FLS Product Updates Haiphong

FLSmidth
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
1
Agenda
Upgrade possibilities of FLS equipment
 Preheater parts upgrade
 Cast Central Pipes
 Kiln inlet Gas Analyzer
 Kiln parts upgrade
 Kiln Inlet/Outlet Graphite seals
 Precast Outlet sectors
 Cooler parts upgrade
 SF – CB Cooler upgrade
 CIS – ABC inlet upgrade
 Atox mill upgrade
 Roller Lubrication Unit
 Roller Split Seals
 45 degree roller segments
 Reduced table liner thickness
 Cement mill parts upgrade
 Smartfill control unit
2
Preheater
 Cast Central Tube
 Kiln Inlet Gas Analyzer
Preheater
Cast Central Tubes
 High separation and thermal efficiency

ensure lowest energy consumption
 Reduction in Energy consumption of

typically 1-2%
 Short delivery time for segments as stock

in FLSmidth Foundry
 FLSmidth in house quality
 resistant for temperatures up to 1100 °C
Preheater
Cast Central Tubes
 Minimizes clogging tendency, as

boltless design ensures low heat
transfer
 Easy installation and maintenance
 Only one type of element
Taylor made individually for increased
total lifetime
15mm segments only 25mm segments in top

row
25mm segments placed in areas 25mm segments only

with exess wear
6
Kilnloq kiln inlet gas analyzer
Highest runfactor in the market
Least and easiest maintenance
Less than 5min to maintain blocked probe
Long filter lifetime (Sinter metal)
Safe water cooling
Only supplier with process Cement knowhow
23 June 2014 7
KilnLoq One-Pipe layout
23 June 2014 8
Automatic cleaning
23 June 2014 9
Kiln
Inlet/Outlet Seals
Precast Outlet Sectors
Kiln
Inlet graphite seal
2 5
1. Graphite Block.
1
3 2. Cooling duct.
3. Shovel / Cast cone
4. Sealing Ring.
4
5. Shovel chamber.
6. Spillage hopper
7. Flange with cone to avoid
dust accumulation.
7
6
Kiln graphite seal. 23 June 2014

Kiln
Graphite design
 Overlapping graphite blocks ensure full

sealing effect and no risk of blocks
getting stuck when worn
 Expected lifetime of graphite, 3-5 years
 Minimized false air intake
 Installation supervision
23 June 2014 12
Kiln
Outlet graphite seal
2 1. Graphite block.
1 2. Seal casing.
3. Heat protection shield for
graphite blocks.
4. Air casing.
5. Cooling duct.
3
6. Spillage hopper.
5
6
Graphite seal overlap
Graphite block
Steel plate in between
graphite blocks
Graphite block to move in
radial direction.
Graphite block overlap
28
Septem
Wire rope assembly
Two independent rope systems,
each rope system will cover
one row of graphite blocks.
Each rope system is fixed at 6’0

clock position , to prevent rope
sliding over the graphite block.
Rope is designed to run for a

full production campaign.
28
Septem
Graphite block replacement
Graphite locking bolt will not allow the

graphite block to fall down, if rope fails.
Special shape distance spacer is

designed to replace the graphite block
with out dismounting the flanges, the
only graphite locking bolt to be
removed.
Distance spacer
Graphite locking
bolt
28
Septem
Graphite seal
Modular construction.
Each module is pre assembled

before installation.
Graphite adaptor
Graphite block
28
Septem
Graphite cooling system (Outlet seal)
Air in to the rectangular duct.
Air in to the system.
Air out from

rectangular duct.
Kiln rotation
Kiln Inlet graphite seal. 23 June 2014 18

Kiln
Graphite Seal Benefits
 Ensure pressure stability in the kiln by stopping false air entry into the
system.
 Effective leak tightness for hot gases and dust particles coming out from
the kiln.
 Efficient seal results in
 Fuel saving.
 Optimal production.
 Adaptable to all types and sizes of kilns.
 Easy and fast installation.
 Minimum maintenance.
 Back spillage material will be collected trough hopper and flap valve.
Kiln
Replaceable precast outlet sectors
 Reduced Installation time.

