Burner Replacement

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Detailed Structural & Electrical Engineering

The driver behind the burner replacement was a need to improve efficiency and reliability and to maximize kilns production capacity. FLSmidth provided the 3D model, mechanical equipment, and mechanical design - Industrial Ally provided the civil/structural and electrical engineering. Our design solution included new foundations for the new equipment, bins, and building columns, as well as structural modifications to the existing burner building columns, bracing, and floors (to remove interferences with the new equipment installation) plus new framing to accommodate and support the new burner carriages, associated burner equipment, new pulverized coal bins, coal dosing equipment, CO2 inerting system and ductwork. A key to the project success was the close collaboration with FLS to resolve interference issues related to existing to new interface points. The new pulverized coal bins (one for each kiln line) receive the ground coal from the existing coal mill. Separate pneumatic transport systems meter and feed the fuel to the new main burner and existing calciner burner of each kiln line. New coal dust collectors capture the particulate emissions to meet environmental regulations. Explosion vents protect the equipment and ductwork in the event the pulverized coal ignites and causes an explosion. The CO2 inerting system protects the pulverized coal system (including dust collectors and ducting) from fires caused by the coal. New electrical equipment, instrumentation, and PLC Controls were interfaced with existing MCC infrastructure and existing PLC I/O Cabinet Hardware and terminals. SMACC™ reviews at key design milestones ensured recognition and incorporation of all Safety, Maintenance, Access, Constructability, and Coordination items in alignment with our client's project goals.