Get more out of your plant.

Preheater &
Calciner
State-of-the art pyroprocessing
equipment for every application
 Calciner Overview
Preheater &

Preheater &
Calciner
Overview
KHD Humboldt Wedag was the first company to introduce mul- more efficent and more economic solutions that yield extra value
tiple products to the cement industry. Most of these are still for our customers.
the market standard today. This fact underlines our position as
technology leader and expert in the field of cement production Our pyroprocessing equipment offers the highest efficiency for
technology. With regards to essential pyroprocessing equipment, lowest operating cost. And thanks to a modular concept, we are
amongst others, the preheater and the calciner were first intro- able to offer just the right solution for any project-specific
duced by KHD. requirement. No matter what production capacity, fuel concept,
regional prerequisites or emission limitations, we design the best
Today, we build on these roots with the aspiration to always pro- pyroprocessing solution for any application between 2 000 and
vide the best solutions for our clients and their projects. At the 14 000 tpd.
same time we are constantly challenging ourselves to develop
 Stage 1
Double Separator

Calciner Overview
Stage 1 Waste Gas Duct

Preheater &
Stage 2 High Efficiency Cyclone
Stage 2-5 Splash Box
Pyrotop®
reheater &
Pyroclon® R
Stage 3 Pyroclon® Lownox AF
Pyroredox®
Flash Calciner
Stage 4 K-Tube
Pyrobox®
alciner

Stage 5

PyroIncinerator, Combustion Chamber, Pyrorotor®

Bypass Quenching Chamber,

Coal Distributor, Pyrobox®, Gas Ring Burner
 Preheater Range
Preheater Range
The goal is to achieve the best combination of heat transfer, pressure We offer various solutions for specific
drop and building height. In modern cement production, efficient production capacities, based on demand or
drying and preheating of raw meal is not possible regional prerequisites.
without a state-of-the-art preheater.

Making the right choice

Depending on the targeted balance between investment
and operational costs, KHD offers the right model for maximum
customer benefit in any project. Generally, there are two
approaches with regards to cost:
5-STAGE PREHEATER 85 HE 67
Height: approximately 120 -130 m Reduced operational expenditure (OPEX)
The preheater requires a higher building but, due to
90 HE lower pressure drop, also has reduced energy demand.
Ø 9,0 m
This approach has a slightly higher initial investment but
85 HE
Ø 8,5 m requires less energy and hence, yields higher operational
80 HE cost-efficiency.
Ø 8,0 m
Reduced capital expenditure (CAPEX)
The cyclone diameter depends on the desired As the building is smaller in size, your initial investment and
pressure drop level civil cost are lower. As this means the preheater operates
with slightly increased pressure drop levels, the energy de-
mand is slightly higher.
 Preheater Range
Performance range Production [ tpd ]
high ∆p
for single string 8 000
preheaters Ambient Condition: 25 °C, 500 m a.s.l.
Preheater: 5-stage single string, with Pyroclon-R
7 000

6 000

5 000
Example size
4 500 tpd

4 000
low ∆p

3 000

2 000

1 000

56HE44 59HE46 62HE48 65HE50 68HE52 71HE54 74HE56 77HE58 80HE61 85HE67 90HE72 95HE75

Preheater Size
 Preheater Range
Optimized preheater design Influence of raw material moisture
Our preheater design is based on four key features that ensure best-in-
class performance and competitive pricing. HIGH KHD KHD KHD

6 5 4
STAGE PH STAGE PH STAGE PH

mbar
°C

Low High Dust Low Civil

Low High Dust Low Low
Waste Gas Separation Pressure Operation
Waste Gas
Temperature Separation
Efficiency Pressure
Drop Civil
Costs
Temperature Efficiency Drop Costs

Waste gas temperature

Best-in-class performance
In direct comparison to the competition we achieve higher separation effi-
ciency and lower waste gas temperatures after the top stage.

KHD Competitor A Competitor B

Separation Efficiency 96 % 92 % 94 %

Stage 4 PH Waste Gas Temperature 340 °C 350 °C 360 °C

Stage 5 PH Waste Gas Temperature 290 °C 300 °C 310 °C

LOW
Stage 6 PH Waste Gas Temperature 260 °C 270 °C 280 °C LOW Raw material moisture HIGH
 Double Separator
Double Separator Long dip tube

The prevention of dust loss is the core task of the top cyclone stage. For this
reason, a double separator is used to divide the gas flow to achieve the highest
separation efficiency.

