Meal Drop to Kiln in Cement Preheater System

This video, courtesy of aixprocess GmbH, comes from a recent project for a cement plant in Europe where the end client suffered from high preheater exit gas temperatures. Rather than simply modifying the top-stage cyclones to address the local thermal concern, a more holistic analysis also detected massive meal dropout from the meal box in the kiln riser to the bottom stage cyclone, which was caused by an undesirable local gas-particle flow behavior. Ultimately this was determined to also be the root cause for the elevated preheater exit temperatures. After performing digital twin-based engineering analysis, aixprocess developed a plant-specific and low budget modification, which could be implemented quickly during an already planned shutdown.

This video shows how the meal-drop to the kiln inlet shelf has been massively reduced through a simple modification, informed by Barracuda Virtual Reactor simulation. After plant restart, the actual operation showed an immediate and sustainable drop-in kiln exhaust gas temperature by 20°C.

For more information about Virtual Reactor solutions for Cement and other Materials and Chemicals applications, please visit our website.

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