Fan upgrade technology for the cement industry Author:  Ryan Preis,  Application engineering,  AirStream Systems Inc. Co‐Autor: Peter Windmoeller Sales custom fan upgrades Introduction Process improvement is a necessary cost to  improve plant operation: Environmental equipment modifications Increased use of alternative fuels Kiln upgrades Raw mill upgrades Duct modifications Efficiency improvements 2 Process Fan Requirements • Baghouse ID Fans • Kiln ID Fans • Raw Mill Fans • Finish Mill Fans • Cooler Vent Fans 3 Process Fan Costs  Initial capital investment  Ongoing maintenance costs  Operating costs 4 Fan Upgrades  Capital Cost Savings • Minimized equipment costs  (reuse fan housing, motor, bearings,  etc.) • Reduced installation costs  (no foundation changes) • Reduced installation time  (shorter shutdown required) 5 Fan Upgrades  Reduced Maintenance Costs • Maintenance cost reduced up to 50% (reduced dust impingement, improved design technology) • 2x to 4x longer wear life  (longer replacement cycles, reduced replacement costs) • Reduced dust build‐up (gas velocities, engineered blade design) Year  3 After Minor  Repairs 6 Fan Upgrades  Operating Cost Benefits • Electrical cost reduced 10% to 30% (AirStream high efficiency rotors) • Performance increased up to 25% (within existing fan housing, existing motor) • Fast payback, typically 1‐2 years 7 Case Study#1 2700kW Kiln ID Fan Upgrade Canadian cement plant  with:  Calciner  4‐stage preheater Process improvements to  increase production  included modification of:  Preheater  Firing systems  Clinker cooler line 8 Case Study#1 2700kW Kiln ID Fan Upgrade Conditions found at site:  Plant production was fan limited  Fan total efficiency was ~50%  Wear related maintenance caused production stoppages  Annual impeller replacement due to rapid wear rates  Complete fan replacement was seen as only solution 9 Case Study#1 2700kW Kiln ID Fan Upgrade AirStream upgrade achieve the  following results:  Plant production increase of 7%  Power consumption reduced by  over 36% = 1235kW  No noticeable wear after 2 years  During annual maintenance no  repairs were required. 10