COUNTER CURRENT CYCLONE

A new concept in
cyclone technology
More capacity
– less energy

WE DISCOVER POTENTIAL
 Next-generation
top-stage cyclone
FLSmidth’s new counter current cyclone (CCX) delivers cement
plant owners greater opportunities to reduce initial installation
expenses and improve plant operations. Leading the way as the next
generation of top-stage cyclone technology, the FLSmidth CCX is
designed to make the preheating process more economical.

This ground-breaking preheater technology is ideal for new preheat-
er installations, due to its lower civil and structural design require-
ments and ease of installation. It is also well-suited for upgrade
projects as it boosts production capabilities.
Greater operating efficiency
One of the CCX’s ground-breaking technologies is the counter
current heat exchange concept. Developed by FLSmidth, this
reduces operating costs by combining efficient heat exchange
and effective separation of dust and air into one process. Unlike
conventional cyclone designs, material exits the CCX cyclone at a
higher temperature than the exit gas. For retrofits, this delivers two
main advantages:
■■ Net. heat consumption reduced by 8-10 kcal/kg clinker
■■ Less than 50% pressure drop compared to same standard
cyclone diameter
Comparison of a four-stage preheater
with CCX and a traditional five-stage
1 2 3 4 5 6
Lower capital costs
For new preheater projects, the CCX cyclone decreases initial costs
of the preheater structure and installation time – while maximising
production capacity. This is due to the cyclone’s larger capacity
and a new, lighter lining concept, which allows the cyclone to be
lined before being lifted and installed. Furthermore, installation is
simplified as the acting loads are more than 50 percent lower than a
conventional cyclone of the same size.
The CCX cyclone’s improved heat transfer efficiency means it is of-
ten possible to reduce the number of cyclone stages. For example,
a four-stage preheater will often be possible instead of a five-stage
preheater, resulting in lower combined operating costs for fuel and
power as well as significant capital cost savings.
A new perspective on upgrades
Upgrading a preheater to more efficient technology can deliver
compelling commercial benefits. But upgrades have often been
out of reach for plant owners, typically because of excessive civil
and structural costs, installation difficulties, and the impact on plant
layout. The FLSmidth CCX enables owners to meet these challeng-
es, thanks to its unique concept – which makes upgrading a highly
7 8 9 10 11 12 13 14 15 16 17

A
attractive economical proposition.
A

preheater for 3000 tpd clinker production

B B

C
For conventional preheater technology, it is especially the construc-
C

tion height than can escalate costs.

D D

Upgrading to the CCX does not require any reinforcements to the

5 stage traditional
E
existing preheater structure, despite the larger size of the cyclone.
E

preheater
F For owners, this means the ability to boost their preheater opera-
F

tions, but at a lower capital cost.

4 stage preheater
G G

with CCX cyclone

H H

■■ Lowest civil and

I I

installation cost
J J

■■ Lowest lifecycle cost Key benefits

K K
■■ Early production possible

by fastest installation time

L ■■ Lowest civil and structural costs of new preheaters
L

■■ Lowest maintenance cost

M
■■ Lowest operating costs
M

■■ Standard operating costs ■■ Low installation costs

N N

■■ Lightweight construction
Fast, simple installation
O O
■■

P ■■ High flexibility for retrofits and upgrades

P

Q Q
4 Stage preheater with CCX
3000 tpd 3000 tpd

R R

S S
 Design features
The FLSmidth CCX top-stage cyclone combines FLSmidth’s
process and cement production know-how with industry
requirements for reliability, power and heat efficiency and
low installation cost. Several fundamental design features
contribute significantly to its outstanding performance:

Raw meal feed inlet

Material and gases are
then processed naturally by
gravitational and centrifugal
Drive unit forces in the cyclone.

Riser pipe from

Rotating spreader cyclone stage 2
A rotating spreader disperses
the raw meal into the gas
stream ensuring efficient
counter current heat transfer
and separation.
Downward-facing
exit gas outlet
Changes in flow direction
Lightweight lining concept typically seen in conventional
The slim lining concept top-stage cyclones are
reduces the weight of the avoided, leading to a reduced
lining by approximately 60 pressure drop as the work
percent compared with required to lift material is
conventional top-stage eliminated.
cyclones. It also reduces heat
loss and pressure loss by
allowing more effective use of
the volume in the cyclone.

Upward-facing
central pipe
The cyclone cannot be filled
with dust during a stop,
which reduces material
loads on the preheater tower
by 50 percent – making it
possible to install a much
larger cyclone within the Material outlet to
existing structure for retrofits. Gas outlet cyclone stage 2
Project Centre Denmark
FLSmidth A/S
Vigerslev Allé 77
DK-2500 Valby
Copenhagen
Tel: +45 3618 1000
Fax: +45 3630 1820
E-mail: info@flsmidth.com

Project Centre USA

FLSmidth Inc.
2040 Avenue C
Bethlehem,
PA 18017-2188
Tel: +1 610-264-6011
Fax: +1 610-264-6170
E-mail: info-us@flsmidth.com

Project Centre India

FLSmidth Private Limited
FLSmidth House
34, Egatoor, Kelambakkam
(Rajiv Gandhi Salai, Chennai)
Tamil Nadu – 603 103
Tel: +91-44-4748 1000
Fax: +91-44-2747 0301
E-mail: indiainfo@flsmidth.com

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contained in this brochure are for general reference only and may change at any time.