FIELD

The present innovation relates to cement manufacturing and the processing of cement meal, or raw meal. For example, the present innovation relates to separation devices and mechanism that can facilitate the separation of raw meal dust, or solid raw meal particulates that are within a pre-selected size range, from flue gas, an arrangement of one or more such separation devices within a cement manufacturing plant, kits for upgrading a cement

manufacturing plant to include a separation mechanism or separation device, and methods of making and using the same.

BACKGROUND

Cement factories, or cement plants, often process cement meal dust. Examples of cement manufacturing factories, or cement manufacturing plants, can be appreciated from U.S. Patent

Nos. 4,997,363, 5,800,610, 5,954,499, 6,000,937, 7,052,274, 7,390,357, 7,972,419, 8,163,082, and 8,474,387, U.S. Patent Application Publication No. 2010/0180803 and International Publication Nos. WO 2014/048435 and WO 2017/060369. Such cement manufacturing can utilize a series of cyclones. But, we have determined that these cyclone arrangements can result in flue gas inefficiently bypassing the separation system.

SUMMARY

We provide a separation mechanism, a cement manufacturing plant, a kit for retrofitting a plant with at least one separation mechanism, and methods of making and using the same. Embodiments of these innovations can be configured to help improve at least one of: (i) heat transfer from a flue gas to cement meal (or raw meal) via a cross flow heat exchange, (ii) separation of cement meal from flue gas, and (iii) decreasing the pressure drop. Embodiments can be configured so that solid particulates (e.g. cement raw meal) are moved away from or directed away from a central axis of a separator to help facilitate such heat transfer.

Embodiments can also, or alternatively, be configured so that flue gas is passed through a separator mechanism to an exit that is positioned away from a central vertical axis of the separator. In some embodiments, the flue gas exit duct is not coincident at all with the center axis of the separator (e.g. a center of the inner chamber of the separator). Embodiments can be configured so that a temperature of meal leaving a preheater having one or more separator devices has a temperature that is greater than the temperature of the outlet stream of the flue gas.

In some embodiments, a cement manufacturing plant can include at least one separation device. Each separation device can have a body that defines an inner chamber and can have at least one of: (i) a flue gas outlet that is positioned in communication with the inner chamber such that a mouth of the flue gas outlet is unaligned with a central vertical axis of the inner chamber and is not coincident with the central vertical axis, (ii) a distribution mechanism having a rotatable member positioned in the inner chamber to direct raw meal away from a center of the inner chamber toward at least one raw meal outlet positioned adjacent a periphery of the inner chamber adjacent a lower portion of the body, and (iii) a distribution mechanism positioned in an upper position in the inner chamber adjacent an inlet at which flue gas is fed into the inner chamber to direct raw meal into the flue gas so that the raw meal is moved transversely across the flue gas in an outward direction as the flue gas flows within the inner chamber.

In some embodiments, the cement manufacturing plant can include a preheater configured to pre-heat raw meal before the raw meal is fed to a kiln or calciner where the preheater has at least one separation device. In some embodiments of the plant, the separation device has only the flue gas outlet that is positioned in communication with the inner chamber such that the mouth of the flue gas outlet is unaligned with the central vertical axis of the inner chamber and is not coincident with the central vertical axis. In other embodiments, the separation device has only the distribution mechanism having the rotatable member positioned in the inner chamber to direct raw meal away from a center of the inner chamber toward at least one raw meal outlet positioned adjacent a periphery of the inner chamber adjacent a lower portion of the body. In yet other

embodiments of the plant, the separation device has both (i) the flue gas outlet that is positioned in communication with the inner chamber such that the mouth of the flue gas outlet is unaligned with the central vertical axis of the inner chamber and is not coincident with the central vertical axis and (ii) the separation device has the distribution mechanism having the rotatable member positioned in the inner chamber to direct raw meal away from the center of the inner chamber toward at least one raw meal outlet positioned adjacent the periphery of the inner chamber adjacent the lower portion of the body. In yet other embodiments of the plant, the separation device has both of (i) the flue gas outlet that is positioned in communication with the inner chamber such that the mouth of the flue gas outlet is unaligned with a central vertical axis of the inner chamber and is not coincident with the central vertical axis and (iii) the distribution mechanism positioned in the upper position in the inner chamber adjacent the inlet at which flue gas is fed into the inner chamber to direct raw meal into the flue gas so that the raw meal is moved transversely across the flue gas in the outward direction as the flue gas flows within the inner chamber.

