Fan upgrade technology for the cement industry

15 Pages·2013·1.1 MB·English

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