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Issue link: https://cement.epubxp.com/i/189537
FEATURE SHOOT THE CANNONS! A MATERIAL BUILDUP PROBLEM IN A CYCLONE WAS SOLVED USING AIR CANNONS TO RETURN NORMAL FLOW TO THE SYSTEM AND PREVENT FUTURE BLOCKAGES. By Josephine Smith O ne of the largest producers in Turkey, the Büyükçekmece cement plant operated by Akçansa Group – a joint venture between Sabanci Holding and Heidelberg Cement – supplies 10 percent of the country's total demand and 12.5 percent of the total cement and clinker exports. Originally built in 1967, the facility has three clinker production kilns with a capacity of 5,900 tpd. It's also considered the pioneer in alternative fuel use in Turkey's cement industry with a current fuel ratio of 77 percent pet coke and 23 percent alternative fuels. ACCUMULATION ISSUE As the facility's output capacity increased and fuel types changed over the years, workers began having to manually dislodge material buildup in Cyclone 4 of Kiln #2's preheater tower in order to maintain throughput. The unscheduled shutdowns to allow cleanout of the cone and deep tube interfered with production schedules and exposed maintenance staff to potential hazards. In addition to the necessary cooling time, the cyclone cleanout process required 3-4 people working with jackhammers through access doors for several hours. Unfortunately, even after expending all that time and energy, the accumulation became so severe that the problem would typically return within a week, choking off the material flow and forcing yet another shutdown. Plant officials contacted Martin Engineering Turkey to conduct an audit of the process, and a joint effort was developed to determine the optimum solution. A PROVEN APPROACH Upon completion of the audit, it was determined that a series of air cannons would be the best option to return normal flow to the system and prevent future blockages. The timed discharge of a directed air blast can prevent accumulation that impacts process efficiency and raises maintenance expenses, while helping manufacturers to minimize the need for process interruptions and manual labor. 6 Engineers from the two companies met to discuss details, including air cannon design, nozzle selection and specific locations to maintain optimum material flow. To control the material buildups and maintain production stability, 29 Big Blaster Hurricane Air Cannons were supplied by Martin Engineering Turkey, each with a 70-liter reservoir, installed in strategic locations by a Martin Service Team. The installation included hi-velocity and fan-jet nozzles with Martin Thermo Safety Shields to protect maintenance personnel when they inspect or service the air cannon system. Also known as blast guards, Thermo Safety Shields are situated between the process and the air cannon valve itself. Available in manual or air-operated models, these devices help prevent material backflow during service and shield the air cannon valve components from material spray. The new air cannons were arranged in three groups, CEMENT AMERICAS • Fall 2013 • www.cementamericas.com