Latest generation HOTDISC successfully installed in Slovenia

In June 2009 the latest generation HOTDISC – Mk3 - was successfully commissioned in the Salonit Anhovo cement plant in Slovenia. This is the fifth HOTDISC being commissioned and the market is starting to realize the big potential in the unique patented machine.

Worldwide

In Canada, Brazil, Norway and Slovakia HOTDISCs are already running successfully. And even though customers all over the world are pleased about the performance of the HOTDISC, FLSmidth continues to improve and update the HOTDISC in every way possible.

Flexibility a key word

Time and experience has shown that one of the machine’s key forces is its 
big flexibility. The HOTDISC is capable of treating organic fuel in all sizes and shapes, from sludge or grains to huge whole truck tyres. If necessary it can also just be idling without affecting the process in any way. This means that even though customers have bought the same machine, the way they have chosen to benefit from it varies from plant to plant and from country to country. With a HOTDISC installed in the preheater it is possible to profit from the machine in several ways. One might want to benefit from a wide range of waste, choosing an alternative fuel that gives a high waste fee, another could benefit from good, cheap labour force making it possible to handle and transport strangely shaped sizes, and others again want a high calorific organic material in order to cut the costs of fossil fuels as much as possible.

All in all the first eight years of operation have shown that the possibilities for successful operation of the HOTDISC are unlimited.

Successful cooperation

Since the first HOTDISC was commissioned, FLSmidth specialists have been ready to offer immediate on site assistance and guidance to help customers get the very best out of their HOTDISC. Both customers and FLSmidth have benefitted through good cooperation, as any issue coming up is always solved and information stored. This means that knowledge from actual operation is taken into consideration when designing future HOTDISCs.

Over the years computational fluid dynamics (CFD) have contributed more and more to the design of the HOTDISC, making sure that the tertiary/quaternary air mixed with cooling raw meal is floating correctly through the chamber and thereby assuring proper burnout of what ever is on the HOTDISC table.

Mk3 HOTDISC

From monitoring and following up on the already running HOTDISCs, all critical areas have been identified and improved. As a result, the latest generation – the Mk3 HOTDISC – contains many improvements that result in increased flexibility, improved process control, increased capacity and improved durability. In addition, the Mk3 HOTDISC is lower and therefore easier to install in new towers. Hardly ever is there a need to add width or height to the preheater construction. The new lower HOTDISC design also makes it easier to install as retrofit in already existing plants. The HOTDISC in Brazil is a great example of how preheaters with downdraft calciners can successfully incorporate a HOTDISC. Even non-FLSmidth preheaters are often suitable for retrofits.

Salonit Anhovo

In late 2007, Salonit Anhovo decided to upgrade from 2200 tpd to 3500 tpd. This included a new 5-stage ILC preheater with the Mk3 HOTDISC. Anhovo already had a tyre feeding system with a nominal capacity of 2.5 tph and an average dosing rate of 1.5 tph and wanted to reuse as much of the system as possible. Furthermore, they had plans to introduce other types of organic material in near future. The great flexibility of the HOTDISC made it a perfect solution and it would only require a rerouting of the existing conveyor for delivery of the tyres to the HOTDISC triple-flap sluice. Later on a new or an upgraded feeding installation would make it possible to feed whatever desired to the HOTDISC through the very same sluice.

The goal was to reach 25% total fuel substitution through the HOTDISC by increasing the feed rate to 3.7 tph of whole car tyres or minimum 3 tph of truck tyres. Using the upgraded tyre feeding system, originally designed for 2.5 tph, the goal was realized after a few days of commissioning. The maximum output of 4 tph on the feeding system was achieved and measurements show that there is no influence on the amount or quality of clinker produced in Anhovo. Nor are the emissions influenced at all.

Better than ever

Whereas the first machine in 2002 was a prototype, the latest HOTDISC is now a standard machine in the FLSmidth range. The delivery time is reduced and the quality high. Standardization and globalization have also resulted in a lower price. In short, the HOTDISC is better than ever.