Humboldt Wedag, Inc. – KHD Humboldt Wedag International AG’s Americas unit, 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, Md., plant. The contract, which includes a KHD-designed PyroProcessing System, will increase the line’s production rate to 2,400 tpd 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 the bid. 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 PyroFloor clinker cooler. The existing kiln will be cut to achieve a final length of 51 m, transforming the existing long dry kiln system into a modern, environmentally friendly pyro-processing system. The new system will be supplied with a new whole tire handling system and will be capable of co-processing up to approximately 7 percent of whole tires 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.

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

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