In some embodiments, where the separation device has the distribution mechanism having the rotatable member positioned in the inner chamber to direct raw meal away from a center of the inner chamber toward at least one raw meal outlet positioned adjacent the periphery of the inner chamber adjacent the lower portion of the body, the distribution mechanism can include a motor and a drive shaft connecting the rotatable member to the motor. The distribution mechanism can also include a housing that is located in the inner chamber of the body and is configured to direct the raw meal away from the center of the inner chamber. The motor can be positioned outside of the inner chamber or may be within the housing of the distribution mechanism or can be partially in the housing and partially outside of the body).

In some embodiments, the separation device can have the flue gas outlet positioned in communication with the inner chamber such that the mouth of the flue gas outlet is unaligned with the central vertical axis of the inner chamber and is not coincident with the central vertical axis, the mouth of the flue gas outlet being positioned so that flue gas fed into the inner chamber via a mouth of a flue gas inlet moves within the inner chamber along a flue gas flow path so that the flue gas rotates 240° to 330° within the inner chamber from the mouth of the flue gas inlet to the mouth of the flue gas outlet. For such embodiments, the inner chamber can be structured such that the flue gas flow path is defined so that the flue gas rotates l80°to 345°, l80°to 330°, l80°to 300°, 240°-300°, 240°-285°, 255°-280°, or 260°-280° within the inner chamber from the mouth of the flue gas inlet to the mouth of the flue gas outlet prior to exiting the inner chamber. The flue gas may rotate horizontally within the inner chamber about this rotational range. In some embodiments, the flue gas flow path is defined so that the flue gas rotates 270° or approximately 270° (e.g. 260°-280° or 265°-275°) within the inner chamber from the mouth of the flue gas inlet to the mouth of the flue gas outlet.

It should be appreciated that when the separation device has the distribution mechanism positioned in the upper position in the inner chamber adjacent the inlet at which flue gas is fed into the inner chamber, the distribution mechanism can be configured to direct raw meal into the flue gas so that the raw meal is moved transversely across the flue gas in the outward direction as the flue gas flows within the inner chamber. The transverse motion of the raw meal can be a motion that occurs as the flue gas is flowing in a rotational direction along the flue gas flow path within the inner chamber 11.

A separation mechanism for a cement manufacturing plant is also provided. The separation mechanism can include at least one separation device. Each separation device can have a body that defines an inner chamber. Each separation device can also have at least one of: (i) a flue gas outlet that is positioned in communication with the inner chamber such that a mouth of the flue gas outlet is unaligned with a central vertical axis of the inner chamber and is not coincident with the central vertical axis, (ii) a distribution mechanism having a rotatable member positioned in the inner chamber to direct raw meal away from a center of the inner chamber toward at least one raw meal outlet positioned adjacent a periphery of the inner chamber adjacent a lower portion of the body, and (iii) a distribution mechanism positioned in an upper position in the inner chamber adjacent an inlet at which flue gas is fed into the inner chamber to direct raw meal into the flue gas so that the raw meal is moved transversely across the flue gas in an outward direction as the flue gas flows within the inner chamber.

In some embodiments, the separation device has only the flue gas outlet that is positioned in communication with the inner chamber such that the mouth of the flue gas outlet is unaligned with the central vertical axis of the inner chamber and is not coincident with the central vertical axis. In other embodiments, the separation device has only the distribution mechanism having the rotatable member positioned in the inner chamber to direct raw meal away from the center of the inner chamber toward at least one raw meal outlet positioned adjacent the periphery of the inner chamber adjacent the lower portion of the body. In yet other embodiments, the separation device has both (i) the flue gas outlet that is positioned in communication with the inner chamber such that the mouth of the flue gas outlet is unaligned with the central vertical axis of the inner chamber and is not coincident with the central vertical axis and (ii) the separation device has the distribution mechanism having the rotatable member positioned in the inner chamber to direct raw meal away from the center of the inner chamber toward at least one raw meal outlet positioned adjacent the periphery of the inner chamber adjacent the lower portion of the body. In yet other embodiments, the separation device has both of (i) the flue gas outlet that is positioned in communication with the inner chamber such that the mouth of the flue gas outlet is unaligned with a central vertical axis of the inner chamber and is not coincident with the central vertical axis and (iii) the distribution mechanism positioned in the upper position in the inner chamber adjacent the inlet at which flue gas is fed into the inner chamber to direct raw meal into the flue gas so that the raw meal is moved transversely across the flue gas in the outward direction as the flue gas flows within the inner chamber.

