KHD wins bid to modify Holcim's Hagerstown plant

KHD Humboldt Wedag International AG’s Americas Customer Service Center based in Atlanta, Humboldt Wedag Inc, recently signed a contract with Holcim (US) Inc for engineering, delivery of equipment, and site services to modify the existing production line at its Hagerstown, Maryland plant.

The contract, which includes a KHD designed pyroprocessing system will increase the line’s production rate to 2400tpd and be compliant with the new NESHAP environmental regulations.

KHD’s responsiveness and flexibility in meeting technical and environmental requirements played a large role in winning this order. The project incorporates constructing a five-stage single-string KHD LowNOx preheater over the existing kiln, while the kiln is in operation.

Additionally, KHD will modify the existing six-pier rotary kiln to a two pier kiln and add a new KHD PYROFLOOR2® clinker cooler. The existing kiln will be cut to achieve a final length of 51m, transforming the existing long dry kiln system into a new, modern, energy efficient, fuel efficient, and environmentally friendly PyroProcessing system. The new system will be supplied with a new whole tire handling system and will be capable of co-processing up to approximately seven per cent of whole tyres as an alternative fuel.

To control emissions, KHD will supply a dry lime injection system, to reduce SOx emissions, and PYROJET LowNOx burners, a PYROCLON® Low NOX calciner with PYROLOOP® and a modification of the existing SNCR system, to control NOx emissions. New dust collectors will be supplied to meet stringent particulate emissions requirements.

KHD’s scope of supply for the project starts with a modification to the raw material feed system and ends with the clinker handling system into to the existing clinker storage hall. The scope consists of all electrical and auxiliary equipment, a new raw material grinding VRM system, coal dosing systems, as well as civil and structural engineering, and the supply of structural steel.

Core KHD equipment supplied for the PyroProcessing system include:
• five-stage single-string KHD Preheater  PR6742/5
• PYROCLON® LowNOX calciner with PYROLOOP®
• KHD PYROFLOOR2® Clinker Cooler PFC2 530
• KHD PRC Roller Crusher PRC 300-3-ES
• KHD PyroJet and PyroBox Burners.

Commissioning of this new system is planned for mid-2016.