Cement Production
Air-Suspension Blowers Drive Energy Efficiency in Cement Production
A 4,000 t/d cement clinker production line in China faced significant operational challenges with its conventional Roots blowers used for coal injection at the kiln and calciner. The legacy blowers were oversized, consumed excessive power, and generated noise levels above 100 dB, creating a harsh working environment. To improve energy efficiency and operational conditions, the plant replaced two 110 kW Roots blowers with ”air-suspension high-speed centrifugal blowers” featuring air-foil bearings, permanent magnet motors, and Variable Frequency Drives (VFDs).
The air-suspension blowers supply precisely controlled conveying air to transport pulverized coal pneumatically into the kiln and calciner. Unlike oil-lubricated Roots blowers, these units operate with ”100% oil-free, frictionless technology”—there is no mechanical contact between the impeller and shaft, eliminating lubricant requirements and the risk of contamination. The integrated VFD enables stepless, real-time airflow adjustments to match the fluctuating pressure demands caused by changing material bed heights in the calciner—a critical requirement for stable combustion and consistent clinker quality.
The compact design requires only a fraction of the footprint of conventional blowers, and the control system integrates local control and frequency conversion in one unit, eliminating separate control cabinets.
Industry Focused Products!
Result
After commissioning, the plant achieved:
Energy Savings:
Power consumption dropped by ”over 30%” compared to the old Roots blowers, with the 110 kW units replaced by 90 kW air-suspension models, saving approximately 200,000 kWh annually.
Maintenance Reduction:
Oil-free operation eliminated lubricant replacement and mechanical wear, cutting maintenance expenses and enabling long-term, unattended operation.
Noise Reduction:
Noise levels decreased from >100 dB to below ”80 dB”, significantly improving operator comfort and safety.
Conclusion
This case demonstrates that air-suspension blowers offer a reliable, high-efficiency solution for cement plants’ pneumatic conveying systems. By replacing outdated Roots blowers, the facility achieved significant energy cost reductions, enhanced workplace safety, and improved process stability—delivering a rapid return on investment while supporting the industry’s energy-saving and decarbonization goals.
