A large international cement plant owner asked IAC to provide an alternative to land filling cement kiln dust (CKD) collected from two wet process kilns burning hazardous waste oils and solvents. The IAC solution involved adapting the client’s existing storage silo, and adding a second new 18,000 ft³ process silo and two transport destinations. The existing design allowed trucks to be loaded out if required.
The new transport system was designed with a 20t/h capacity at a conveying distance of 1060 ft. to a new process silo that utilized two IAC loss-in-weight (LIW) scale systems to meter variable tonnages of CKD back into two finish mills and one specialty product mixer system. In addition, the CKD transfer system could be diverted to a second silo for rail load-out. This distance was 2515 ft. The pneumatic transport system was designed using a 35psig FLS compressor.
The CKD feeder equipment started a 35 psig compressor; one single double chamber flapper valve, ventilation valve, equalization pressure system and an IAC adjustable “TC Chamber” style pneumatic injector pipe. A total of sixteen IAC Abrasion Resistant (AR) elbows, each with a 10-year life expectancy, were used in the design.
The IAC LIW scale system provided accuracy within 1% from five IAC pulse-jet filters. These were installed to meet air emissions standards. The conveying line was increased (stepped) in order to reduce velocity and pressure. A complete dehumidified product aeration system was used to ensure the flow of CKD.
IAC also designed and programmed a PLC control system with multiple operator interface locations.