Fit for the future

2 Plant concept

3 The heat exchangers for the waste heat power plant and the SCR plant are mounted and connected

4 3D planning – Cross section through the clinker cooler building

5 3D planning – plan and realization (right)

6 The central air suction duct on the grate cooler with integrated silencer for the cooling fans

7 The new burner platform with a view towards the burner/kiln hood

8 Time schedule

9 View of the planetary cooler – the demolition of the burner platform has already begun

10 The kiln hood is arriving – in the background, the 1000 t crawler crane (blue) for the kiln conversion

11 The preassembled structure of the grate is positioned

12 Construction situation before Christmas

13 The clinker cooler has been hoisted in and the kiln hood is mounted

14 The heat exchangers for the heat recuperation from the mid-air are mounted

1 3D Planning – cross section. The heat transfer system is located on the topmost platform. The entire plant could only be placed by stacking in the vertical direction

Within the scope of a project subsidised by the German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety (BMU), the kiln system at the Rohrdorf cement plant was modernised. A waste heat recovery system was among. Extraction of the mid-air from the grate cooler results in a further reduction of heat loss and an increased degree of heat recuperation.

1 Introduction

At the end of a two-year planning and construction period, SPZ recommissioned its comprehensively modernised kiln system in spring 2011. With the installation of the world’s first “Low-Dust” Selective Catalytic Reduction (SCR) denitrification system downstream of a cement plant’s preheater tower, the modification of the rotary kiln and replacement of the old planetary cooler with an IKN grate cooler, the Rohrdorf kiln system is now one of the most modern in the world. A special feature of technological alliance is a heat transfer system that transports waste heat from the clinker...