CEMENT
CEMENT
By
Ramesh Babu Dadi, Deputy Manager
Process Design Cement
@ NCBM, Hyderabad
2016 FLSmidth. All Rights Reserved
Agenda
Bypass Systems
Flame Theory
Low Nox Calciner Pet Coke Application
Emissions
SNCR System
Alternative Fuels - Hot Disc Technology
CB Cooler - ABC Inlet
Hot air recirculation from Cooler
HRB For Clinker Crushing
BYPASS CIRCUITS-
Preheater Dust
By-pass dust
Chloride Salts
Raw m eal
Burner Requirements
Able to burn coal, coke, fuel oil, natural gas, waste fuels and mixtures thereof
Important parameters:
Fuel type/quality
Excess air
Mixing rate
Burner type
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Flame Formation
F u el and
p r im a r y a ir
S w ir l a ir
H ot
se c o n d a r y a ir
In te r n a l
r e c ir c u la tio n
zone
E x te r n a l
r e c ir c u la tio n
zone
For combustion to take place, Three elements have to be present, fuel &
oxygen and Heat.
The fuel is fed to the combustion area and is mixed with oxygen
(combustion air) in the correct quantity.
This combustion air has three sources primary air, secondary air,
tertiary air and false air. The sum of all the air into the kiln is called
the combustion air
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Momentum
Uniflow burner
20% x 75 m/s
1500 % m/s
Swirlax burner
1500 % m/s
Duoflex burner
1500 % m/s
6% x 250 m/s
1500 % -2000m/s
Flame Temperature
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Excess Air
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Combustion Air
The combustion air for the Kiln is supplied from the three sources
Primary air
Secondary Air
The secondary air is regulated via the draft through the kiln
maximize the amount of hot secondary air and minimize the use of cold
primary air.
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Oxygen is the essential one required for combustion of any fuel, which
is abundant in atmospheric air (21% Vol.)
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FL
Where,
X Heat consumption (Kcal/Kg cl.)
P Production (TPD)
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FL
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FLSmid
th
2010,
all
rights
Due to inadequate mixture of air and fuel even, excess air coefficient
is required to have complete combustion of fuel. Preferrably by
maintaining 3% O2 level at kiln inlet.
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FLSmid
th
2010,
all
rights
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Duoflex Burner
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Duoflex Burner
Primary air inlet
Burner trolley
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4
2016 FLSmidth. All Rights Reserved
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Air
Temperature in secondary firing zone
Fuel
High
temperature
ILC Low NOx
Calciner
Pet coke
solid residue that remains after extraction of all valuable liquid and
gaseous components from crude oil.
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Challenges
Finer grinding
Slow combustion
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Problems
Recommendations
because of Pet
coke
High CO (due to Fine grinding based
Low volatility)
volatility.
Operation
Calciner
as
HOT
on
the
BOTTOM
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Why we need?
A high momentum burner -quick burnout.
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Adjusting Radial and axial air for good amount of fuel intermixing done in
the flame.
Why we need to divert some material from 3rd bottom cyclone to the
middle of calciner?
Finer clinker??.
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Frequent sampling of bottom cyclone hot meal - alkali, SO3 & Chlorine
content in hot meal to be done.
Hot meal SO3 content should not exceed 2.5% ..depending on plant
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Separator speed
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Emissions
Direct toxicity
Global warming
Respiratory
problems
Harmful to nature
Emissions
Urban area
Process gas
measurement
Cars
Industrial processes
Acid rain
NOx Sources
Thermal NOx
Fuel NOx
high NO
High O2 concentration
high NO
high NO
NOx Sources
Fuel NOx (From fuel bound N ) - Formed in calciner by combustion of N atoms in fuel
NOx formation in calciner firing
N +O
NO
N + NO
N2 +O
820- 1100oC
Second reaction is highly affected by temperature
NO
Fuel-N + O2
N2
Preheater
(N in raw meal may
form or reduce NOx)
solid
gas
fuel
Calciner
( reburning and
fuel NOx formation)
Clinker cooler
60 %
Kiln (thermal NOx)
40 %
Air
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Fuel type
Excess air
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(1)
2CO + 2NO
2CO2 + N2
(2)
C + 2NO
CO2 + N2
(3)
2N + 2NO
2N2 + O2
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SNCR injection.