Long cylindrical shaft

KHD‘s double separator has a small diameter-to-height ratio and a longer
dip tube compared to standard system cyclones. With the combination
of these design features, we achieve a separation efficiency of 96 % and are
able to reduce dust losses to a level below 25 g/m³. As the high separation
efficiency serves for a low meal circulation, the pressure drop and heat losses
of the complete preheater are reduced significantly and we can ensure a sta-
ble and continuous operation of the pyroprocess.
Spider plate prevents whirl-up of
Waste gas duct design separated material and minimizes dust
KHD‘s standard is the outlet spiral which reduces the height of the waste gas losses
duct by approximately 60 % compared to the widely used Holderbank bend
design. However, if required due to overall tower layout, we offer various alterna-
tive waste gas duct designs.

Upgrade option
Top stages of older preheaters are often not properly sized.
An exchange of the top stage with a state-of-the-art double separator
lowers the overall pressure drop and meal losses. Replacing the top stage
is a proven and relatively simple measure to improve efficiency and increa-
se the production. Such modifications can be executed quickly and offer a
Outlet spiral Holderbank bend Standard bend fast return of investment.
 Cyclone Design
Cyclone Design Advantages of the new cyclone design
· Optimized dip tube and gas inlet geometry
· Up to 15 % reduced weight, optimized by FEA based on Eurocode III
· 70° inclination of cyclone cone to prevent material accumulation
Cyclones ensure that the heat from the gas stream is efficiently · Bent cone tip for controlled and continuous meal flow
transferred to the raw meal. · No vortex breaker required as the long distance between
the dip tube and cone tip prevents unwanted accumulation
With our new high efficiency design we were able to downsize all cyclones of material
by up to two sizes while maintaining the same performance in terms of
pressure drop, waste gas temperature and separation efficiency.

Pressure drop
KHD‘s cyclones, dip tubes and gas riser ducts are optimized for best-in-class
heat transfer and lowest pressure drop. They offer proven performance and
extra saving potential, both already achieved at many operating plants. old
designs

Latest design improvements

latest high
efficiency design
15 % 18 % 21 %
Weight
reduction
Smaller
footprint
Less
volume
100 %
Performance
Velocity
 Cyclone Design
Prestressed cyclone ceiling During erection
Standard expansion joints in the gas ducts – as utilized by other suppliers – The cyclone ceiling is
pretensioned in relation
require repeated and meticulous maintenance. The prestressed cyclone
to the cyclone size.
ceiling is a smart design feature by KHD that demands no maintenance,
yet offers the necessary length compensation. With negligible extra effort
during erection and installation, KHD‘s cyclone design reduces cost, completely
eliminates maintenance effort for cleaning, and improves the operational
safety of the equipment, as proper compensation for thermal stress
is always ensured.
In operation
When the preheater
Splash boxes for ideal meal distribution
is commissioned, the
KHD‘s splash boxes are equipped with a prestressed ceiling
dispersion plate to ensure best possible reshapes to its original
meal distribution into the hot gas flow. dimensions as a result
For full customization and flexibility, the of thermal expansion.
dispersion plate is fully adjustable in terms
of positioning and can be replaced if needed.

Dispersion plates
· Uniform meal distribution Upgrade option
· Controlled meal flow Our splash boxes are available as retrofit items that can
· Better heat transfer be installed quickly and easily. Thanks to a short downtime
and low investment cost, splash boxes are upgrades with a
very small payback time in comparison to new cyclones or
other extensive modifications.
 1
Special Projects
Special 10 000 tpd in the
Himalayas (1)

Projects For a client in India we have

designed a preheater that works at
an exceptionally high altitude
Although we offer a wide range of (1 370 m above sea level). At the
same time the client wanted a
standardized products for most use cases,
6-stage preheater to achieve the
we are often approached by clients with highest level of fuel utilization and
exceptional or challenging requests for heat efficiency. On top of that, the
their projects. As a technology leader regional administration set a
and customer-focused OEM, we make building height limit for the project.
Combining all of the above with a
sure that our clients always get the
desired production capacity of
best solution possible, no matter how 10 000 tpd the outcome was a
demanding the project might be. four string preheater combined
with two Lownox calciners.
2 3
Special Projects
Flexible production demands Energy-efficient production
a flexible solution (2) for a semi-wet process (3)
Based on client‘s request we For a Russian client with
developed and built a three slurry raw material (chalk) we
string, 6-stage preheater designed a state-of-the-art
that requires just a single semi-wet production line.
ID fan for the entire waste gas To ensure best-possible raw
flow. The preheater also nee- material deagglomeration,
ded to be flexible in terms of grinding and drying, the
production: the client preheater tower comes with
requested a capacity range two impact hammer mills.
from 6 000 to 10 000 tpd. Thanks to these, a uniform
To ensure long-term particle size and composition
operation, even with the can be achieved.
likelihood of further intensified
emission level limitations, we
combined the preheater with
a Lownox AF calciner and a
highly sophisticated Pyroredox®
precalcining unit for lowest
possible NOX emissions.
 Calciner Series
Calciner Calciner sizes and performance range