In some embodiments where each separation device has the distribution mechanism having the rotatable member positioned in the inner chamber to direct raw meal away from the center of the inner chamber toward at least one raw meal outlet positioned adjacent the periphery of the inner chamber adjacent the lower portion of the body, the distribution mechanism can have a motor and a drive shaft connecting the rotatable member to the motor. The distribution mechanism can also have a housing positioned in the inner chamber to direct raw meal toward the one or more raw meal outlets positioned adjacent the periphery of the inner chamber adjacent a lower portion or a bottom of the body that defines the inner chamber. In some embodiments, the separation device can have the flue gas outlet that is positioned in communication with the inner chamber such that the mouth of the flue gas outlet is unaligned with the central vertical axis of the inner chamber and is not coincident with the central vertical axis such that the mouth of the flue gas outlet being positioned so that flue gas fed into the inner chamber via a mouth of a flue gas inlet moves within the inner chamber along a flue gas flow path so that the flue gas rotates 240° to 330° within the inner chamber from the mouth of the flue gas inlet to the mouth of the flue gas outlet.

It should be appreciated that embodiments of the separation device can have the distribution mechanism positioned in the upper position in the inner chamber adjacent the inlet at which flue gas is fed into the inner chamber to direct raw meal into the flue gas so that the raw meal is moved transversely across the flue gas in the outward direction as the flue gas flows within the inner chamber. The transverse flow of the raw meal can occur as the flue gas is flowing in the inner chamber and is rotating in the inner chamber along the flue gas flow path.

It should be appreciated that methods of providing a cement manufacturing plant that includes providing the plant and operating the plant are also provided. Additionally, it should be understood that kits that can include components of a separation mechanism or can include at least some components of the separation device for retrofitting a pre-existing cyclone in a cement manufacturing plant can be provided. Such kits can include at least one of: (i) structure for modifying a flue gas outlet so that the flue gas outlet is positioned in communication with the inner chamber such that a mouth of the flue gas outlet is unaligned with a central vertical axis of the inner chamber and is not coincident with the central vertical axis, (ii) structure for providing a distribution mechanism having a rotatable member positioned in the inner chamber to direct raw meal away from a center of the inner chamber toward at least one raw meal outlet positioned adjacent a periphery of the inner chamber adjacent a lower portion of the body, and (iii) structure for providing a distribution mechanism positioned in an upper position in the inner chamber adjacent an inlet at which flue gas is fed into the inner chamber to direct raw meal into the flue gas so that the raw meal is moved transversely across the flue gas in an outward direction as the flue gas flows within the inner chamber.

Other details, objects, and advantages of the separation mechanism, a cement manufacturing plant, a kit for retrofitting a plant with at least one separation mechanism, and methods of making and using the same will become apparent as the following description of certain exemplary embodiments thereof proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the a cement manufacturing plant, a kit for retrofitting a plant with at least one separation mechanism, a separation mechanism having at least one separation device, and methods of making and using the same are shown in the accompanying drawings. It should be understood that like reference numbers used in the drawings may identify like components.

Figure 1 is schematic view of a first exemplary embodiment of a cement manufacturing plant.

Figure 2 is a perspective view of an exemplary separator device 3 that can be included in the first exemplary embodiment of the cement manufacturing plant.

Figure 3 is a schematic top view of the exemplary separator device 3 shown in Figure 2.

