World Cement - July 2020

capacity of 70 000 t. This addition will allow

for better flexibility of McInnis’ expanding

distribution network while allowing for

maximum utilisation of their growing marine

fleet.

In addition to the supplemental storage, a

second loading alley equipped with self-loading

ability was constructed to minimise waiting time

for its customers base.

The project lasted a little over a year and

was completed in time for the 2020 shipping

season.

Ravena plant, LafargeHolcim

FCT Combustion delivered a Turbu-Jet burner

to the Ravena plant, which was installed at the

plant’s main burner. The Turbu-Jet is capable

of firing 31% oil, 100% coal and 100% natural

gas, to meet the plant’s requirements. A

calciner burner designed to fire 100% natural

gas was also supplied.

Rillito Plant, CalPortland

CalPortland was selected to carry out the

Rillito Plant Stage 1 Cyclone Replacement. The

preheater tower is a key component of modern

pyro processing systems. For it to function

correctly and at maximum efficiency, all the

components in the tower must be working

correctly. In the case of the Rillito #4 cement

kiln preheater tower, the lower three stages of

the four-stage preheater were in good condition

and functioning correctly. The same could not

be said for the top or first stage cyclones and

outlet ducts, which had been in operation for

25 years.

The cyclones were not refractory lined and

had been buckled and distorted, and the steel

was worn thin through the years of operation.

The buckling was due to the thermal expansion

of the unlined steel cyclones exceeding

the design parameters, an issue that was

made worse by the steel being worn thin by

the abrasive wear of the kiln feed over the

operational life.

It was determined that there were several

reasons for the early replacement:

Lack of refractory lining.

Attachment of cold structural walkway and

platform steel to the perimeter of the hot

cyclones and ducts.

Inadequate allowance for expansion when

considering current operating parameters.

The design process started with an evaluation

of the tower structure with the aim of

determining early on what structural constraints

the design team would need to contend with.

The Rillito preheater tower is a reinforced

concrete tower designed in the 1960s to the

codes of the day. Structural design codes

and standards have changed since the tower

was built, therefore a complete and detailed

analysis of the tower was required to determine

the structural limitations for the new stage one

cyclones.

The upgrade to the first stage cyclones

and ducts was a successful project and was

installed within the allocated kiln outage

window. Meeting the installation schedule was

only possible with assistance of the plant, the

contractor and everyone else involved in the

kiln outage activities.

The operating performance of the cyclones

has been in line with the predictions of the

model, with the collection efficiency slightly

higher than design. The higher collection

efficiency has not caused any adverse impacts

to plant operation. The redesigned cyclone inlet

and riser duct have delivered the predicted

reduction in differential pressure. This will

provide the plant with energy savings through

reduced electrical energy consumption on the

kiln ID fan. The plant will see this benefit for

the operational life of the cyclones.

Also at the Rillito plant, Bricking Solutions

supplied the plant with a Mini Econ-O-Ring

single arch bricking machine, designed for

kilns with 1194 – 2489 mm (47 – 98 in.)

brick ID. The Mini Econ-O-Ring (MECOR) is

a single arch bricking machine with a single

adjustable frame system that allows the

MECOR to be adjusted to different diameter

combinations within its range. The MECOR is

designed for burning chambers for paper mills,

tertiary return ducts, satellite cooler tubes,

small vessel, kilns and furnaces.

Sparrows Point, LafargeHolcim

FCT Combustion will modify the existing burner

management system at the Sparrows Point

plant, as well as the natural gas valve train,

to comply with NFPA 86 requirements. The

modifications will also improve the operation of

both burners installed at the slag dryer.

Sumterville plant, Suwannee American Cement

Fives will supply Suwannee American Cement

with one Pillard NOVAFLAM burner for the

rotary kiln for coal and gas firing.

Bricking Solutions’ Universal Safety Cage for

kilns ranging from 4 m to 6 m was supplied to

the Sumterville plant.

The Universal Safety Cage is designed to

withstand a solid impact of 114 kg from a

height of 2438 mm. The cage, being half the

weight of the traditional style, is easily carried

by two plant personnel.

World Review 2020

World Cement