Series Production [ tpd ]

14 000 high
∆p
60 % of the fuel used at modern cement plants is
12 000
required in the calciners. Having introduced flash
calcination in the cement industry, KHD continues 10 000
to innovate in this center of fuel consumption with low
∆p
efficient and project-specific solutions. KHD calciners 8 000

feature the best flow and reaction conditions for

6 000
continuously stable operation at lowest possible fuel
cost and highest possible alternative fuel rates.
4 000

2 000

6 985
4 985
2 985

5 985
4 035

6 585
3 885

4 385
4 585
4 765
2 835

3 285

3 585

5 385
5 585
3 435

7 385
5 785
3 735
2 610

6 185
4 185

5 185
2 710

3 135
Calciner Size
 Calciner Series
Pyroclon® R Pyroclon® R Process Scheme
Pyroclon® R
The Pyroclon® R is KHD‘s simplest calciner with smallest building
1
height and lowest pressure drop, making it a highly attractive
low investment option. The Pyroclon® design is the basis for all of
KHD‘s more sophisticated and specialized calcining solutions.
2
Pyroclon® R design features

OXIDING ZONE
· Individual, case-to-case calculation of the length to achieve best fuel
residence time and a complete burn-out (> five sec)
· Aerodynamically optimized geometry for safe meal and fuel transport 3
avoiding drop-out and pumping 7
1 Pyrotop®
· Constricted orifice in the kiln riser duct to maintain gas balance and
2 Penultimate cyclone
prevent fall-through of coarse fuel 4 8 3 Bottom cyclone
· Comes with a Pyrotop® compact mixing chamber for complete burn-out 4 Fuel feed
5 Tertiary air duct
6 Rotary kiln
All Pyroclon® R calciner design features above also apply to KHD‘s 5 7 Meal to calciner
8 Meal to kiln
specialized calciner types like the Pyroclon® Lownox AF and addons 6
like the Pyroclon® Combustion Chamber. Exhaust gas (high NOX level)

Lean gas (high CO level)

Tertiary air (high O2 level)

Final exhaust gas after completed

combustion and calcination
(low NOX, CO & O2 levels)
 Calciner Series
Pyrotop® Mixing Chamber Optimized Gas Flow and Burn-Out
thanks to Pyrotop®

Our Pyrotop® ensures that combustion is complete before

the gas stream enters the lowest cyclone stage. This is achieved by
bringing together and mixing all gas strands for a complete burn-out.

Enhanced functionality at the gas turning

point at the top part of the calciner
· Allows intensive mixing of meal and gas strands with
lowest possible pressure loss
· Extended residence time
· Complete burn-out of CO
· Allows increased firing of alternative fuels
 Low NOX Solutions
Low NOX Achievable NOX emission levels
with available technologies

Solutions 1 750

* Requires a constant
high ammonia (NH3)
1 500
A high output of harmful emissions such as NOX was tolerated far injection.
** SNCR in combination
too long in cement production. In recent years, regulations have with Pyroredox® requires
1 250 considerably less ammonia.
continuously limited acceptable emissions. This trend is certain Kiln Burner
Optimization
to continue and is the right decision when looking at sustainability
1 000

