Counter Current Cyclone

CCX

More capacity – less

energy

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CCX top stage cyclone presentation - Usage

Regard the presentation as a slide library where you pick and choose the relevant slides

Customize your presentation so it fits the specific project/customer the best

Always use the latest version from Marketing Sharepoint – as we will update the

presentation on an ongoing basis

External handout should always be in PDF format

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 11 July, 2019 2
CCX top stage cyclone
Benefits
Lowest civil cost in new preheaters
Lowest operating costs
Low installation costs
Low weight construction
Fast, simple installation
High flexibility for retrofits and
upgrades

Net heat consumption

reduced by 8-10 kcal/kg
clinker
Less than 50% pressure
drop compared to same
standard cyclone diameter

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 11 July, 2019 3
CCX Cyclone Agenda

CCX development
Application
Cyclone design
Cases and
Reference
Maintenance
Conclusion

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Development of the FLSmidth first stage cyclone

CCX Potential for

Counter elimination
Current of one Development
Cyclone cyclone
driven by
DDX 4 stage
Down Draft
Cyclone
Civil/structural
cost
HR+ 3 Power
High
Recovery
consumption
2 Production
LP-CA
Low
capacity
Pressure increase
1

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FLSmidth® CCX applications

New
preheater
systems in
new or
existing
lines

For upgrade
projects of
existing
preheater
systems
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Innovative features introduced
1

1.Raw feed to top of 2

cyclone
2.Rotating spreader 5
3.Central pipe is
pointing upwards
4.Exit gas outlet
naturally pointing
3
downwards
5.Integrated heat
exchange and
separation
4

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 11 July, 2019 7
Animation of the CCX functionality

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 11 July, 2019 8
Reducing civil and structural loads and pressure drop

Low Larger size For instance ø6.3 m HR+ Load elements:

pressure cyclones can be loads correspond to - Steel
drop over chosen without
ø7.5 m CCX loads. - Dust during blockage
adding load to
cyclone
1 the PH structure - Refractory

Standard HR+ Cyclone ø6300 CCX Cyclone ø7500

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Integrating heat exchange and separation

The CCX cyclone combines heat

exchange and material
separation in one process,
resulting in a more efficient
cyclone with low pressure drop.

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CCX reduces pressure drop further

Both material and gas flow

naturally by gravity and
centrifugal forces.

Changes in flow direction as

in traditional top stage
cyclones are avoided leading
to reduced pressure drop as
the work required to lift
material is eliminated.

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 11 July, 2019 11
Lightweight lining concept implemented reducing
loads on structure

Densulate 2 layer light

lining weight lining
concept concept

2 ensures

60% 30% cost Increased Short installation Same

weight reduction cyclone as cyclone can be surface
reduction volume = lined and lifted heat loss as
lower from ground standard
pressure level design
drop

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 11 July, 2019 12
Case story and achievements
In operation since Dec. 2015 at a European cement plant

Existing LP 5.7m top cyclone modified in two

steps to DDX 6.3m and to CCX 6.3m.

Kiln capacity, clinker Design: 2300 tpd

Operating at 3400 tpd
Production increase (tpd /%) from DDX 200 tpd corresponding to 6-8%
to CCX
Reduced pressure drop 30-40% at similar conditions
Recorded gas material temp. difference 70°C
Possible fuel savings 1-2%
Cyclone heat efficiency recorded 1,8
Load on civil structure reduced More than 50%

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 11 July, 2019 13
Preheater system 2
comparison at same 1
installed power

1)3000 tpd Height reduction:

4 stage, single string 12,6 m
with CCX Civil/structural cost per
meter depends on
CCX: 719 kcal/kg
region

2)3000 tpd
5 stage, single string
with HR+/CCX
HR+: 709 kcal/kg
CCX: 702 kcal/kg and 5%
higher production or 10%
reduced power consumption The
information
contained or
referenced in
this
presentation is
confidential
and
proprietary to
FLSmidth and
is protected by
copyright or
trade secret
11 July 2019 laws.
14
 Case example
Benefits obtained when larger cyclones can be used

Production …….. 4300 tpd (forced production)

Top cyclone…….. HR+ 6300
DPHR+ …………… 1860 Pa
Total Loads……… 4109 kN

Production …….. 4300 tpd

Top cyclone…….. CCX 7500
DPCCX …………… 440 Pa
Total Loads……… 4116 kN
Production …….. 4600 tpd
(with same ID fan power)

Down Draft
15
Cyclone
Access to and maintenance of spreader made easy

Access to
and removal
of spreader
Maintenance
platform
Inspection
door
and access
from platform

Maintenance
door

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Why choose the Counter Current Cyclone?

Lowest civil cost in new preheaters

Lowest operating costs
Low installation costs
Low weight construction
Early production due to fast, simple installation
High flexibility for retrofits and upgrades

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 11 July, 2019 17
Want to know more about the
COUNTER CURRENT CYCLONE - CCX ?

Product Animation
leaflet

Case story

Articles

Visit flsmidth.com >>

Kiln Inlet
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 11 July 2019 graphite seal.
18
 The Counter
Current Cyclone
A top stage cyclone technology by FLSmidth

For more information, please visit www.flsmidth.com

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 11 July, 2019 19
Backup slides

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 11 July 2019 20
CCX Cyclone
Benefits
Civil
Low installation costs
(civil and construction)
Lower civil costs in new
preheaters
Low weight construction
Product
Low operating costs
Fast, simple installation
High flexibility for retrofits
Advantages Features
1. Neither the tangential outlet nor the first approximately 20m 1. The air outlet duct is naturally pointing downwards
of downcomer are required. 2. Central pipe is at the bottom
1. Low weight construction 1. EL3 considerably reduced
2. Possibility to reduce one stage 2. Improved heat exchange
1. Loads of lining (EL2) is considerably reduced 1. New lining type
2. Loads of dust (EL3) is considerably reduced compared to 2. Can only be filled up to the central pipe, which is
standard cyclones at the bottom
1. Reduced power consumption on ID fan 1. Low pressure drop (reduced compared to HR+ Top
2. Reduced net heat consumption Cyclone and DDX)
2. Improved heat exchange
3. Material is fed to top of cyclone and spread in the air
stream minimizing energy consumption in lifting material
1. The Top Cyclone can be assembled at ground floor and lifted 1. New low weight lining
in one piece
1. Ability to replace with bigger sizes without reinforcing the civil 1. Very low weight
structure 2. Cyclone can be assembled at ground floor incl.
2. Reduce kiln stop time refractory
11 July 2019 1