Figure 4 is a schematic view of an exemplary meal distribution mechanism 21 that can be positioned in an exemplary embodiment of a separator device 3 of the first exemplary embodiment of the cement manufacturing plant. Figure 5 is a schematic view of an exemplary meal distribution mechanism 21 that can be positioned in an exemplary embodiment of a separator device 3 of the first exemplary embodiment of the cement manufacturing plant.

Figure 6 is a schematic view of an exemplary meal distribution mechanism 21 that can be positioned in an exemplary embodiment of a separator device 3 of the first exemplary embodiment of the cement manufacturing plant.

Figure 7 is a schematic view of a second exemplary embodiment of a cement manufacturing plant having exemplary embodiments of the separator device 3 included within a preheater 2. It should be understood that the exemplary embodiments of the separator device 3 shown in Figures 2-6 and 8 can be included in the embodiment of the cement manufacturing plant shown in Figure 7.

Figure 8 is a fragmentary view of the exemplary embodiment of a separator device 3 that can be included in the first and second exemplary embodiments of the cement manufacturing plant.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Referring to Figures 1-8, a cement manufacturing plant 100 can include a combustor 4 or calciner 4a (or kiln) that combusts a fuel. Exhaust gas, or flue gas, from a combustor 4 or other process element that emits hot gas can be passed through a pre -heater 2 for pre-heating cement raw meal material (e.g. solid particulates used for in processing for the formation of cement) prior to the cement raw meal being fed to a calciner or other processing device. The preheater 2 can include a series of separator devices 3. The number of separator devices 3 that are included can depend on a pre-selected set of design criteria. For instance, the series of separator devices 3 can include a plurality of separator devices 3 that can include a first separator device, a second separator device, a third separator device, a fourth separator device, and a fifth separator device. For example, there can be a top separator device 3, a bottom separator device 3, and one or more intermediate separator devices 3 between the top and the bottom separator devices 3. The flue gas may pass from the combustor 4 to the bottom separator device 3 and subsequently pass through the one or more intermediate separator devices before passing through the top separator device 3.

As can be seen from the exemplary embodiment shown in Figure 1 , cement raw meal can be fed into the preheater 2 via the top separator device 3. A feed conduit 17 or other type of feed mechanism can facilitate feeding of the cement raw meal into the top separator device 3. A distribution mechanism can be provided at the top of the separator device 3 to facilitate distribution of the cement raw meal at the top of the separator device within an inner chamber l2a of the separator device 3. In other embodiments, such as the exemplary embodiment illustrated in Figure 7, cement raw meal can be fed into different separator devices 3 via feed conduits 17 that introduces the cement raw meal into flue gas that is passing from one separator device 3 to another separator device 3 (e.g. in a flue gas feed conduit that may feed flue gas into a separator device) as the raw meal is moved toward a calciner 4a for feeding to the calciner 4a. The cement raw meal may pass through one or more of the separators in countercurrent flow with the flue gas and absorb heat from the flue gas as the cement raw meal passes out of the separator device 3 and toward a calciner. The heated cement raw meal may pass out of a bottom outlet 9 or other outlet. The flue gas may pass out of the separator device 3 near a top or near an upper region of the separator at a flue gas exit, or flue gas outlet 5. The flue gas may be introduced into the separator device via a flue gas inlet 3a. The separator device may have a body 12 that defines an inner chamber l2a that is in fluid communication with the cement raw meal outlet 9 and the flue gas inlet 3 a and outlet 5 so that the inlet and outlets are in

communication with the inner chamber l2a defined by the body 12 to facilitate the ingress and egress of the flue gas and the receipt and output of the cement raw meal.

The body 12 can be structured so that there is a central vertical axis 11 of the separator device 3. The flue gas outlet 5 can be positioned so that it is not aligned with the central axis 11, but is off-center. For example, no part of the flue gas outlet 5 may have an opening for the egress of flue gas that is aligned with the central axis or that is coincident with that central axis 11. As may be seen from Figure 3, such a positioning of the flue gas outlet 5 can help ensure that the flue gas flow 6 passing into the body 12 via the flue gas inlet 3a flows in a circular-type flow pattern along the periphery of the shape of the body 12 so that it rotates approximately 270 degrees (e.g. between 240 and 330 degrees) or at least 270 degrees from the inlet mouth 3b of the flue gas inlet 3a that feeds the flue gas directly into the inner chamber l2a of the body along the circumference or perimeter of the inner chamber before being able to pass out of the body via the mouth 5 a of the flue gas outlet 5 that is in communication with the inner chamber l2a for egress of the flue gas out of the inner chamber l2a. Such a positioning of the flue gas outlet 5 can also help avoid flue gas passing quickly out of the body 12 without having been retained in the inner chamber l2a of the body 12 sufficiently to transfer much heat to cement raw meal within the inner chamber. The positioning of the flue gas outlet 5 can help increase the residence time of all the flue gas within the body.