NOx (mg/Nm3)
and our environment!
750 KHD Pyroclon®
As market leader for sustainable and environmentally-friendly Lownox AF
Calciner
technologies, KHD supports this initiative and is the right partner 500 Limit Europe SNCR*
Selective
to help you reduce your emission output. Non-Catalytic Pyroredox® SCR*
Selective
Reaction
Catalytic
250 Reaction
Limit Germany
Depending on the current emission limits in your country, it might be enough
Pyroredox®
to retrofit a Pyrojet® kiln burner or a Pyroclon® Lownox AF calciner from Limit China (populated provinces) + SNCR**
0
KHD. But when planning long-term, you should consider our newest
innovation. Pyroredox®, a sophisticated gasifying reactor, can sustainably
reduce NOX emissions without any negative impact on production capacity,
power consumption or fuel demand! And that at a fraction of the cost
of other potential solutions such as SCR systems.
 Low NOX Solutions
Pyroclon® R Lownox AF Pyroclon ®
Pyroclon® R Lownox AF Process Scheme
1
2
Pyrotop
Penultimate cyclone
LowNOx AF 3 Bottom cyclone
4 Fuel feed
The calciner that perfects the 5 Tertiary air duct
1 6 Rotary kiln
staged combustion
7 Oxiding zone
1 8 Pyrotop®
Meal to LowNOX zone
The Pyroclon® Lownox AF is KHD‘s core solution for low emissions 2 Penultimate cyclone
9 Meal to kiln
3 Bottom cyclone
without any extra end-of-the-pipe actions. Due to the additional 10Fuel
Meal
feedto oxiding zone
2 4
reduction zone (in comparison to a standard calciner like the Pyroclon® R) 5 11Tertiary
Lownox zone
air duct
6 Rotary kiln
the nitric oxides from the kiln can be reduced to the greatest possible
7 Oxidizing zone
extent. 8 Exhaust
Meal gas (high
to oxidizing zone NOX level)
9 Meal to Low NOX zone
7 3 10 Lean
Meal gas (high CO level)
to kiln
8 11 Low NOX Zone
4 Tertiary air (high O2 level)
9
10
Final exhaust gas after completed
Exhaust gas (high NOX level)
combustion and calcination
(low NOx, CO & O2 levels)
Lean gas (high CO level)
5
11 4 Basic DeNO
Tertiary reactions
air X(high O2 level)for Pyroclon
®

and Pyroredox®
6 · Final
2 NO exhaust
+ CO gasNafter
2
completed
+ CO 2
· combustion
2 NO2 + 4 and
CO calcination
N2 + 4 CO2
(low NOX, CO & O2 levels)

Basic DeNOX reactions for Pyroclon®

and Pyroredox®

· 2 NO + CO N2 + CO2
· 2 NO2 + 4 CO N2 + 4 CO2
 Pyroredox® Gas Flow &

Low NOX Solutions

Reaction Scheme
Pyroredox® Pyroredox® Process Scheme

Taking primary NOX reduction to the next level

The Pyroredox® is our newest development for reduced 1 1 Pyrotop®
1 Pyrotop
2 Penultimate cyclone
emissions. Pyroredox® is a gasifying reactor that supports 2 Penultimate cyclone
3 Bottom cyclone
the formation of CO- and CH-radicals and therefore 3 4 Fuelcyclone
Bottom feed
5 Tertiary air duct
reduces the amount of overall NOX emissions. 4 Fuel feed
6 Rotary kiln

PYROCLON LOOP
5 Tertiary
7 Mealair duct
2 to Pyroclon®
Pyroredox® offers various advantages for 6 Rotary
8 Meal kiln
to Pyroredox®
7 9 Meal
Meal to kiln
to kiln

PYROREDOX LOOP
your calcining process:
8 Meal to Pyroclon
· Suitable for all typical fuels gas (high NOX level)
9 MealExhaust
to Pyroredox
· Creation of a reduction zone, rich in CO- and CH-radicals
4 7 3 Leangas
Exhaust gas (high
(high CO
NOlevel)
level)
· Additional fuel residence time of approximately four seconds X
8
· Thermal pretreatment dries and partially gasifies solid fuels LeanTertiary air (high
gas (high O2 level)
CO level)
· Emission reduction in range of SCR systems 4 9 Finalair
Tertiary exhaust
(high gas after completed
O2 level)
· No need for extra reagents like ammonia combustion and calcination
· No investment for secondary measures Final(low
exhaust gas
NOX, CO & Oafter
2 completed
levels)
combustion and calcination
· Can be combined with SNCR for emission levels below 50 mg 5 (low NOX, COloop
Pyroredox® & O2 levels)
· Reducing zone
6 ·
PyroredoxMajor amount of fuel
loop
· Small
· Reducing zoneamount of meal
DeNOX reaction
· Major amount of fuel under
optimal conditions
· Small amount of meal
DeNOX reaction under
Pyroclon®
optimal loop
conditions
· Oxidizing zone
Pyroclon
· loop amount of fuel
Small
More details:
· Oxidizing
· zone
Major amount of meal
khd.com/pyroredox · Small amount
Completeofcombustion
fuel of
· Major amount
gasified of meal products
reaction
Complete combustion of
gasified reaction products
 Alternative Fuel Solutions
Alternative
Fuel Solutions
Pyroincinerator
A Pyroincinerator is the most cost-efficient and quickest upgrade
for alternative fuel processing. It works in any existing preheater
and does not require extensive or costly conversions.

