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Per­for­mance im­prove­ment in ce­ment & con­crete pro­duc­tion through in­no­v­a­tive retro­fitting

A shared goal: High-qual­ity ce­ment & con­crete tech­nolo­gies for sus­tain­able con­struc­tion pro­jects

In­creased ef­fi­ciency in ce­ment & con­crete pro­duc­tion through retro­fitting – a pro­ject to op­ti­mise the per­for­mance of ex­ist­ing in­fra­struc­ture

Ce­ment and con­crete are es­sen­tial in the cre­ation of sta­ble, durable struc­tures – whether for trans­port in­fra­struc­ture, liv­ing spaces or power plants. The ver­sa­til­ity of ce­ment and con­crete makes them the ba­sis of mod­ern in­fra­struc­ture. As a lead­ing sup­plier of grey and white ce­ment as well as ready-mixed con­crete, Dy­ck­er­hoff makes an im­por­tant con­tri­bu­tion to cre­at­ing a sus­tain­able built en­vi­ron­ment.

In con­nec­tion with retro­fit pro­jects for plant in the ce­ment and con­crete in­dus­try, Scheuch COM­PO­NENTS re­place out­dated com­po­nents with highly ef­fi­cient so­lu­tions as at the Dy­ck­er­hoff pro­duc­tion fa­cil­ity in Göll­heim in SW Ger­many. All com­po­nents were pre­cisely tai­lored to the lo­cal con­di­tions. In ad­di­tion to in­creased plant ef­fi­ciency and re­duced op­er­at­ing costs, the pro­ject also achieved sig­nif­i­cant noise mit­i­ga­tion. Thanks to co­or­di­na­tion by Scheuch COM­PO­NENTS of all ser­vice providers, im­ple­men­ta­tion was com­pleted smoothly and on sched­ule – a tai­lor-made so­lu­tion with tan­gi­ble added value for peo­ple, the en­vi­ron­ment, and pro­duc­tion.

Pipework with division of the chimney into two pipe runs to the silencers

Pipe for connecting the existing system to the chimney

New double-flow impellers incl. shafts

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Per­form bet­ter

Increased performance & reduced noise through innovative retrofitting

By retro­fitting its plant, Dy­ck­er­hoff has achieved a sig­nif­i­cant in­crease in ef­fi­ciency and through­put rates, thereby op­ti­mis­ing pro­duc­tion ca­pac­ity. These changes have re­sulted in higher pro­duc­tiv­ity and ef­fi­ciency be­cause more air can be pumped, in­creas­ing over­all plant ef­fec­tive­ness.

In ad­di­tion, the new baf­fle si­lencers en­sure an al­most com­plete re­duc­tion in noise pol­lu­tion. Sub­se­quent sound mea­sure­ments con­firm that the val­ues achieved are com­fort­ably within the legally pre­scribed lim­its. This means that the plant not only com­plies with the re­quire­ments of rel­e­vant noise pro­tec­tion reg­u­la­tions, but sig­nif­i­cantly ex­ceeds them – a clear win for res­i­dents and em­ploy­ees.

An­other ad­van­tage of retro­fitting is the re­duc­tion of op­er­at­ing costs. Re­plac­ing older com­po­nents with more mod­ern, ef­fi­cient so­lu­tions re­duces en­ergy con­sump­tion, gen­er­at­ing long-term sav­ings. In ad­di­tion, the new, im­proved com­po­nents ex­tend the ser­vice life of the plant, re­duc­ing the fre­quency of re­pairs and break­downs.

With the retro­fit com­po­nents from Scheuch COM­PO­NENTS, Dy­ck­er­hoff has achieved a sus­tain­able in­crease in ef­fi­ciency in con­crete pro­duc­tion and an im­prove­ment in op­er­at­ing con­di­tions – both for em­ploy­ees and for the en­vi­ron­ment.

Key com­po­nents

Tailor-made retrofit solutions for handling large air volumes

All sup­plied com­po­nents were spe­cially de­vel­oped as in­di­vid­ual retro­fit so­lu­tions for ce­ment and con­crete pro­duc­tion, and pre­cisely tai­lored to the con­di­tions at Dy­ck­er­hoff. The in­ter­face for the pipe con­nec­tion was also adapted to the ex­ist­ing sit­u­a­tion so that the con­ver­sion could be im­ple­mented with­out com­pli­ca­tions.

These com­po­nents en­able the ef­fi­cient trans­port of huge air flow rates of up to 560,000 m³/​h:

  • Duct sections that are pre­cisely tai­lored to the plant sit­u­a­tion

  • Pipelines that are tai­lor-made for the spe­cific con­nec­tion on site

  • Impellers with shaft units and new bear­ings to work with huge air flow rates of 280,000 m³/​h and ex­tract them from the ex­ist­ing fil­ter sys­tem

  • Silencers that cre­ate a vir­tu­ally noise-free op­er­at­ing en­vi­ron­ment

  • Baffles and absorber panels that fur­ther im­prove sound re­duc­tion

  • Various accessories, such as com­pen­sators for ther­mal ex­pan­sion, which in­crease the re­li­a­bil­ity and safety of the plant.

To en­sure a smooth and ef­fi­cient in­stal­la­tion work­flows, at the cus­tomer’s re­quest, we also took over the co­or­di­na­tion and or­gan­i­sa­tion of all con­trac­tors in­volved in the pro­ject. The scaf­fold­ing, the pro­vi­sion of a crane, and the roof­ing work were or­gan­ised by our pro­ject man­age­ment team. The com­po­nents were in­stalled by qual­i­fied Scheuch fit­ters.

These cus­tomised so­lu­tions and the com­pre­hen­sive co­or­di­na­tion of all ser­vices, not only meant a seam­less in­te­gra­tion of the new sys­tems, it meant that we were also able to of­fer Dy­ck­er­hoff a com­pre­hen­sive, all-in-one pack­age for their retro­fit pro­ject.

Talk to us now about ef­fi­ciency po­ten­tials with­out oblig­a­tion

Per­for­mance data

Components from Scheuch COMPONENTS

Flow rate with 2 ra­dial fans: 560,000 Am³/​h
Im­pellers for a speed of: 1,200 rpm
Max. op­er­at­ing tem­per­a­ture: 300 °C

Silencer by Scheuch COMPONENTS

Our part­ner

Dyckerhoff GmbH

Dy­ck­er­hoff GmbH is a lead­ing sup­plier of ce­ment and con­crete prod­ucts head­quar­tered in Wies­baden, Ger­many. The com­pany of­fers a wide range of ce­ment types, in­clud­ing grey ce­ment and white ce­ment, as well as tai­lor-made con­crete so­lu­tions for de­mand­ing con­struc­tion pro­jects in sec­tors such as in­fra­struc­ture, ar­chi­tec­ture and in­dus­try. Dy­ck­er­hoff re­lies on in­no­va­tion, the high­est qual­ity stan­dards and sus­tain­able pro­duc­tion processes.

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Sabine Pupeter, contact person at Scheuch COMPONENTS

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