Asia Cement reduces energy consumption with a Ventura two-stage fluid bed dryer
Project Overview
Asia Cement sought to improve the efficiency of its sand drying system by replacing an existing drum dryer with a more energy-efficient solution. The installation needed to reliably process different types of sand, including sea sand with relatively high clay content, while maintaining stable product quality and meeting strict environmental requirements.
To achieve these objectives, Ventilex supplied and commissioned a customized Ventura two-stage fluid bed dryer designed for high-capacity operation and optimized energy performance.
The challenge
The existing drying system presented several operational challenges:
- High energy consumption
- Variable feed materials with differing moisture characteristics
- Drying of sea sand containing relatively high clay levels
- Requirement for stable outlet moisture content
- Compliance with stringent emission regulations
Asia Cement required a solution that would reduce operational costs while ensuring reliable and consistent process performance.
The Ventilex solution
Before finalizing the dryer design, Ventilex conducted extensive testing to evaluate the drying characteristics of the different sand types.
Based on these results, a customized Ventura two-stage fluid bed dryer was engineered with sufficient thermal capacity to handle challenging operating conditions and varying feed materials
Key features of the installation include:
🔸Ventura two-stage fluid bed dryer
🔸Capacity of approximately 50 tons per hour
🔸Outlet moisture content of 8%
🔸Optimized thermal capacity across both drying zones
🔸Low-NOx burner technology
🔸Accurate air-to-fuel ratio control
🔸Energy-efficient dryer design
Results
The new drying installation successfully met the performance objectives established at the start of the project.
Key outcomes include:
- Significant reduction in energy consumption
- Lower operational costs
- Reliable drying performance under varying conditions
- Stable moisture reduction for multiple sand types
- Compliance with emission requirements
- Smooth transition from commissioning to operation
The achieved heat consumption closely matched the performance targets proposed during the design phase, contributing directly to improved process efficiency.
Customer testimonial
“We would like to express our sincere gratitude to the Ventilex team for their professional support in sales, technical, and related areas. The Ventura (two-stage fluid bed dryer) system meets the agreed performance criteria and operates reliably. We are highly satisfied with the performance of the dryer, particularly in terms of its energy and heat consumption. The cooperation throughout the project was professional and solution-oriented, ensuring a smooth transition to operation.”
Mr. Lim, Asia Cement
Looking for a more energy-efficient drying solution?
Ventilex has delivered more than 1,000 drying installations worldwide. Whether you are replacing an existing drum dryer, increasing production capacity, or reducing energy consumption, our drying specialists can help identify the most efficient solution for your process.