As can be seen from Figure 3, the central vertical axis 11 is shown as being in the direct center of the inner chamber l2a. That is the location at which the central vertical axis 11 is present and the flue gas outlet 5 can be positioned so that the flue gas outlet is not coincident with this vertical axis. No part of the mouth 5a of the flue gas outlet 5 can be aligned with the vertical axis 11 so that no part of the vertical axis passes through the mouth 5a or along the mouth 5 a. The mouth 5 a can be positioned so that it is entirely off center to help ensure that the flue gas moves along a flow path 6 so that the flue gas rotates 270° or about 270° (e.g. 180°- 345°, l80°-330°, l80°to 300°, 240°-330°, 240°-300°, 240°-285°, 255°-280°, 260°-280°, etc.) in a horizontal plane, or horizontal direction, from the mouth 3b of the flue gas inlet 3 a to the mouth 5a of the flue gas outlet 5. For example, the mouth 5a of the flue gas outlet 5 can be positioned so that flue gas fed into the inner chamber l2a via a mouth 3b of a flue gas inlet 3 a moves within the inner chamber l2a along a flue gas flow path 6 so that the flue gas rotates a pre-selected amount of rotation Q within the inner chamber l2a from the mouth 3b of the flue gas inlet 3 a to the mouth 5a of the flue gas outlet 5 within the inner chamber l2a. The preselected amount of rotation Q of the flue gas can be less than a full revolution, or less than a full 360° amount of rotation. For instance, the pre-selected amount of rotation Q of the flue gas within the inner chamber can be in the range of l80°-345°, l80°-330°, l80°to 300°, 240°-330°, 240°-300°, 240°- 285°, 255°-280°, 260°-280°, or be approximately 270° (i.e. 265°-275°).

In some embodiments, the central vertical axis 11 can be located at the center of the width W and thickness T of the inner chamber as indicated in Figure 3, or at the central, inner point of a radius R of the inner chamber that extends from the outer wall defining the inner chamber 12a to a central region of the inner chamber l2a. It should be appreciated that both the thickness T and width W are perpendicular to the height or length of the body 12 and that the radius R is perpendicular to the height or length of the body 12.

Each separator device 3 can also include a cement raw meal distribution mechanism 21 positioned within the inner chamber l2a to help guide cement raw meal fed within the body 12 of the separator device and into the inner chamber 12 so that the cement raw meal is directed toward an outer region of the inner chamber for cross flow contact with the flue gas fed into the inner chamber l2a. Figures 3, 4, 5, and 6 illustrate different embodiments of separator devices 3 that can be included in the plant 100 that has a cement raw meal distributor mechanism 21. Each separator device 3 of the plant illustrated in Figure 1 can have the same type of cement raw meal distributor mechanism 21 positioned therein or a different type.

The top separator device 3 can be configured to receive cement raw meal from a top feed conduit and may include a distribution mechanism suspended from the top of the preheater structure or top of the top separator device 3. Alternatively, the top separator may have a distribution mechanism 21 that is positioned inside the inner chamber. The intermediate and bottom separator devices 21 positioned inside the inner chamber l2a of the body. Frame elements can be configured to connect to the distribution mechanism to support a rotating element or moving element of the distribution mechanism inside the inner chamber 12. In some embodiments, each distribution mechanism can be centrally located (e.g. aligned with the vertical axis 11 ) to help ensure that cement raw meal is distributed away from the middle of the inner chamber and into the flow path of flue gas so that the raw meal passes in a cross-flow with the flue gas to help maximize the interaction between the raw meal and the flue gas to facilitate heat transfer from the hot flue gas to the cooler cement raw meal within the inner chamber l2a. For such embodiments, the cement raw meal feed conduit 17 can be configured to extend at an angle relative to vertical so that the raw meal is not centrally fed onto the plate, but is instead configured to direct cement raw meal toward the rotatable member at an angle that is vertical, approximately vertical (e.g. within 5° of being vertical), or is not perfectly vertical (e.g. a 15°- 85° relative to perfectly vertical, a 25°-75° relative to perfectly vertical, a 30°-60° relative to perfectly vertical, a 45° relative to perfectly vertical) so that there is a horizontal component of cement raw meal momentum that can help facilitate distribution via rotation of the rotatable member 2la toward the outer region of the inner chamber l2a.

