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

Fan upgrade technology for the cement industry Author: Ryan Preis, Application engineering, AirStream Systems Inc. Co ‐ Autor: Peter Windmoeller Sales custom fan upgrades

Introduction 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 2

Process Fan Requirements • Baghouse ID Fans • Kiln ID Fans • Raw Mill Fans • Finish Mill Fans • Cooler Vent Fans 3

Process Fan Costs  Initial capital investment  Ongoing maintenance costs  Operating costs 4

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) 5

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 6

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 7

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 8

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 9

Case Study#1 2700kW Kiln ID Fan Upgrade AirStream upgrade achieve the following results:  Plant production increase of 7%  Power consumption reduced by over 36% = 1235kW  No noticeable wear after 2 years  During annual maintenance no repairs were required. 10

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 11

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 12

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 13

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 14

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. 15