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%