9
FIXED SIZES IN CEMENT PRODUCTION: FANS FROM REITZ. n REITZ - Cement
FIXED SIZES IN CEMENT PRODUCTION:
FANS FROM REITZ.
n REITZ - Cement
REITZ – ENHANCING PERFORMANCE IN EVERY RESPECT
Dust, wear, extreme temperatures. 24-hour cement production makes maximum demands on the robustness and performance
of ventilation components. REITZ fans have proven to be reliable solutions which maintain the production process, even under
harsh operating conditions. This is why REITZ fans are the first choice throughout the entire process of notable plant and cement
manufacturers around the world. MADE BY REITZ stands for consistent quality and maximum efficiency pursuant to the European
Energy Efficiency Directive, regardless of the application and location of production.
A FULL RANGE MADE BY REITZ: FROM HIGH-PERFORMANCE PROCESS FANS TO STANDARD FANS FOR SIMPLE REQUIREMENTS
FILTER FANS
The basis for uniform air purification, use down-
stream of the filtering separator enables use of fans
with high efficiency levels
1PRIMARY AIR FANS
Optimised efficiency, single-stage design possi-
ble, for improvement of combustion processes
in the kiln through optimum atomising of fuels
5
KILN EXHAUST FANS, PREHEATERS
For continuous extraction of kiln and heat exchanger
exhaust gases
2
RAW MILL FANS
For reliable dust extraction during the milling process
3
CLINKER COOLER FANS
For cooling the clinker
4
AIR SLIDE FANS
For smooth conveyance of cement into the air
slide
7
SEPARATOR FANS
For uniform extraction during fine milling
6COOLER EXHAUST FANS
For cooler exhaust takeover following the coo-
ling process
8
limestone quarry
crusher
storage sandlimestone
ferruginous additives (iron oxide)
filter
raw mill plant
filter fan preheater
raw mill fanblendingand stock silo
heat exchanger
rotary kiln
primary air fanclinker cooler
clinker cooler fan
clinker siloGips
Anhydritgypsum
clinker storage
cement mill
separator fan
air slide fan
machine for packing and palletizing
filter1
2
3
5
4
6
78
REITZ – OPTIMISED FOR FUTURE CHALLENGES
High levels of efficiency and long service life of ventilation components are an absolutely vital prerequisite for efficient 24h
operation in the cement, lime and plaster industry. Downtimes due to unnecessary wear cost millions. Poor efficiency, ineffi-
cient control systems and poor aerodynamic design of gas-conveying system components leads to the unnecessary waste of
energy. In cooperation with prestigious university institutes, technical colleges and external service providers, the REITZ deve-
lopment department focuses continually for this reason on the optimising of fans and their components, including with regard
to their use in the system process. The assurance of a high degree of availability of fans and their components is reflected in
the operational reliability and profitability of the entire process.
Modern process optimising and increasingly fine cement types have increased the importance of wear protection as a factor which
impacts on the efficiency and reliability of overall production. REITZ has gained decades of experience with fans which convey solid
matter, continually promoting development of special impeller geometries and effective coatings using high-performance materials for
the most difficult operating conditions
Advantage of REITZ:o Wear protection systems optimally adapted to process requirementso Innovative wear protection technologyo High service life guarantee, reduced downtimes, minimised repair costs
––> Safe, efficient cement production
INNOVATIVE WEAR PROTECTION –
MAXIMUM SERVICE LIFE IS ASSURED
Achieving the balance between the demands of wear protection and best-possible efficiency is the noble art of engineering. Meticulous
monitoring of processes during individual production steps has enabled REITZ to adapt impeller geometries to suit process conditions.
Efficiency levels of over 80% for solid matter conveying fans represent the rule rather than the exception. Efficiency levels which even
exceed 85% can be realistically achieved, depending on the pressure and flow range.
Advantage of REITZ:o Latest engineering plus innovative measurement techniques for process optimising of impeller geometries
o High efficiency plus wear protection for efficient production procedures
HIGH EFFICIENCY –
OVER 85%, THANKS TO OPTIMISED GEOMETRIES
Special surface structures, materials and geometries minimi-se sticking of even abrasive solid matter and increase service lives.
Basis for a high degree of efficiency: The impeller is adapted to the process and optimised right down to the last detail (high efficiency in partial load range through use of variable speed control)
REITZ – PIONEERING FOR EFFICIENCY AND THE ENVIRONMENT
Issues such as environmental protection and the reduction of emissions are growing in importance on an international
level. REITZ variable speed control manages to kill several birds with a single stone as, in contrast to speed control using
dampers and inlet guide vanes, the rated motor power is adapted to the respective demand to reduce energy costs and
CO2 emissions by up to 30%. Pre-engineering through CFD and FEA aims to simulate operating conditions, tailor the
design perfectly in advance to suit requirements and determine the potential for optimising gas-conveying system com-
ponents.