As can be appreciated from Figures 1, 7, and 3, the distribution mechanism 21 can include a mechanism at which cement raw meal is fed into a flue gas path within or adjacent the inner chamber l2a and near, in or adjacent the mouth 3b of the flue gas inlet 3a that introduces flue gas into the inner chamber l2a such that the flue gas flows along a flue gas flow path 6 around the inner chamber and towards the upper flue gas outlet mouth 5a that is positioned at an upper location in communication with the inner chamber l2a to receive flue gas for exiting the inner chamber l2a. The distribution mechanism 21 can be coupled to an outlet 17a of a feed conduit 17 that is in fluid communication with the flue gas inlet 3a adjacent the mouth 3b of the flue gas inlet 3a for directing the cement raw meal into the flue gas flow path 6 or can be considered the outlet l7a of the feed conduit 17 that is in fluid communication with the flue gas inlet 3a adjacent the mouth 3b of the flue gas inlet 3a. It should be appreciated that the location at which the outlet l7a and/or distribution mechanism 21 is positioned adjacent the mouth 3b of the flue gas inlet 3a can be a location in the inner chamber, in the mouth 3b, near the mouth 3b, or can be positioned so that it is at the interface of the mouth 3b and inner chamber l2a such that the outlet l7a and/or distribution mechanism 21 is positioned in both the inner chamber l2a and the mouth 3b of the flue gas inlet 3 a.

As can be appreciated from Figures 1, 7, 3-6, and 8, other embodiments of the distribution mechanism 21 can also include a distribution mechanism 21 that includes a rotatable member 2la positioned in the inner chamber l2a or alternatively the separation device 3 can include a second distribution mechanism 21 that has the rotatable member 2la in addition to a first distribution mechanism 21 coupled to or incorporated into the cement meal feed conduit outlet l7a in communication with the flue gas inlet 3 a and/or mouth 3b of the flue gas inlet 3a adjacent the inner chamber l2a. The rotatable member 2la can be configured to rotate clockwise or counterclockwise 2 la. In some embodiments, the rotatable member 2 la can be a rotatable plate, a rotatable distributor plate, a rotatable grooved plate, a rotatable member having a plurality of protuberances or ribs for facilitating distribution of cement raw meal, or another type of rotatable body that is configured to contact cement raw meal and force the raw meal towards the outer wall defining the perimeter of the inner chamber l2a. The distribution mechanism 21 can include a motor 2 lb that is coupled to the rotatable member 21 a via a drive shaft 2lc. The motor 2 lb can rotate the drive shaft 2lc to cause the rotatable member 21 a to rotate. The distribution mechanism can also have frame elements that are coupled to portions of the body 12 to support the rotatable member 2la within the inner chamber l2a. The motor 2 lb can be positioned outside of the body and the drive shaft 2lc can extend from outside the body 12 to a position inside the body 12. The drive shaft 2lc can be positioned so that it can be cooled during rotational operations. The frame elements of the distribution mechanism can define an outer shape, or outer housing 2ld that may at least partially enclose the drive shaft 2lc and can also (or alternatively) provide a distribution profile for directing meal within the inner chamber l2a to one or more meal outlets 22 defined at a lower portion of the body 12 or at the bottom of the body 12 in communication with the inner chamber l2a adjacent a periphery of the inner chamber l2a (e.g. away from the center of the inner chamber and away from vertical axis 11 of the inner chamber. The one or more cement raw meal outlets 22 can be located at a periphery of the inner chamber l2a adjacent a sidewall of the body 12 that may define the outer shape of the inner chamber l2a. The one or more cement raw meal outlets 22 may be a single annular shaped outlet along a periphery of the bottom of the inner chamber l2a or may be multiple different outlets arranged at spaced apart locations along the periphery of the bottom of the inner chamber l2a or adjacent a lower portion of the body 12 in fluid communication with the inner chamber l2a near the periphery of the inner chamber l2a.

