UPGRADING THE COAL FEED CONVEYOR SYSTEM AT HOLCIM CEMENT PLANT

Initial Situation

In 2014, AERZEN’s Application Sales Team identified an opportunity for upgrading the pneumatic coal feeding system to the main kiln, also known as the Pfister system. In this application, two AERZEN GM 35S three-lobe blowers from the 1990s were in operation. Each blower operated with an inlet air volume of 37.4 m³/min, a differential pressure of 600 mbar, and a 75 kW (100 HP) electric motor. The noise generated was calculated at 102 dB, as the blowers were not equipped with soundproofing hoods (local Colombian regulations mandate a maximum allowable noise level of 80 dB). The power consumption for the system was measured at an average of 54 kW/h per machine, resulting in an annual energy cost of $78,000 (based on an electricity rate of $0.1/kW and a mean time between repairs (MTBR) of 20,000 hours).

At Holcim Colombia, each production area operates independently. This makes it easier to upgrade specific applications. At Holcim, the company’s policy emphasizes that every kilowatt counts.

Delta Hybrid - AERZEN Technology for the Cement Industry

AERZEN proposed an upgrade solution using the Delta Hybrid Blower, model D62S, with the primary goal of improving the following aspects:

    •    Noise Reduction: Lowering noise levels to 72 dB under the same operating conditions, complying with Colombia’s 80 dB regulation.

    •    Energy Efficiency: Reducing energy consumption by 10%, resulting in annual savings of approximately $7,800.

    •    Power Capacity: Decreasing installed power thanks to the efficiency of the Delta Hybrid by replacing the existing 75 kW motor with a high-efficiency IE3 55 kW motor.

    •    Process Stability: Enhancing process stability due to the Delta Hybrid’s operating principle, which reduces pulsation when conveying airflow, delivering a more laminar air flow that ensures smoother combustion.

Additionally, the use of the Delta Hybrid Blower reduced operating costs by 40%, with the blower operating for 40,000 hours—doubling the Mean Time Between Repairs (MTBR)—and delivering 50% higher efficiency compared to standard three-lobe blowers.

Total Cost of Ownership (TCO) - Project Assessment

In addition to the clear technological upgrade advantages, evaluating the TCO of new machinery within the system is crucial for Holcim. AERZEN provided a 5-year forecast, projecting that with the Delta Hybrid Blower, operating costs would be reduced by 40%, with the blower running at a Mean Time Between Repairs (MTBR) of 40,000 hours—delivering 50% higher efficiency compared to conventional three-lobe blowers.