 Improved life time of permanent sector
 Easy handling of the precast sector.
1. Kiln Shell
2. Permanent sector.
3. Hanging sector.
4. Closing part.
5. Cowl shell
6. Precast blocks
7. Brick
Kiln
Replaceable precast outlet sectors
 Hanging sectors are locked in
circumferential/radial directions.
 Weight of precast hanging sector for
ϕ 5.0 m kiln is approximately 60Kg.
 Closing part is fixed to the permanent
sector.
FLSmidth Cross Bar Cooler
Modular replacement and retrofit
Cross bar cooler modules
When is an upgrade appropriate?
Upgrading to the FLSmidth Cross-Bar Cooler’s advanced

clinker cooling technology is worth considering if you need to:
- Eliminate bottlenecks
- Increase capacity and/or availability
- Decrease operating costs
- Eliminate fall through of clinker
23 June 2014 23
SF CROSS-BAR™ (SFC) COOLER UPGRADE
SFC upgrade
An advance in technology
Why upgrade:
 If your present SF cooler installation is too highly loaded

 If there is requirement for Improved lifetime on wear parts
 If transport ability needs to be Improved
 If there is future plans for production increase
SFC upgrade
An advance in technology
Result of upgrade:
 Improves the transport ability of clinker with up to 10%

 Reach a transport efficiency of more than 70%
 Maintain same hydraulic flow volume with fewer strokes
 Increased control of the clinker bed under heavily loaded conditions.
Work plan for SFC upgrade
To-do List
 Replacement of cross-bars
 Mount new grate protection plates
 Dismantling drive plates and cylinder bracket
 Divide the drive frame in two drive plates
 Replacement of cylinder brackets and inter-modular straps
 Install hydraulic blocks and new hydraulic piping
 Upgrade PLC program and a few electrical parts
Example of SFC upgrade
Existing SFC Cooler
Retainer brackets -
removed
All Cross-bars -
removed
Upgrading SFC Cooler
Retainer brackets -
removed
New Cross-bars Old grate protection

plates
Upgraded SFC Cooler
New Cross-bars
Grate Protection plates
How is higher transport efficiency
achieved in the SFC upgrade?
Features:
 SFC upgrade has only 6 moving cross-bars along the length of a module and
no stationary.
 Stationary cross-bars are not there to hold back material on forward stroke
 Shuttle drive motion used, where all cross-bars move forward together, and
reverse in alternate strokes.
 Cross-bars cover 2 grates wide, compared to 4. Gives more control across
the width of the cooler.
 Full-scale cold testing at our R&D facility and 2 operating industrial
references have confirmed the concept.
First SFC upgrade project
 Ramliya plant, Egypt
 Arabian Cement Co.
 6000 t/d FLS plant,
 SF 4x6 Cooler
 Kiln shutdown
– 18 January 2010
 Kiln Feed on
– 11 February 2010
Ramliya SFC upgrade – Bottom Line
Existing SFC Cooler
Before upgrade
6150 t/d
22 spm
Ramliya SFC upgrade – Bottom Line
Upgraded SFC Cooler
Before upgrade After upgrade

6150 t/d 6800+ t/d
22 spm 11-12 spm
SFC upgrade - Bottom Line
 Regaining control over your SF Cooler performance.
 Prepare it for a future production increase.
 Upgrade on installed SFC cooler can be completed during a
normal kiln stop for 2-3 week.
 Investment are comparable to a set of cooler wear parts
 Manpower required are comparable to a normal cooler
maintenance job
ABC Inlet
• No Problems With Snowmen
• Low Clinker Temperature
• Improved Heat Recuperation
• Increased Production
• Short return of investment
CIS/MFR upgrade to ABC inlet
ABC Inlet – features
Non return
valve Cast
grates
MFR’s
Air blasting
manifold
Support
Frame
38
Creating a horizontal air stream
Blast air
Process air
ABC Inlet grates after 4500 hours
of operation
Pennsuco – benefits of converting
CIS to ABC Inlet
Pennsuco, USA Before After Change

Clinker production (MTPD) 5300 5430 2,5 %
Secondary air temp (°C) 1046 1259 20 %
Tertiary air temp (°C) 937 1109 18 %
Clinker temp (°C) 137 116 - 18 %
Snowmen 1/day 0 
Payback time on investment:

Less than 6 months
Customer Services Engineering

41 – ABC Inlet
ATOX Raw/Coal Mill
Lubrication station
• Advantages:
 Available for all mill sizes 20-57.5
 Increased oil flow
 Finer oil filtration
 Increased cooling capacity
 Inline water sensor
 Indicator for magnetic material
 Inline magnets for removal of iron/steel
particle
Lubrication station
Mill size 22.5-30: 7-pump solution replacing flow divider system
Advantages:
 Available for mill sizes 22.5-30
 Same feature as latest design
Retrofit
For most old lubrication station then

following features
Can be incorporated in the existing
lubrication system
-Magnetic filter
-Water saturation sensor
-Metal chip switch
Grinding roller Split seals
Split seal
The outer oil seals
(towards the mill housing)
The inner oil seal
(towards the mill centre)
Old seal arrangement
Grinding roller Split seal
To access the inner oil
seal the…
Outer covers and seals must be

removed
Bearings must be removed
Hub parts to be removed as well

Old seal arrangement cut-through
This cannot be done with the

roller sitting inside the mill…
Conventional seal vs. new split seal
5
3
4
2 7
1
3
2
4
1
5 6
Old seal arrangement cut-through New seal arrangement cut-through