The most convincing argument in favour of frequency converter technology is the fact that the additional expense pays off within the
shortest time period. Following the amortisation phase, production plant operators persistently save up to 30% of the energy require-
ment for ventilation components through needs-oriented adaptation of the rated motor power. This simultaneously improves the envi-
ronmental balance.
(This is a particular advantage in the partial load range and is also positively reflected in the acoustic data.)
Advantage of REITZ:o Needs-oriented consumptiono Reduced wearo Lower noise developmento Energy savings of up to 30%o Short-term amortisation of investmento Significant improvement in environmental balance (reduced CO2 emissions)
VARIABLE SPEED CONTROL –
PERFORMANCE ADJUSTMENT WITH ENORMOUS SAVINGS POTENTIAL
++ =Motor FrequenzumrichterVentilator Max. Energieeffizienz
LeistungsbedarfskurvenC1 = DrosselregelungC2 = DrallregelungC3 = Drehzahlregelung
REITZ has developed future-oriented fan monitoring concepts to ensure smooth operation. These range from simple monitoring
equipment with signalling to process control technology to online condition monitoring which enables timely initiation of maintenance
measures.
o Complete unbroken monitoring
o Avoidance of downtimes
o Above-average system availability
PROCESS MONITORING –
FAULT-FREE OPERATION
During planning, flow simulation with CFD analyses indicates the improvement potential during plant design and the inflow and outflow
situation of fans. On the one hand, improved efficiency enables the realisation of considerable energy saving potential and, on the other,
even investment costs can frequently be lowered (e.g. through component reduction).
Advantage of REITZ:o Optimum flow situations = energy savingso Enhancing of efficiency, also resulting in the optimising of acoustic datao Reduced investment costs
PRE-ENGINEERING –
SETTING THE COURSE FOR SUCCESS
Measures to improve flow in the inlet duct and reduce pressure loss
AfterBefore
REITZ – STRONG BUILDING MODELS FOR THE CEMENT INDUSTRY
REITZ radial fans set standards. Designed for maximum performance, maximum availability and extreme conditions, they
can reliably tackle any ventilation task in cement production. Whether primary air fans with total pressure increases of
up to 4,000 daPa and air volumes of up to 75,000 m³/h for optimum atomising of fuels, or material-conveying fans with
volume flows of up to 2,000,000 m³/h are involved, REITZ can supply everything from standard types to highly individual
special design, providing exactly the fan types you need for smooth production. You can, of course, also obtain all ne-
cessary accessories and effective sound protection from REITZ.
Each REITZ fan is designed to order and is, consequently, optimally adapted to suit your system. In addition, each model can be
individually customised in any size and any design to meet customer requirements:
o Special designs involving special steels and employing temperature-resistant and low-wear materials
o Gastight designs
o Shaft seal in special design
o Equipping of fans with monitoring equipment
o Explosion-protected design pursuant to ATEX
o Pressure-resistant and pressure shockproof designs
SPECIAL DESIGNS –
PERFECTLY NORMAL AT REITZ
KXE KBA KBZ KBE MXE
REITZ – MAJOR MODERNISING SUCCESS
Overall, modernisation of individual components is frequently enough to make a reliable system more powerful, less
susceptible to malfunction and more efficient and/or environmentally friendly. REITZ can provide support along the way,
from needs analysis to planning and coordination, installation and commissioning. As an experienced specialist for sys-
tem modernisation, we can assure you that all installation and repair work will be realised on schedule and with the least
possible impairment of production.
