Successful modernisation of the PFR kiln stone charging system at KPAB in Sweden

The project involved the full replacement of the kiln’s skip system and the installation of corrosion-resistant stainless steel shaft closing flaps — both designed to enhance reliability, safety, and long-term performance.

The new state-of-the-art Maerz-engineered design replaces the original skip system, dating back to 1988. The new system features:

• A top-mounted skip winch with a hydraulic secondary safety brake
• Guided bucket wheels and variable skip speeds
• Slack-rope detection
• An independent control system
• A redesigned skip bridge with a safety grid and cladding

Maerz provided the detailed engineering for the new system, as well as the key components such as the skip winch, control panels, and instrumentation. KPAB supplied and installed the skip bridge and skip bucket based on Maerz’s specifications and managed the overall installation and integration under supervision of Maerz technical personnel.

The project also included the replacement of the kiln’s original shaft closing flaps. The new stainless steel shaft closing flaps have been chosen specifically for their superior corrosion resistance. In addition to material improvements, the new flaps feature an “inward opening design” that effectively seals the kiln with the internal kiln pressure.

This latest upgrade reflects KPAB’s continued dedication to plant modernization and long-term operational improvement through strategic investment in advanced kiln technology.