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Technology Symposium

10 Mai 2016 _ Tehran- Iran

Farid Salehi
Andreas Hand
Stefan Seemann
Since 1856
KHD in Iran: A Leading Technology Supplier, Since 1974

Since 1974:
Supplied and Commissioned
22 lines in IRAN,
Installed capacity of
17 Mtpa.
.

Others
(PSP-IKN, FLS
LVT, IHI) 29%
26%
O&K
1%
FCB Polysius KHD
6% 17% 21%*

* Market Share, on the installed capacity


KHD in Iran: Operational Branch Office in Tehran since 2004
KHD in Iran: Focus on Modernization, Rehabilitation

Context:

Competition on maintaining quality

and sustaining the finished price

30 lines > 25 years old

Opportunities:

New Coolers (vs. Satellite Cooler)

New Roller Presses for Upgrades/

Green filed

Waste Heat Recovery Systems

Secondary Fuel Projects

Debottlenecking

Process & Mechanical Audits

KHD expertise recommendations


KHD in Iran : Localization of Services

Roller Press Refurbishment Customer Service Process Training & Automation


Portable unit - Refurbishment is Spare parts and replacement of SIMULEX: Simulation software
done on-site. wear parts. for remote or classroom training.

Fast roller refurbishment. Training and technical assistance. SCANEX: Infrared kiln shell
Hydraulic Inspections. diagnostic system.
Re-weld two rollers at the same
Kiln Inspections: ROMIX Family: Provides
time.
advanced adaptive computer
On-site. Kiln survey and alignment. control of raw meal composition
Mechanical inspections. with raw material identification and
Flexible, work can be performed minimization of additive cost.
inside the machine - no Thermal assessment of pyro
dismantling required. equipment. PYROEXPERT: Kiln automation
system based on expert
Reliable. 3D Scanning Services. knowledge, fuzzy logic and broad
Plant, process, and equipment process know-how.
audits.
Pyroprocess Technologies

Andreas Hand

Head of Pyro Process Technology


with KHD Since 1992
Preheater Technology

Preheater PYROCLON Calciner PYROTOP

KHD built the worlds first preheater in High calcination rate. Low CO.
1952. Today, KHD is still recognized Lower NOx-emission due to no Complete burn-out of gases, leads
as industry leader. The latest formation of thermal NOx in the to low CO.
preheater design offers: PYROCLON.
Modular set-up e.g. combustion
Flexibility.
chamber.
Low waste gas temperature.
Processes alternative fuels.
High dust separation efficiency.
Complete burn-out.
Low power demand.
Kiln & Cooler Technologies

PYRORAPID 2-pier kiln Burner Systems PYROFLOOR Cooler

KHD was the first to develop the PYRO-JET & PYROSTREAM Operates on the proven moving
short kiln. Burners. floor principle.
Ratio : length = 1: 11 12. Effectively burn alternative fuels. Static grate with horseshoe.
Lower construction costs and Easy exchange of the refractory Reliable operation.
smaller space requirements tube. Long operating life.
associated with only two piers. The lifetime of the nozzle system Easy to install and maintain.
Best clinker quality. is more than two years per set.
High recuperation.
Increased wear protection.
Capacities ranging from 2,000 to
12,000 tpd.
Cooler Technologies: PyroFloor2 Cooler

PYROFLOOR2 combines established advantages from the original PFC, including the
efficient conveying of the proven moving floor principle, with new features, to make it more
environmentally friendly, cooling more efficient, maintenance easier, and operation more
reliable. PYROFLOOR2 is the next evolution in proven KHD cooler technology.

Capacities ranging from 2000 to 12000 tpd.


Minimized wear conveying system with autogenous wear
protection.
Small aeration sections.
Low cooling air amount : 1,80 / 2,1 Nm/kg.
High thermal efficiency: >73%.
Modular design based on standard parts.
Enhanced heat recuperation.
Low pressure drop.
Static grate with horseshoe.
Dr. Stefan Seemann

Head of Grinding Process Department


with KHD Since 2007
Grinding Technologies: Most Efficient Grinding Solution

V Separator Roller Press COMFLEX System

Efficiently separates fine material, Serves kiln capacity up to 10,000 Modular, compact, all-around
large mass flows, abrasive material, tpd. grinding system for raw, finish, and
and material with a wide range of Roller wear life 35,000+ hours. slag.
sizes and high levels of feed moisture. Low energy requirements.
Lower energy consumption than
Ball Mill or VRM. Low maintenance requirements.
Easy to maintain. Roller exchange in under 24 Suitable for abrasive materials.
hours.
Energy efficient.
Low operating costs.
Low investment costs.
Suitable for:
Carries out a range of process
functions. highly abrasive material
material with high moisture
content.
Grinding Technologies: Comflex

COMFLEX, FLEXible COMminution, is the ideal single stage grinding system for raw material, blast furnace
slag and cement. Combined with a ball mill and set up as a two-stage grinding system, COMFLEX will exceed
customer expectations in terms of product quality and capacity. It can be used with different applications and
products and is suitable for new installations and upgrades of existing grinding plants.

Comflex 2005 to 2013 (units)


Angola 1
SEPMASTER Brazil 3

Pneumatic Material lifting Austria 1


Ivory Coast 1

Mechanical Material lifting Srilanka 1


India 21
Roller Press Malaysia 4
China 6
Russia 4
V-Separator
Turkey 2
Total Comflex 44
Roller Press Globally, till today (units)
Total Roller Press 315
COMFLEX - Strengh of the Systems

Two set COMFLEX S COMFLEX D


300t/h OPC, 220 t/h slag, 300t/h OPC, 220 t/h slag,
860 t/h raw meal 860 t/h raw meal
Finished Grinding with RP - Particle Size

In the past people believed that the particle shape was the major disadvantage of Roller Press
Technology.
The German Cement Research Institute (VDZ) has proven that the above statement is not true

Clinker B (3000)
1,0

0,8
Roundness

0,6

0,4
VRM
0,2 RP
BM

0,0
0,1 1 10 100
Source: VDZ Dsseldorf Particle Size in m
Current technologies: Specific energy consumption

Specific energy consumption

Ball Mill (100%)

VRM(60%)
[kWh/t]

Horomill (70%)

Roller Press
(50%)

Specific surface

Source: VDZ Dsseldorf


Roller Press Trends: India, Past 6 Years
104 Roller Presses sold in India

Raw Material Slag


Built and commissioned 55 ball mill systems
25 23

Clinker
56
Above graphs depict overall grinding market share in India 2010 - 2016

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