Each REITZ fan is designed to order and, consequently, optimally adapted to suit your system. In addition, each model can be
individually customised in any size and any design to meet customer requirements:
o Needs analysis through CFD, FEM and modal analysis
o Planning
o Dismantling
o Installation
o Commissioning
o Monitoring
o Maintenance
MODERNISATION FROM A SINGLE SOURCE –
PLANNED AND REALISED BY REITZ
o Improvements in production procedures through changing of operating parameters: fitting of additional filters, larger
heat exchangers or rotary kilns, enlarging of raw mills or classifiers, expansion or modernisation of clinker coolers
o Modification of system concept
o Replacement of used fans or components
o Energy saving through use of impellers with higher levels of efficiency
o Energy saving through use of energy-efficient drive systems (variable speed control with frequency converters)
ADVANTAGE OF MODERNISATION –
GREATER POWER, FEWER FAULTS, GREATER EFFICIENCY
o Impeller replacement with the blade design, impeller version and inflow nozzle appropriate for the application
o Wear protection on the impeller and housing
o Speed increase through frequency converters or belt drives by altering the transmission ratio, provided the dynamic limiting
values of the machine are not exceeded
o Replacement of fan components (e.g. bearing, shaft, coupling and belt drive)
o Old fan replaced by new
MODERNISATION EXAMPLE –
MINOR MEASURES, MAJOR EFFECT:
REITZ – GLOBALLY MORE SERVICE AND SUPPORT
These figures demonstrate why the REITZ Group is regarded as a powerful and committed partner all around the world: more than
800 employees, 11 subsidiaries, 5 production facilities and group certificate DIN EN ISO 9001:2008 in Germany, China and India.
The setup of our service network reflects this international mission. Wherever preventive servicing and maintenance is required
and questions or problems arise, our service team is close at hand and can be with you at the shortest notice to provide you with
advice and assistance.
o Project planning
o Installation and commissioning
o Retrofitting, assembly, dismantling, repairs
o Preventive maintenance and online condition monitoring
o Documentation
o Inspections
o Advice on optimising of existing components
o Measurements (flow, noise, vibration)
REITZ SERVICES –
FOR YOUR OPERATIONAL RELIABILITY
o 800 employees
o 11 subsidiaries
o 5 production facilities
o Group certificate DIN EN ISO 9001:2008
REITZ GROUP –
CONSISTENT QUALITY WORLDWIDE
REITZ – THE BENCHMARK IN STATE-OF-THE-ART SYSTEMS
Because conditions encountered in cement production are harsh and make enormous demands on fans, we are proud that our
products set standards in terms of efficiency, reliability and environmental protection in the latest cement, lime and earthworks.
In cement production facilities from Brazil to Indochina, REITZ fans ensure smooth production and the long-term success of our
customers.
Exhaust fan
Project Zementwerk, D
Model KBZ200-630010-02
Volume flow 414.000 m3/h
Pressure difference 841 daPa
Temperature 300 ºC
Design temperature 500 ºC
Rated motor power 1.600 kW
Wellenleistung 1.287 kW
Housing made of S355J2G3
Impeller made of 1.8928
Shaft made of 42CrMo4
Cooler ESP Fan
Project CityCement, KSA
Model KBZ045-1200007-00
Volume flow 720.000 m3/h
Pressure difference 230 daPa
Temperature 280 ºC
Design temperature 350 ºC
Rated motor power 710 kW
Housing made of S355J2G3
Impeller made of 1.8928 inkl. Eurodur 3500
Verschleißauflage
Shaft made of 42CrMo4
EGR fan
Project Zementwerk, D
Model KBA050-450010-00
Volume flow 250.000 m3/h
Pressure difference 332 daPa
Temperature 115 ºC
Design temperature 180 ºC
Rated motor power 315 kW
Housing made of S355J2G3
Impeller made of S355J2G3
Shaft made of 42CrMo4
Cooler exhaust fan
Project NatalCement, SA
Model KBZ031-400010-00
Volume flow 260.000 m3/h
Pressure difference 150 daPa
Temperature 280 ºC
Design temperature 350 ºC
Rated motor power 200 kW
Housing made of S355J2G3
Impeller made of 1.8928
Shaft made of 42CrMo4
Raw mill fan
Project Zementwerk, D
Model KXA125-200012-01
Volume flow 120.000 m3/h
Pressure difference 870 daPa
Temperatuer 120 ºC
Design temperature 180 ºC
Rated motor power 500 kW
Housing made of S235JRG2
Impeller made of S355J2G3 inkl. Eurodur
3500 Verschleißauflage
Shaft made of S355J2G3
Raw mill fan
Project Ambuja Cement, IN
Model KBZ200-2240010-00
Volume flow 1.344.000 m3/h
Pressure difference 1200 daPa
Temperature 20 ºC
Design temperature 180 ºC
Rated motor power 5600 kW
Housing made of 1.8928 inkl. Eurodur
3500 Verschleißauflage
Shaft made of 42CrMo4
Reitz Holding GmbH & Co. KGKonrad-Reitz-Straße 1 • D-37671 Höxter-Albaxen • Germany
phone: +49 (5271) 9 64 - 0 00
[email protected] • www.reitzgroup.com
