralised clinker, Customer Services can license the technology and provide assistance in commissioning and optimising production.
For additional information, please see Brochures.
Conversion to petcoke
Firing with petcoke instead of traditional fuel is normally attractive due to the lower price of petcoke. But petcoke usually has lower volatile and higher nitrogen and sulphur contents than traditional fuels, so changing to petcoke can also entail certain operational problems such as: blockages in the preheater cyclones, build-up in the kiln riser duct, increased NOx, SO2 and CO emission, a dusty kiln and a more unstable calciner operation. Longer downtime due to these problems can easily offset the advantage of lower production costs, and the effect of changing to petcoke should therefore be carefully evaluated before the change is made.
If requested, Customer Services will send a process design specialist to the plant to study the performance of the kiln system and the type of fuel currently being used. This survey will form the basis for considering the implications of changing to petcoke firing. The visit to the plant will include gathering process data for the kiln system and the necessary material and gas sampling. Also, the performance of the kiln burner and the coal mill grinding capacity will be included in the survey.
The results are compiled in a report with recommendations for any modifications to the kiln parameters or the raw mix which should be made before changing to petcoke firing. For the actual implementation of the change, Customer Services offers to send a specialist to assist plant personnel with troubleshooting and addressing any initial difficulties.
For additional information, please see Brochures.
Gas emission control Stronger demands for protection of the environment have led to greater focus on the emission of NOx, SOx etc. from cement plants. Cement producers are therefore facing increasingly stringent limits for plant emissions.
Customer Services provides process specialist who are able to measure the emissions and compare them with the permissible levels. The next step of the specialist's investigation is to determine the sources of the emission by examining the process parameters and the kiln system. The specialist may also suggest changes to the preheater design, primarily the pre-calciner, the operational procedures or process parameters in order to lower emission. The specialist can also be contracted to assist with tests to verify the effects of these changes at the plant.
Any action taken to eliminate or reduce emissions is always aimed at eliminating the sources of the emissions. If the source of the high emission cannot be eliminated or reduced sufficiently, the next step will be to examine the possibility of either transforming or absorbing the NOx, SOx, etc., and if possible, to include a practical test of the method(s) that might be applicable.
The results of the investigation and tests are described in a report that includes recommendations for future action.