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1.10b introduction of nhu_brylicki

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Process & Resource Recovery Days 2011 Jakub Brylicki

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presentation of a cement plant in Poland

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Page 1: 1.10b Introduction of NHU_Brylicki

Process & Resource Recovery Days 2011

Jakub Brylicki

Page 2: 1.10b Introduction of NHU_Brylicki

Cement Plant Krakow – Nowa Huta

Location: 7 km from the centre of the Cracow

Built as grinding plant near steelworks in 1959

Dry process clinker production start in 1961 (first cement plant in Poland with dry process production)

Limestone from the beginning delivered from the quarry located 40 km from the plant

Page 3: 1.10b Introduction of NHU_Brylicki

Raw milling and blending Raw materials for the raw mix

a) Limestone

b) Wet fly ashes

c) Sand

d) Iron adds

Raw materials open storage, dosing by the cranes

Two closed circuit raw mills with static separators, capacity 30-40 tph per mill

6 homo silos

Page 4: 1.10b Introduction of NHU_Brylicki

Burning and cooling

Kiln no1: out of operation

Kiln no2 - 4800 working hours per year:

- Length: 50,4

- Diameter: 3,6 m

- Nominal capacity: 450 tph (actual 420 tph)

- Fuel: coal

- Burner: classic one channel

Preheater tower: 4 stages cyclones (double cyclone on the top)

Grate clinker cooler

ESP

Gases from preheater used for drying raw mix and coal

Exhaust air from clinker cooler used for drying fly ashes for cement

Page 5: 1.10b Introduction of NHU_Brylicki

Cement grinding

4 cement mills in operation

3 mills with open circuit – capacity 20 tph

1 mill with closed circuit (QDK Pfeiffer separator) – capacity 30 tph

Mixing station – capacity 50 tph

Pneumatic transport of finish product to the silo

8 cement silo

Products:

- CEM II/B-V 32,5 R (bags and bulk)

- CEM II/A-V 42,5 N (bulk)

Page 6: 1.10b Introduction of NHU_Brylicki

Process and quality control

XRF and XRD are not available

Wet chemistry for composite samples

Kiln gasses analyzer (behind the heat exchanger), measurement: O2 and CO

Lack of the automatic production and measurements data record

Central control room doesn't exist

Start burning nozzle: none

Page 7: 1.10b Introduction of NHU_Brylicki

Plant priority in 2011 - 2013

Safety Implementation group safety standards

POM Adjustment organization according to POM model

ORIONIncrease clinker production

Full year production (replacement of ESP)Increase kiln output up to 500t/d

Launch new products (slag cements)

Industrial standards

Implementation power consumption master

Page 8: 1.10b Introduction of NHU_Brylicki

Thank you


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