The one or more distribution mechanisms 21 can be configured so that the cement raw meal can flow within the inner chamber l2a in cement raw meal flow path 16 (shown in broken line in Figure 3) that moves at a cross-flow relative to the flue gas moving in the inner chamber l2a along the flue gas flow path 6 so that the cement raw meal moves in a cement raw meal flow path 16 that is at a cross-flow to the flue gas within the inner chamber l2a. For instance, as shown in Figure 3, the cement raw meal flow path 16 (shown in broken line) can be at least partially defined by a rotatable member 21 a positioned in the inner chamber that can direct the cement raw meal away from the center of the inner chamber and toward a periphery of the inner chamber (e.g. an outer portion of the inner chamber). The cement raw meal flow path 16 can also be facilitated (e.g. partially defined or fully defined) via use of the cement raw meal feed conduit outlet l7a being adjacent an inlet 3b of the flue gas inlet conduit so that the cement raw meal is directed transversely in the cement raw meal flow path 16 so that the cement raw meal moves across the flue gas flow path 6 as the flue gas flows in a rotating direction around the inner chamber l2a. As discussed elsewhere herein, a cement raw meal distribution mechanism can utilize a rotatable member 2 la, a cement raw meal feed conduit outlet l7a being adjacent an inlet 3b of the flue gas inlet conduit, or both of these features for providing the cement raw meal flow path 16 so that the cement raw meal flows at a cross-flow relative to the flue gas within the inner chamber l2a as the flue gas flows along the flue gas flow path 6 within the inner chamber toward the mouth 5 a of the flue gas outlet 5. As can be seen from Figures 4-6, the shape and configuration of the body of each separator device 3 can be the same or may differ to account of a particular set of design criteria. For example, the intermediate and bottom separator devices may have a feed conduit 17 that feeds cement raw meal into the inner chamber l2a of the body of that separator device 3 to direct the cement raw meal to the rotatable member 2 la. This cement raw meal feed conduit 17 can be present and include a cement raw meal feed conduit outlet that is positioned within the inner chamber l2a away from the flue gas inlet 3b of the conduit 3 a instead of a cement raw mail feed conduit outlet l7a being provided adjacent the inlet 3b of the flue gas inlet conduit or this cement raw meal feed conduit 17 can be provided in addition to the cement raw meal feed conduit l7a provided adjacent the inlet 3b of the flue gas inlet conduit 3a.

The body 12 can also have an upper flue gas outlet mouth 5 a that is positioned at an upper location in communication with the inner chamber l2a. That upper location can be at a top of the body 12 as shown in the example of Figure 5, or at a left or right side of the body 12 near the top of the body 12 or top of the inner chamber l2a as shown in Figure 6, for example. It should be appreciated that while Figure 6 illustrates the mouth 5a of the flue gas outlet 5 for that body to be on a side that is fully opposite the mouth 3b of the glue gas inlet, that may not be the case. The mouth 5a of the flue gas outlet 5 can be located at a position that is about 270° (e.g. 180° to 345°, 180°to 330°, l80°to 300°, 240° to 330°, 240°-300°, 240°-285°, 255°-280°, 260°- 280°, 265°-275°etc.) away from the mouth 3b of the flue gas inlet 3a.

In some embodiments, the separator device 3 can be structured so that the distribution mechanism 21 has a rotatable member 21 a positioned near a top of the separator device 3 or near a top of the inner chamber l2a. In such embodiments, the rotatable member 2la can be configured as a top spreader for spreading the cement raw meal within the inner chamber l2a to help direct the raw meal toward a periphery of the inner chamber l2a to provide a cross flow of the cement raw meal for mixing with the flue gas flowing within the inner chamber l2a.