1. Inner air seal ring 1. V-lip seal
2. Outer air seal ring 2. Oil seal
3. Bearing end cover 3. Split inner air seal
4. 2 x oil seals 4. Split outer air seal
5. Seal ring 5. Rotary seal ring
6. Seal ring
7. Seal housing parts
8. Bearing end cover
Maintenance kit
V-lip seal
Oil seal
A new O-ring
Adhesive (glue)
Benefit from installing Split seal
 Replacement of seals without dismantling roller

 Replacement of seals within 15 hours
 Only normal hand tools are required
 Reduced mill downtime
Advantages of having
split seal installed
45 degree segments with extended clamps for rollers
Advantages of 45 degree segments
50% improved fixation of each wear segment

Less risk of deformation of hub
Available as HiCr and Ceramic insert
Advantages of extended clamps
Improved wear protection of hub and wear

segments
Available in hardfaced version
Improved fixation by use of 3 bolts/segment
full coverage and hard faced wear segment clamps
(for 30 deg roller segments)
 Improved wear protection of hub and wear segments

 Available in hardfaced version
 Improved fixation by use of 3 bolts/segment
Table segments with reduced thickness
 Lower weight and cost

 Same lifetime
 Improved material utilization
 Chamfered inner part of grinding track
 Less risk of contact between table and
roller segments
 Available as HiCr and ceramic insert
Split bellow for piston rod
Advantages:
 Fast and easy retrofitting
 Easy access for inspection
 Protection of Piston rod
Ball Mill
Inlet head
The outer oil seals
(towards the mill housing)
The Shell
innerlinings
oil seal
Shell linings
(towards the mill centre)
Stanex Diaphragm Outlet Grate
FOLAFON replaced by SMARTFILL
High precision level and temperature sensors for ball mills
Low level
High pitched
sound
Ideal level
„quiet“
High level
Microphone Very „quiet“
SMARTFILL
Wireless transmission of structure borne sound
Advantages of SMARTFILL
Wireless transmission of signals for both sound and temperatures
 Simple interface as output signals are available as a 4-20mA
 No interference by other sound emitters
 Easy installation on mill shell
 System is less sensitive against dust etc.
 No batteries required (integrated generator)
6/23/2014
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FLSmidth

 Cast Central Tube

 Kiln Inlet Gas Analyzer

 High separation and thermal efficiency

 Reduction in Energy consumption of

 Short delivery time for segments as stock

 FLSmidth in house quality

 resistant for temperatures up to 1100 °C

 Minimizes clogging tendency, as

 Easy installation and maintenance

 Only one type of element

15mm segments only 25mm segments in top

25mm segments placed in areas 25mm segments only

Kiln graphite seal. 23 June 2014

 Overlapping graphite blocks ensure full

 Expected lifetime of graphite, 3-5 years

 Minimized false air intake

Graphite block overlap

Each rope system is fixed at 6’0

Rope is designed to run for a

Graphite locking bolt will not allow the

Special shape distance spacer is

Each module is pre assembled

Air out from

Kiln Inlet graphite seal. 23 June 2014 18

 Reduced Installation time.

Upgrading to the FLSmidth Cross-Bar Cooler’s advanced

 If your present SF cooler installation is too highly loaded

 Improves the transport ability of clinker with up to 10%

New Cross-bars Old grate protection

Grate Protection plates

 Ramliya plant, Egypt

 Arabian Cement Co.

 6000 t/d FLS plant,

Before upgrade After upgrade

• Low Clinker Temperature

• Improved Heat Recuperation

• Short return of investment

Pennsuco, USA Before After Change

Tertiary air temp (°C) 937 1109 18 %

Clinker temp (°C) 137 116 - 18 %

Payback time on investment:

Customer Services Engineering

Mill size 22.5-30: 7-pump solution replacing flow divider system

For most old lubrication station then

The outer oil seals

(towards the mill housing)

The inner oil seal

(towards the mill centre)

Old seal arrangement

Outer covers and seals must be

Bearings must be removed

Hub parts to be removed as well

This cannot be done with the

Old seal arrangement cut-through New seal arrangement cut-through

 Replacement of seals without dismantling roller

Advantages of 45 degree segments

50% improved fixation of each wear segment

Advantages of extended clamps

Improved wear protection of hub and wear

 Improved wear protection of hub and wear segments

 Lower weight and cost

The outer oil seals

(towards the mill housing)