The relationship between the Ukraine-based plant and FLSmidth has spanned almost twenty years, including two production lines at the plant commissioned by FLSmidth in 2008 and 2014. The plant had already installed the precursor Down Draft Cyclone (DDX) in a successful upgrade project in 2015, and was therefore keen on commissioning the CCX on one of its production lines.
The new cyclone at our plant is a considerable breakthrough in the cement industry, and we are proud to be the first to install one. When we saw reduced pressure losses of 40-50 percent, we were pleasantly shocked!
The CCX top cyclone explained
Conventional cyclones separate dust from gas, but unlike the conventional types, the CCX combines heat exchange and separation into one process. As a result, not only is heat transfer improved, but meal exits the cyclone at a higher temperature than the exit gas. This guarantees reduced net heat consumption of 8-10 kcal/kg clinker along with a 50 percent pressure drop compared with a conventional cyclone of the same size.
The CCX’s improved heat transfer efficiency means it is often possible to reduce the number of cyclone stages. For example, a four-stage preheater will often be possible instead of a five-stage preheater, resulting in lower structural and installation expenses.
A special feature is the gas outlet duct installed at the bottom of the CCX cone. This prevents the cyclone from being filled with dust from a blocked meal outlet pipe. This allows a much larger cyclone to be installed, resulting in a lower pressure drop across the cyclone.
Low-cost, fast installation
For new preheater projects, the CCX will decrease the initial cost of the preheater structure and installation time. In existing preheater towers, the acting loads on the structure usually limit installation of larger top-stage cyclones than originally installed. However, due to its lightweight design, the CCX is well suited for such upgrades. For plant owners, this means the ability to boost preheater operation at a lower cost.
I want to thank FLSmidth for their collaboration on this upgrade project. Their new CCX is far ahead of anything else on the market and enables us to increase our outputs. We are very happy with the results.