The raw meal processed in the kiln first passes through the preheater absorbing the heat content of the kiln and PYROCLON® gases minimizing the heat consumption of the system.

KHD Preheaters with modern designed cyclones produce low pressure drops and are high in separation efficiency.

The resulting low waste gas temperatures lead to reduced heat losses, waste gas quantitites, CO2 emissions, dust emissions and electrical energy consumption.

Especially for using secondary raw materials and secondary fuels of significant chlorine and/or sulfur contents the KHD Bypass System enables a flexible kiln operation at varying fuel and/or raw-material mixtures.

A portion of the volatile components will be removed from in the area of the inlet chamber by means of a bypass and thus be withdrawn from the circuit. This will lower the level of the volatile circuit to such an extent that coatings remain controllable and operational reliability.

Compact and Efficient
Kiln plants with two and three station rotary kilns from KHD Humboldt Wedag are top of the line. One reason: highly efficient precalcining systems, which were developed by KHD Humboldt Wedag, revolutionizing the clinkering process.

Rotary kilns no longer have to function as calciners which mean that they can be substantially smaller in size. The advantage for customers is lower investment and operating costs. These systems quickly gained excellent reputations among our customers.

The KHD PYRORAPID® rotary kiln with a length to diameter ratio of approx. 11:1 to 12:1 fulfills high availability, considerable flexibility and cost-effectiveness.

The KHD PYRORAPID® rotary kiln with a length to diameter ratio of approx. 11:1 to 12:1 fulfills high availability, considerable flexibility and cost-effectiveness.

The three-station kiln from KHD Humboldt Wedag is a classic kiln which has been thoroughly tried and tested over the decades. Its proven standardized parts are also used in the PYRORAPID® kiln. Regular optimization of standardized parts leads to even greater operational reliability and efficiency. The interaction of all components ensures the overall problem-free continuous operation of the kiln:

• Optimized kiln configuration ensures even load and force distribution
• The low shell stresses ensures low shell deformation and low consumption of refractory material
• The floating tire fastening system ensures optimal load transmission to the rollers supported in double slide bearings
• The large service factor of the kiln drive ensures extremely flexible plant operation
• The repeatedly proven kiln inlet and outlet seals ensure minimum false air infiltration

These kiln components, essential for ensuring maximum availability, are furnished with high levels of safety and service factors.

High heat recuperation:

• Decoupling of wear effects from aeration
• Wear – if any – will not influence aeration and heat transfer
• Self-regulating aeration
• Sudden changes within the clinker layer are compensated automatically
• No more fountains – optimum aeration on the whole grate

Low wear:

• No more perpendicular pushing surfaces that would be subject to wear
• (Almost) no more relative movement between clinker granules and metal parts
• No cast wear parts

Easy maintenance:

• No maintenance during the production year
• No exchange of spare and wear parts for at least two years
• Robust modular system

Basic principles for best clinker transportation and specific aeration for maximum heat recovery

• Clinker transportation by moving floor
• Moving floor bottom and aeration cassette
• Flow regulators
• Clinker crusher

The PYRO-JET®

Thirty years of experience in the operation of KHD PYRO-JET® burners in more than 700 rotary kilns has resulted in safe and reliably designed burners operating in a number of various conditions.

Because of its outstanding combustion properties, this burner is not only suitable for coal, but also for difficult solid fuels such as anthracite, pet coke, mixed fuels with oil and gas.

The PYROSTREAM®

The high performance PYROSTREAM® burner of KHD is designed to allow the highest possible alternative fuel substitution rates. Sharing the double-pressure primary air system and the sandwich flame concept, the main design feature is the adjustable jet nozzle system. This adjustment allows a more precise flame setting than conventional burners without adjustable nozzles.

• Focus on maintenance and service time

Besides the advantageous features to the process, KHD’s engineers took special care to improve the service time and make maintenance as easy as possible:

• Maximum protection for the burner in case of power outages
• Easy exchange of the refractory tube
• The lifetime of the nozzle system is more than two years per set
• Maximum flame momentums up to 11N/MW

Unparalleled Toughness
Thanks to their robust construction the KHD fans are designed for especially rough operating conditions at a high degree of operational safety. For all materials used great importance is attached to good weldability and high toughness.