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Reduce NOX level from flue gas by injecting ammonia solution in to the post
combustion flue gas at a temperature suitable for the commencing chemical
reaction without the presence of catalyst
Ammonia slip may results from higher molar ratios & Location: Calciner
outlet
SNCR Reactions
Alternate Fuels
Why Alternative Fuels?
Why
Alternative Fuels?
Put waste to good use by turning it into energy
CO2 emissions can be reduced
Put waste to good use by turning it into energy
fuelearnings
costs
Convert Convert
fuel costs into
into earnings
Continuously
increasing wastes
created by
society can
be reduced
Continuously
increasing
wastes
created
by society
can
be reduced
Save natural
resources and fossil fuels for future
Save natural resources and fossil fuels for future
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HOTDISC Technology
A HOTDISC Reactor:
Cold Raw
Meal Bin
Raw Meal
to Calciner
& HOTDISC
Triple Flap Sluice /
AF feed point
Tertiary Air
HOTDISC
What is HOTDISC?
The HOTDISC is a safe, simple and effective combustion device that
maximize the substitution of fossil fuels by alternative fuels in a controlled and
environmentally sound manner.
Combustion of Alternative Fuels takes place in Oxygen rich atmosphere.
Variable retention time based on the type of Alternative Fuel is possible to
ensure complete combustion.
Can accept lumpy materials Whole truck tyre , apart from the small size
materials.
Calciner TSR of up to 60 % can be achieved.
This is a proven system and Globally working very well, including India.
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Bleaching earth
Paper sludge
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Key benefits
Controlled emissions
Guaranteed performance
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References
Cimsa Eskisekir-Turkey
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FLSmidth Cross-Bar
cooler
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tons
kcal
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Constant airflow to
clinker bed,
irrespective of
conditions above the
grate line
kcal
Air through
idle hole
Air through gaps
Air through
holes in
tongue
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Internal
check valve
MFRs
Cast grates on
sloped profile
Flexible control of
blasting area
Air blaster
manifold and
pipes
blasting frequency
blasting intensity
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Step 1.
All cross bars
move forward
ton
s
Step 2.
Every other line
moves backwards
Step 3.
Remaining lines
move backwards
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Stationary Cross-Bar
Movable Cross-Bar
FLSmidth Cross-Bar Cooler
All Cross-Bars movable, moving
in shuttle motion
One drive for each 2-grate wide
unit
SF Cross-Bar Cooler
Alternating stationary and
movable Cross-Bars
One drive for each 4-grate wide
cassette
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Summary
Result is one of the most competitive and high performance coolers on the market
At an extremely attractive
installed cost!
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Ramliya SF upgrade
Before
upgrade
6150 t/d
22 spm
After upgrade
6800+ t/d
11-12 spm
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HIGH BED
RESISTANCE
LOW BED
RESISTANCE
LOWER
HIGHER
VALVE dP
VALVE dP
C O N STANT
AIR
FLOW
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Zone division
PLC control with pre-programmed sequences of varying intensity
(frequency, volume, area)
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Zone Blasting
Sequence 1
Sequence 2
Mega Blast
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Snowm
an
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Blasting
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can achieve the reliable operation, low wear, and better efficiency with hot
air circulation which is an additional feather to the crown of CB cooler
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Basis:
Kiln capacity
Recirculating air
Cooling air
Hot air to WHR
:
:
:
:
6000 TPD
1.55 kg air/kgcl
2.30 kg air/kgcl
0.8 kg air/kgcl
Scenario
Cooling air
Temp
Hot air
temperature
to Boiler
Clinker
temp
Estimated
WHR Power
Extra fan
power
Net gain
30 C
390 C
65 C+ amb
3 MW
0 kW
3 MW
120 C
445 C
125 C+ amb
4 MW
370 kW
3.6 MW
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BENEFITS
Dust reduction
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Jetflex Burner
Increased productivity for our customers due to better availability (less maintenance)
and better fuel economy.
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JETFLEX Burner
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Jetflex Burner
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Jetflex Burner
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Thank you
for your attention
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