The Pyroincinerator enables the combustion of coarser alternative fuels

in hot conditions (above 1 100 °C). The Pyroincinerator requires no direct
meal feeding, can handle a wide range of fuels and uses tertiary air as
combustion air.

· Requires no extra height in preheater structure

· Fuel is mechanically dropped into incinerator; no complex feeding required
· No direct meal feeding necessary
· Adjustable temperature through variable amount of tertiary air
· Quick upgrade with short downtime
· Short payback time

Upgrade option
· Easiest & quickest AF upgrade
· Minimal height requirement
 Alternative Fuel Solutions
Solutions for alternative
fuel processing AF pre-processing depth Fuel particle size

Pyrojet Kiln Burner Pyroclon R Pyroclon R with Pyroclon R with Pyroclon R with
Processing alternative fuels is a great opportunity to reduce cost and Pyrojet Kiln Pyroclon®
Calciner R Pyroclon
Pyro R with
Calciner ® Pyroclon
Combustion R with
Chamber
®
Pyroclon® R
Pyrorotor with
Burner Calciner Pyroincinerator Combustion Pyrorotor ®

emissions. In developed countries, the share of alternative fuels is Chamber

already way above 60 % and constantly on the rise. KHD offers a wide
Waste oil /
range of solutions and retrofits, from quick upgrades for prepared alternative Animal meal /
fuels, to sophisticated equipment that can efficiently process almost any Sewage slud-
ge
kind of alternative fuel, even large and nearly unprepared materials or fuel
with extremely poor burning properties. Biomass max. max. max. max. max.
2×1×1 mm (3D) 5×5×2 mm (3D) 20×20×5 mm (3D) 40×40×10 mm (3D) 100×100×15 mm
(3D)

We offer solutions that are great upgrades for preheaters from all manufacturers.
Plastics max. max. max. max. max.
Because available space is often an issue, some of our products, for example 2×1×1 mm (3D) 5×5×2 mm (3D) 20×20×5 mm (3D) 40×40×10 mm (3D) 300×100×100 mm
(3D)
the Pyroincinerator, require very little height in your existing structure. Our
Pyrorotor® on the other hand is highly flexible and can be installed inside the RDF / Fluff max. max. max. max. max.
10×10 mm (2D) 30×30 mm (2D) 70×70 mm (2D) 100×100 mm (2D) 300×300 mm (2D)
preheater building or positioned on an extra platform outside of the preheater,
if needed. Tire Chips max. max. max. max.
40×40×25 mm (3D) 50×50×25 mm (3D) 70×70×25 mm (3D) 300×300×25 mm
(3D)

Whole Tires
 Alternative Fuel Solutions
Pyroclon®
Combustion
Pyroclon® R Chamber
Combustion Chamber Process Scheme

Combustion Chamber
The Combustion Chamber (CC) enables the firing of coarse alternative 1
1 Pyrotop®
fuels in hot tertiary air. After one second of material retention time, 2 Penultimate cyclone
the fuels have lost enough of their physical mass to be carried by the 3 Bottom cyclone
1 Pyrotop
gas stream into the calciner, were final combustion takes place. 4 Fuel feed
2 5 Penultimate
Tertiary air cyclone
duct
Within the CC the walls are protected by a constant meal curtain 2 3 6 Bottom
Rotarycyclone
kiln
to reduce wear and increase refractory lifetime. 4 7 Fuel
Oxidizing
feed zone
8 Meal to combustion chamber
5 Tertiary air duct
9 Meal to kiln
· Start of combustion in pure air and at 6 Rotary kiln
7 Oxiding zone
Exhaust gas (high NOX level)
high temperatures (approximately 1 200 °C) 3 8 Meal to combustion chamber
· Total fuel retention time above six seconds 7
8 9 Lean
Meal to gas
kiln(high CO level)
· Low demand for fuel preparation 4
Tertiarygas
Exhaust air (high
(high ONOlevel)
level)
· Fuel inlet feed up to 800 mm in diameter 2
X

