Snowmen disappear in

Florida – more uptime

and efficiency appear

CASE: Titan America - Pennsuco Plant, USA

Great collaboration helps Titan improve various key parameters –
and leads to the first Air Blast Controlled cooler inlet in the U.S.
2

Relationship
continues after
major project ends
The FLSmidth Customer
Service Projects team
(CSP) took over cus-
tomer support after
installation of a new
production line and
helped Titan gauge –
and address – priorities FLSmidth installed the ABC cooler inlet, three
cooler fans and a new heat exchanger to
improve the original Controlled Impact Section.
 3

The collaboration between FLSmidth

and Titan ensured a successful
installation with minimal downtime.

The objective
Titan Florida had recently finished the installation of a new
production line supplied by FLSmidth and wanted FLSmidth’s
help to deal with a number of challenges, including severe
snowman formation caused by chemistry fluctuations. Every
eight hours their kiln was creating a snowman – and while their
pit crew could hydroblast it out of the cooler inlet in less than
30 minutes, a more efficient solution was required. The snowmen
were also affecting the wear life of the original cooler inlet and
costing the plant major annual repairs.

Defining the project

An overall engineering and financial study laid the groundwork
for the upgrade project. It then led to an incremental, multi-year
plan developed in close collaboration with Titan Florida to
continuously improve the plant’s uptime, operation, reliability
and efficiency.

Working with Titan Florida, FLSmidth’s CSP group eased the

transition from the close of the major project by creating new
ties with plant staff and helping them gauge priorities. Address-
ing the snowman problem was at the top of the list.

The solution
The solution featured the first ABC cooler inlet on the U.S.
market – installed to improve the original Controlled Impact
Section and set the model for future retrofits.

In addition to the ABC Cooler Inlet, FLSmidth also supplied

three new cooler fans, a new heat exchanger to protect the
cooler vent fan from temperature spikes, and modifications to
the kiln dust handling system.

Challenges
The upgrade required modifications to the plant that could only
be performed during a shutdown. Because of the high demand
for cement at the time, the downtime had to be minimised.
FLSmidth and Titan worked closely together to ensure solutions
and designs that would allow for quick installation and short
downtime.
Results
Following the upgrade, both operational efficiency and uptime
increased. Snowmen were eliminated; secondary and tertiary air
temperature increased; and fuel consumption, clinker exit
temperature and compressed air consumption decreased. As of
2011, the inlet has been installed for more than four years and
looks virtually new.

PARAMETER RESULT
Secondary Air Temperature INCREASED 210°C
Tertiary Air Temperature INCREASED 175°C
Fuel Consumption DECREASED 3%
Clinker Exit Temperature DECREASED 20°C
Compressed Air Consumption DECREASED
Snowmen NONE
Daily Operator Intervention ELIMINATED
Personnel Safety INCREASED

Today Titan has eliminated all snowman

formations and overall operational
efficiency has significantly increased.
“The ABC inlet was a major
improvement to the plant.
Snowmen are quickly removed
from the top, and maintenance
work has not been performed
since installation. The ABC
project upgrade was a
significant improvement for
plant operations and Scan here
TO READ MORE CASE
maintenance.” STORIES ON FLSMIDTH’S
UPGRADE SOLUTIONS.
Mr. Guillermo Haberer, Maintenance Manager
Titan America - Pennsuco Plant

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