Retrofit

Zinc processing / production of sulphur chemicals

Improved air flow

Two redundant combustion air fans and a cracking gas blower were supplied for one of the leading zinc processors and manufacturers of sulphur chemicals. The combustion air fans were to ensure optimum air flow and effectively keep particles such as dust and ash away from the cracking furnace. The cracking gas fan had to safely handle highly toxic process gas and meet extreme noise requirements.

The main task was to design the cracking gas blower to be gas-tight and resistant to abrasive dust. In addition, a significant reduction in the noise level to below 88 dB(A) was required.
The combustion air fans required a solution to prevent contamination from dust and had to enable quick and efficient maintenance work.

→

Zinc processing / production of sulphur chemicals

Implementation

Combustion air fans: Instead of the planned two silencers with intake filters, a Y-piece was introduced on the intake side. A class G1 Delbag filter was implemented to effectively separate dust and ash.

Cracked gas blower: Equipped with a hydraulically disengageable impeller unit for uncomplicated maintenance. The housing remained on site, while the motor and impeller were replaced as a unit. The noise requirements were met by a two-part, movable sound enclosure and 300 mm housing insulation.

Cement and lime plant

Operational readiness

A long-established cement and lime works originally planned to replace a cooler exhaust fan and renew the old belt drive. In the course of the project, the requirements were expanded, which made additional adjustments necessary.

The challenge was to divide the project into precisely defined phases. This included the replacement of the blower, the installation of an active balancing unit and the delivery and installation of a cyclone, including the necessary piping adjustments. Each phase had to be carefully planned and executed to ensure continuous operational readiness.

→

Cement and lime plant

Implementation

Fan replacement: The existing cooler exhaust fan was replaced with the new KXE fan. This was equipped with a disengageable bracket and EURODUR VL33 wear protection to withstand the high temperatures (500°C) and medium temperatures (370°C).

Active balancing unit: An active balancing unit was installed to optimize fan operation and minimize vibrations.

Cyclone delivery and installation: A cyclone with a Densit Wear Flex 2000 lining (25 mm thick) was delivered and installed, including the necessary adjustments to the piping. Precise 3D scanning was carried out prior to installation to ensure an exact fit.

Fiber cement construction materials

Wear protection measures

A major manufacturer of fiber cement building materials needed to replace its fiber conveying fans and renew the piping systems from the shredder mills to the cyclones.

The installation of the fans in confined spaces, the integration of wear protection measures and the extensive disassembly and assembly work in an ATEX environment were challenging. The greatest difficulty was the complex pipe routing over 5 floors, which also had to be equipped with robust wear protection.

→

Fiber cement construction materials

Implementation

Replacing the fans: Three fiber conveyor fans were installed, which were split several times due to the limited space on site.

Replacement of the piping: The entire piping system from the shredder mills to the cyclones (approx. 210 meters in total) was replaced and lined with EURODUR wear protection, including the pipe bends and the fan impellers and housings.

3D laser scanning and engineering: Precise 3D laser scanning was carried out before the replacement to ensure accurate planning and adaptation.

ATEX: ATEX regulations were taken into account and complied with throughout the project.