9 Final
Lean gasexhaust
(high gas
CO after
level)completed
combustion and calcination
Tertiary air
(low NO X (high 2O2 level)
, CO & O levels)
5
Final exhaust gas after completed
6 combustion and calcination
(low NOX, CO & O2 levels)

Upgrade option
The combustion chamber is the perfect upgrade for a
Lownox AF calciner as it can be retrofitted without major
adaptation to the preheater building, which is already of
the required height.
 Alternative Fuel Solutions
Pyrorotor® Pyrorotor® Process
Pyroclon R ® Scheme 1

KHD‘s most advanced technology for the

with Pyrorotor®
processing of the coarsest alternative fuels. 1

The Pyrorotor® is a combustion reactor that

processes materials with inferior burning
1 Pyrotop
properties reliably as secondary fuel. 2 2 Penultimate cyclone
It constantly circulates fuel with sufficient 3 Bottom cyclone
retention time to guarantee a complete burn-out. 4 Fuel feed
5 Tertiary air duct
This lets you use the coarsest waste-derived 6 Rotary kiln
3 7 Oxiding zone
materials, without any pre-processing, to produce 7
8 Meal to calciner
low-cost energy. The result? More fuel options, easier 4 1 Pyrotop®
8 9 Meal to kiln
2 Penultimate cyclone
procurement, less time requirement, and above all, much
3 Bottom cyclone
lower costs, giving your pyroprocess an unmatched level of 9 Exhaust
4 Fuel gas
feed (high NOX level)
4
efficiency and flexibility. 5 Tertiary air duct
Lean gas (high
6 Rotary kiln CO level)
7 Oxidizing zone
5 Tertiary air (high O level)
· Gas temperature depending on tertiary air flow rate, up to 1 200 °C 8 Meal to calciner 2
9 Meal to kiln
· Operation at adjustable speed between 0.3 and 3.0 rpm allows 6 Final exhaust gas after completed
varying fuel retention times combustion and calcination
Exhaust gas (high NOX level)
(low NOX, CO & O2 levels)
· Can be retrofitted into any existing plant structure
Lean gas (high CO level)

Tertiary air (high O2 level)

Final exhaust gas after completed

combustion and calcination
(low NOX, CO & O2 levels)
 Clay Calcination
Flash Calciner
Clinker substitution has been identified as one of the key pillars in
1
getting the cement industry to lower CO2 levels. A promising solution
relies on clay as an alternative raw material.

CO2 emissions are a natural byproduct of the calcination of clinker. Its production
will therefore always produce high levels of CO2. Due to that, the substitution of
clinker is inevitable and will occur. At the same time, the main objective remains
to produce a cement that has early‑strength and binding properties competitive to
2
ordinary Portland cement (OPC).
3

To substitute clinker with clay is an established option. The so called LC3 cement
offers the same properties as OPC, but requires 50 % less clinker. LC3 consists of
approximately 50 % clinker, 30 % clay, 15 % limestone and 5 % gypsum.
4
5
The calcination of clay requires a different arrangement of equipment. The 3D
illustration and the following flow sheet give an initial overview of the process.

1 Flash calciner
2 Hot gas generator
3 Cyclones
4 Dryer
6 5 Cooling cyclones
6 Hammer mill
 Alternative Fuel Solutions
1 Flash calciner
2 Cyclone preheater
3 Cyclone cooler
The processing of clay, ideally caolinitic clay, has a significantly lower CO2 Flash Calciner Process Scheme for finish product
footprint and is not as equipment heavy as OPC clinker production. 10 4 Impact hammer mill
There is no need for a rotary kiln, a cooler, or even a primary burner. Hence, 1 forFlash
feed preparation
calciner
5 2 Seperator
Cyclone for dried
preheater
the production line has considerably lower investment cost and a much
3 feed material
Cyclone cooler for finish product
smaller plant footprint (given that the remaining amount of required 8 6 4 Filter
Impact hammer mill for feed preparation
6 7 Hot gas generator
clinker is procured and not produced). 5 Seperator for dried feed material
for flash dryer
6 Filter
8 Fan
7 Hot gas generator for flash dryer
On top of that, the operational costs of processing clay are lower because 9 Flash dryer
8 Fan
10 Waste gas to stack
of the overall reduced energy demand. This energy saving potential is mainly 9 Flash dryer
C 10 Waste gas to Stack
influenced by the average moisture of the used clay.
A Material – fresh feed
B Material – oversized particles
1 A Material – fresh feed
C Material – dry & pulverized material
B Material – oversized particles
(to calciner)
C Material – dry & pulverized material (to calcine
2 D Material – final product
D Material – final product
E Material – fuel
E Material – fuel