In other embodiments, the rotatable member can be positioned near a middle location or a lower portion of the inner chamber l2a and be configured to contact with cement raw meal after it is fed into the inner chamber l2a for helping to direct the cement raw meal toward the outer periphery of the inner chamber l2a. Such embodiments can be configured so that the rotatable member 2la is a rotating distributor member, a rotating plate having a profile for facilitating the directing of the cement raw meal, or a rotating spreader within the inner chamber l2a and below a top of the inner chamber l2a.

Embodiments of the separation mechanism or a separation device 3 can be configured for replacement or retrofitting into a pre-existing cement manufacturing plant. For example, it is contemplated that a conventional cyclone device could be removed from a plant and an embodiment of a separation device 3 can be included in its place. As another example, it is contemplated that a pre-existing, conventional cyclone can be modified to include a distribution mechanism 21 utilizing a plate member positioned in the inner chamber that may be moveable or rotatable, an off-center flue gas outlet 5 that has a mouth 5a that is not coincident with a central vertical axis of the separator device, or both the off-center flue gas outlet 5 and the distribution mechanism 21. As yet another example, it is contemplated that a pre-existing, conventional cyclone can be modified to include a distribution mechanism 21 at which cement raw meal is fed into a flue gas flow path 6 via a feed conduit outlet l7a (shown in broken line in Figures 3-6) adjacent an inlet 3b of the flue gas inlet conduit so that the cement raw meal is directed transversely across the flue gas flow path 6 as the flue gas flows in a rotating direction around the inner chamber l2a, an off-center flue gas outlet 5 that has a mouth 5 a that is not coincident with a central vertical axis of the separator device, or both of these features. As yet another example, it is contemplated that a pre-existing conventional cyclone can be modified to include all three features such that modified cyclone includes the off-center flue gas outlet 5, a first distribution mechanism 21 configured so that cement raw meal is fed into a flue gas flow path 6 via a feed conduit outlet l7a adjacent an inlet 3b of the flue gas inlet conduit so that the cement raw meal is directed transversely across the flue gas flow path 6 as the flue gas flows in a rotating direction around the inner chamber, and a second distribution mechanism 21 the includes a plate or other member that may be moveable within the inner chamber l2a as shown, for example, in Figures 4-6. Kits may be sold to a cement manufacturing plant operator to facilitate the modification of such cyclones. The kits that are sold may be offered in a customized way so that a particular flue gas outlet 5 structure and a particular distribution mechanism 21 are able to accommodate a pre-existing design of a plant for retrofitting or modifying pre-existing conventional structures of the plant.

It should be appreciated that different embodiments of the cement manufacturing plant 100 and different embodiments of the separation mechanism can utilize different arrangements to meet a particular set of design criteria. For instance, the geometry, height, width (or diameter) of each separator device can be sized to meet a particular design objective (e.g. account for pre existing support structure of a plant, account for a desired processing capacity, etc.). As another example, the number of separator devices can depend on a particular set of design criteria. In some embodiments, it is contemplated that only one separator device 3 may be needed or only bottom and top separator devices could be needed. In yet other embodiments, three separator devices 3 can be used or more than four separator devices can be used (e.g. five, six, seven, etc.). The geometry and shape of each body 12 can be any particular configuration that meets a particular set of design criteria. As yet another example, embodiments can be configured so that the size and configuration of feed conduits, flue gas conduits, or other conduits, are configured to meet the flow rates, desired temperature ranges, and desired pressure ranges of operation for the preheater 2, the separation mechanism or a particular separation device 3.

It should also be appreciated that some components, features, and/or configurations may be described in connection with only one particular embodiment, but these same components, features, and/or configurations can be applied or used with many other embodiments and should be considered applicable to the other embodiments, unless stated otherwise or unless such a component, feature, and/or configuration is technically impossible to use with the other embodiment. Thus, the components, features, and/or configurations of the various embodiments can be combined together in any manner and such combinations are expressly contemplated and disclosed by this statement.

Thus, while certain exemplary embodiments of the cement manufacturing plant, kit for retrofitting a plant with at least one separation mechanism, the separation mechanism having at least one separation device, and methods of making and using the same have been shown and described above, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims.