Kiln Plant 11 at the Lagerdorf Cement Works - Design concept, construction and initial operating results

The newly built rotary kiln plant 11 with a clinker capacity of 4500 t/d was successfully brought into operation at the Lagerdorf works of Alsen-Breitenburg Zement- und Kalkwerke GmbH in. December 1995. The idea of upgrading the existing 3 000 t/d Lepol rotary kiln plant dating from 1973, even at great expense, to raise the clinker capacity and improve environmental protection. and cost-effectiveness had been rejected after extensive preliminary investigations, so the decision was made to build a new kiln plant. Because of the raw materials - the CaCO3 component is a very wet chalk - this new kiln, plant retains the well-tried semi-wet process and is equipped with a double-string cyclone preheater and a calciner supplied with tertiary air. The new plant came into operation. in December 1995 after a construction time of only 18 months; this followed a licensing procedure which lasted over 3 years and was centred on the voluntary implementation of an environmental compatibility investigation. Kiln plant 11 was designed specifically for the use of secondary raw materials and fuels. The clay the essential Al2O3 component - is completely replaced by fly ash, and up to 50% of the fuel energy requirement can. be covered by replacement materials. A completely new rotary kiln concept - a kiln on 2 support stations with direct drive through the support rollers - has been implemented successfully. Six months' operating experience have confirmed that the plant cart produce the required clinker capacity of 4500 t/d with an improved product quality, comply with the emission limits, and achieve the expected improvements in, cost-effectiveness. The integration of the new kiln plant into the existing infrastructure of the works can be pronounced successful.