Applying modern technology in a step by step approach to improve the capacity and efficiency of a preheater/calciner kiln system

By applying emerging technologies to an existing preheater/calciner kiln, Lehigh Portland Cement Company (USA) was able to increase Mason City's kiln No. 8 capacity from 1590 MTPD to 2350 MTPD (48%). The major modifications accounting for this substantial increase in clinker capacity are described. Lehigh applied a step-by-step approach to the capacity increase program by using these modifications. As one modification program was completed, Lehigh would than analyze the success/shortcomings of that project and find the system's new limitations. Similarly, as new technologies were brought onto the marketplace, Lehigh would evaluate how these technologies could overcome the system's current limitations. Kiln No. 8 has obtained clinker production levels in excess of 2350 MTPD on a weekly basis. By following this methodology, Lehigh was able to increase the clinker capacity of this preheater/calciner kiln by almost 50%, reduce fuel consumption by 11% and increase kiln availability by 20%.