BSP Engineering for Heidelberg Materials’ Rezzato cement plant.
BSP Engineering is contributing to the project at the Rezzato-Mazzano plant in Italy, formerly Italcementi, with the supply of a bypass dust storage silo and a ROTOBOX planetary extractor.
The solution combines storage and extraction in a flat-bottom silo, designed to meet the requirements of material handling and feeding downstream equipment.
Another application of BSP technology in the cement industry, where material characteristics call for solutions tailored to each specific process.
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How does a cement kiln bypass work?
During clinker production, chlorides entering with raw materials and fuels can volatilise in the hot kiln and condense in the cooler preheater. This creates an internal recirculation cycle that can lead to salt build-up, deposits and blockages.
A bypass system extracts a portion of the gas at the kiln inlet and rapidly cools it, causing salts to condense onto dust particles. A filter then separates this chloride-rich material, known as bypass dust, from the gas stream.
Removing these solids reduces chloride recirculation and helps stabilise kiln operation.
BSP Engineering provides the downstream storage and extraction solution: a dedicated silo and ROTOBOX planetary extractor for controlled feeding of the collected bypass dust to the downstream handling lines.
BSP Scope
BSP was awarded the contract to supply a planetary extractor for a 4.5 m diameter stainless steel silo, with a maximum discharge capacity of 60 m³/h.
The ROTOBOX extractor is equipped with a variable-frequency drive (VFD) to provide an adjustable discharge rate from 10 to 60 m³/h, feeding two separate discharge lines. It is also designed to withstand the elevated temperature of the incoming material, which reaches 80°C.
The silo is thermally insulated and mounted on load cells for continuous monitoring of the stored material’s weight. A protective enclosure on the silo roof houses the dust filter.
Equipped with control and monitoring systems, the ROTOBOX extractor is designed to meet the installation’s stringent safety requirements and support reliable, continuous operation.
