Problem
Breedon's Hope Works is the UK’s largest cement plant, producing more than 1.5 million tons annually from twin dry process kiln lines. It’s also one of the oldest in the UK and if that doesn’t present enough challenges, the plant has also been a leader in using a range of waste-derived fuels (to reduce fossil fuel reliance) and alternative raw materials (to reduce the rate of use of local shale). The mixed properties of the raw meal and alternative fuels going into the plant have increasingly presented challenges of hard buildups caused by sticky materials accumulating in cyclones, hoppers, and bends in the process, causing reduced and unstable flow. Worse still, the team struggled with poor service and lack of spare parts from their previous air cannon supplier.
Solution
A major plant upgrade in 2015 aimed at increasing the use of waste-derived fuels involved modifying the kiln inlets, riser sections, and cyclones. The team turned to Martin Engineering for 30 Tornado Air Cannons in the kiln inlet – fitted and maintained by Hope’s expert in-house team. Then in 2018, when planning a further upgrade, Martin® Hurricane Air Cannons were specified throughout, from the first-stage cyclones right through to the clinker cooler. Hurricanes feature a positive-acting valve that provides greater force, uses less air, simplifies installation, and makes for easier, safer maintenance. The risk of accidental discharge is eliminated and the control solenoid can be placed away from harsh conditions so it’s easier to access.
Results
Breedon fitted the first Hurricanes in 2019 and the benefits were clear. That led to further installations in all cyclone stages, kiln inlets, burner pipes, clinker cooler, and coal feed hopper. By 2022, there were 140 Hurricanes installed, all with 70-liter tanks and positive-acting valves. The two burner pipe air cannons use a 150-liter tank for maximum power to clear the “rhino’s horn” buildup at the tips. The Hurricane arrays can handle the frequent firing required to keep things clean, and the high-pressure air system is monitored centrally so the team can track performance. Knowing the risk of buildups and blockages is being controlled, the team is now further diversifying its raw meal and fuel mixes.