5 E Combustion gases from

Combustion gases from calcination process
calcination process
Hot combustion air from product cooler
HotReheated
combustion air for
gases from
raw material drying
product cooler
Fresh air
Reheated gases for raw
Gas with suspended material in flash dryer
material drying
Waste gas and recirculated gas to impact ham
Fresh air
E 8
Gas with suspended material
in flash dryer
B
7
9 Waste gas and recirculated gas to impact
hammer mill
3
A

4 D
Upgrades and

Upgrades and
Modifications
Bypass

Modifications
Prevent build-ups in the kiln system
· Extraction of sulfur and chlorine at the point
of highest concentration
· Best quenching through dual tangential air flow layout
We offer a wide range of efficient and affordable products that help · Continuous availability thanks to advanced mixing
you boost your production capacity and plant efficiency. All of these chamber design
· Suitable for any production capacity and extraction rate
solutions are suitable for preheaters and calciners of all manufacturers.

Pyrotop® Mixing Chamber

Preheater & Calciner Upgrades Enhanced functionality at the gas turning
point at the top part of the calciner
K-Tube · Allows intensive mixing of meal and gas strands with
lowest possible pressure losses
Best separation & easy installation · Extended residence time
· Complete burn-out of CO
· Sturdy cast design for longest lifetime · Allows increased alternative fuel firing
· Mounting made of material with ceramic-like properties
· Exceptional chemical corrosion resistance of segments Splash Box
and mounting
· Segments can be handled by one person thanks to Best possible meal distribution into the hot gas flow
small dimensions · Optimized heat transfer between meal and hot gas
· The installation of a K-Tube can be conducted in · Dispersion plate is adjustable in position and can
less than four days be replaced if needed
· Sealed design avoids false air intrusion
Firing System Upgrades

Upgrades and
Modifications
Gas and Oil Burner Pyrobox®

Gas ring burners from KHD enable fast ignition Fire solid fuels without primary air
of fuels in the calciner duct, even under · Direct ignition and intense mixture of fuel
challenging conditions. and raw meal by unification of both
· Consists of one or two burners with flow streams
ignition system · Unified heat profile in the calciner without
· Up to eight injection units installed on the hot spots
circumference of the calciner duct · Low NOX emissions due to low-temperature
· Injectors require no cooling air and can combustion
stay in place even if not in operation · Requires no primary air
· Creates a strong, two-stage flame to ignite gas · Suitable for all types of pulverized fuels
even at low tertiary air and kiln gas temperatures

Coal Distributor

Replaces a pulverized fuel dosing system

at a fraction of the cost
· Perfect for Low NOX calciners
· Suitable for any production capacity
· Up to 50 % reduced cold air intake into the calciner
· Sturdy design for long, maintenance-free operation
Get more out
of your plant.
Founded in 1856, KHD Humboldt Wedag
is a global leader for cement plant equipment,
technologies and services with more than
160 years of experience in the cement industry MOSCOW
COLOGNE DESSAU
sector. Process engineering, project management
and sustainable solutions are among the core ISTANBUL BEIJING
ATLANTA
competencies of the technology-focused group. TEHERAN
FARIDABAD
NEW DELHI
KHD offers a wide spectrum of products and
HYDERABAD
services for the cement industry. With distinct

Preheater &
focus on the development of environmentally
friendly and energy-efficient solutions for the
grinding and pyroprocessing sections of cement
plants, KHD helps its clients to continuously
improve production performance, raise efficiency
Headquarters
and ensure long-term environmental sustainability.
Subsidiary
Sales Offices
The holding company KHD Humboldt Wedag
International AG, based in Cologne, Germany, Workshop

coordinates its international operating subsidiaries.

Five Customer Service Centers and additional re-
gional sales offices serve customers worldwide.
 WEDAG
HUMBOLDT
KHD
KHD Humboldt Wedag International AG
Colonia-Allee 3
51067 Cologne
Germany
+49 221 6504 0

www.khd.com