Fan upgrade technology for the cement industry Author: Ryan Preis, - - PowerPoint PPT Presentation

Author: Ryan Preis, Application engineering, AirStream Systems Inc. Co‐Autor: Peter Windmoeller Sales custom fan upgrades

Fan upgrade technology for the cement industry

Process improvement is a necessary cost to improve plant operation:

• Environmental equipment modifications
• Increased use of alternative fuels
• Kiln upgrades
• Raw mill upgrades
• Duct modifications
• Efficiency improvements

Introduction

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Process Fan Requirements

• Baghouse ID Fans
• Kiln ID Fans
• Raw Mill Fans
• Finish Mill Fans
• Cooler Vent Fans

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• Initial capital investment
• Ongoing maintenance costs
• Operating costs

Process Fan Costs

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Fan Upgrades

Capital Cost Savings

• Minimized equipment costs

(reuse fan housing, motor, bearings, etc.)

• Reduced installation costs

(no foundation changes)

• Reduced installation time

(shorter shutdown required)

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Fan Upgrades

Reduced Maintenance Costs

• Maintenance cost reduced up to 50%

(reduced dust impingement, improved design technology)

• 2x to 4x longer wear life

(longer replacement cycles, reduced replacement costs)

• Reduced dust build‐up

(gas velocities, engineered blade design)

Year 3 After Minor Repairs

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Fan Upgrades

Operating Cost Benefits

• Electrical cost reduced 10% to 30%

(AirStream high efficiency rotors)

• Performance increased up to 25%

(within existing fan housing, existing motor)

• Fast payback, typically 1‐2 years

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Case Study#1

2700kW Kiln ID Fan Upgrade Canadian cement plant with:

• Calciner
• 4‐stage preheater

Process improvements to increase production included modification of:

• Preheater
• Firing systems
• Clinker cooler line

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Case Study#1

2700kW Kiln ID Fan Upgrade Conditions found at site:

• Plant production was fan limited
• Fan total efficiency was ~50%
• Wear related maintenance caused production stoppages
• Annual impeller replacement due to rapid wear rates
• Complete fan replacement was seen as only solution

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Case Study#1

2700kW Kiln ID Fan Upgrade AirStream upgrade achieve the following results:

• Plant production increase of 7%
• Power consumption reduced by
• ver 36% = 1235kW
• No noticeable wear after 2 years
• During annual maintenance no

repairs were required.

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Case Study#2

4500kW Raw Mill Fan Upgrade New 1.8Mt/y cement plant in Southern US:

• Previous project with this

customer resulted in 1804kW power savings

• Original process fans had

light construction

• AirStream invited to

evaluate Raw Mill ID Fan

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Case Study#2

4500kW Raw Mill Fan Upgrade Conditions found at site:

• Uneven material loss due to

insufficient wear protection and light construction

• Heavy maintenance required

after first year of operation

• Fan pressure was only 82% of

design value at full speed

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Case Study#2

4500kW Raw Mill Fan Upgrade AirStream upgrade achieved the following results:

• Restored full design

performance

• Reduced power use by

804kW

• Increased wear life by more

than 4 times

• Significantly reduced

maintenance requirements

• Economical project cost

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Summary

New technology by AirStream improves process fan operation:

• Electrical cost reduced by 10% to 30%
• Maintenance cost lower by up to 50%
• Dust build-up reduced
• Impeller wear life increased by 2x to 4x
• Performance increased by up to 25%
• Fast payback

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Conclusion

Still No Wear!!

Peter Windmoeller p.windmoeller@airstreaminc.ca +1 (514) 887-7172 AirStream Systems is a full service supplier of large process fans to cement plants throughout North America, Central America and the Caribbean.

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