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CEMENT

The document discusses advances in pyroprocessing including bypass systems, flame theory, low NOx calciners for petcoke application, emissions control systems, and alternative fuels. Bypass systems help reduce volatiles like sulfur, chloride and alkalis. Proper flame formation and control of combustion air are important for high flame temperature. Low NOx calciners and SNCR systems help control emissions. Alternative fuels require considerations like grinding and burner design.

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Vijaya Kanakala
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© © All Rights Reserved
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100% found this document useful (2 votes)
799 views99 pages

CEMENT

The document discusses advances in pyroprocessing including bypass systems, flame theory, low NOx calciners for petcoke application, emissions control systems, and alternative fuels. Bypass systems help reduce volatiles like sulfur, chloride and alkalis. Proper flame formation and control of combustion air are important for high flame temperature. Low NOx calciners and SNCR systems help control emissions. Alternative fuels require considerations like grinding and burner design.

Uploaded by

Vijaya Kanakala
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
Download as pdf or txt
Download as pdf or txt
You are on page 1/ 99

Advances in PYRO Processing

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

2016 FLSmidth. All Rights Reserved

BYPASS CIRCUITS-

Reasons for Installing Bypass

Reducing the concentration of Volatiles.

What are the Volatiles ?

Main elements are: S,Cl,K,Na.

What challenges with volatiles?

Adverse effect of Volatiles are as follows,


 Emissions
 Corrosion
 Clinker quality

Which element is more Vulnerable in all the volatiles?

2016 FLSmidth. All Rights Reserved

Challenges caused by volatile components


 Coatings in riser pipe
 Cyclone blockages
 Kiln ring formation
 Kiln shell corrosion
 Dip tube corrosion
All these effects shall be included when the pay back time for a bypass is estimated!

2016 FLSmidth. All Rights Reserved

Places of evaporation and condensation


of chloride


Thermal evaporation in the burning zone

Condensation in calciner and lower cyclones

2016 FLSmidth. All Rights Reserved

Bypass Installation Pictures

Installation of Bypass @ Al Khaleez Cement, Qatar

2016 FLSmidth. All Rights Reserved

Differences between by-pass and filter


dust

Preheater Dust

By-pass dust

Chloride Salts
Raw m eal

2016 FLSmidth. All Rights Reserved

Sulfur Alkali ratio:


Sulfur dioxide + excess alkali -------Alkali Sulfates.

The limit of excess sulfur is recommended to be 250-600 g/kg


clinker w.r.t plant experience the value can be different.

2016 FLSmidth. All Rights Reserved

Flame Theory/ Burners

2016 FLSmidth. All Rights Reserved

Burner Requirements


Able to burn coal, coke, fuel oil, natural gas, waste fuels and mixtures thereof

Short, narrow, strong radiant flame

Dense ,stable coating formation on refractories in the burning zone of Kiln

Lower consumption of primary air

What is the Key Factor for Kiln Burner Performance ?????




Flame formation and heat transfer

Important parameters:

Fuel type/quality

Combustion air temperature

Excess air

Mixing rate

Burner type

2016 FLSmidth. All Rights Reserved

10

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

2016 FLSmidth. All Rights Reserved

11

Kiln burner: Primary air momentum


Flame momentum: Primary air, % of Lmin X Discharge velocity
Burner type

% P.A x Discharge velocity

Momentum

Uniflow burner

20% x 75 m/s

1500 % m/s

Swirlax burner

10.7% x 140 m/s

1500 % m/s

Duoflex burner

7,5% x 200 m/s

1500 % m/s

Jet flex Burner

6% x 250 m/s

1500 % -2000m/s

Theoretical Combustion air sufficient ????


Primary + secondary air + Tertiary Air+ false air = Combustion air
Stoichiometric combustion air + excess air =Combustion air

2016 FLSmidth. All Rights Reserved

FLSmidth 2007 all12

Flame Temperature


Heat Value and Chemical Composition.

Preheating of combustion air

A high temperature of the combustion air.

Amount of excess air.

Actual flame temperature is 80-85 % of the theoretical value.

2016 FLSmidth. All Rights Reserved

13

Factors for High Flame Temperature


Temperature of Combustion Air.

Effective recuperation of the clinker heat.

A high temperature of the secondary air.

Excess Air

An Optimum amount of excess air.

Low excess air gives a long flame.

Mixing Of Fuel & Air.




decisive for the actual flame temperature.

the combustion proceeds rapidly & high temperatures are achieved

2016 FLSmidth. All Rights Reserved

14

Combustion Air
The combustion air for the Kiln is supplied from the three sources
Primary air


Shaping the flame, secondary air in the flame.

expressed as a percentage of the stochiometric combustion air.

range of 4-25% by depending on the burner design and firing system

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.

2016 FLSmidth. All Rights Reserved

15

Combustion Air requirement.




Oxygen is the essential one required for combustion of any fuel, which
is abundant in atmospheric air (21% Vol.)

Combustion air is the minimum dry atmospheric air required to


complete the combustion of a fuel. It said as Theoretical or
Stoichiometric amount of air required.

To calculate the combustion air, the fuel analysis is to be known

2016 FLSmidth. All Rights Reserved

16

Lecture 05-13 Theory

FL

Combustion air calculation


L min. flow: minimum combustion air required, which is used as basis for
primary air or kiln air calculations (Kg Air/h)

Where,
X Heat consumption (Kcal/Kg cl.)
P Production (TPD)

2016 FLSmidth. All Rights Reserved

17

Lecture 05-13 Theory

FL

 Hi, fuel Heat value of the fuel (Kcal/Kg)

 C Carbon, H Hydrogen, O Oxygen,


 S Sulphur & N Nitrogen.

2016 FLSmidth. All Rights Reserved

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Lecture 05-13 Theory

FLSmid
th
2010,
all
rights

Excess Air Coefficient




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.

Excess air coefficient

2016 FLSmidth. All Rights Reserved

19

Lecture 05-13 Theory

FLSmid
th
2010,
all
rights

Flame formation in Duoflex and Traditional


Burners

2016 FLSmidth. All Rights Reserved

20

Duoflex Burner

2016 FLSmidth. All Rights Reserved

21

Duoflex Burner
Primary air inlet
Burner trolley

Burner pipe with


refractory

Valve for radial air

2016 FLSmidth. All Rights Reserved

Valve for axial air

22

Problem with Traditional Burner


Flame Towards Charge


Thermal decomposition in the burning zone

Evaporation caused by carbon in the burning zone

Evaporation caused by carbon in the kiln inlet

Formation of gypsum rings in the kiln inlet

4
2016 FLSmidth. All Rights Reserved

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Evaporation caused by carbon


Unburned carbon from burners is mixed with the charge and forms SO2(g)
CaSO4 + C = CaO +CO(g) + SO2(g)
Na2SO4 + C = Na2O +CO(g) + SO2(g)
K2SO4 + C = K2O +CO(g) + SO2(g)
A frequent source to troubles with kiln operation


Formation of gypsum rings in the kiln inlet

2016 FLSmidth. All Rights Reserved

24

NOx formation in Calciner Firing


 Nitrogen content in the fuel

 Oxygen level in the firing zone

 Initial NOx concentration in the combustion gas

Air
 Temperature in secondary firing zone

Fuel

2016 FLSmidth. All Rights Reserved

High
temperature
ILC Low NOx
Calciner

2016 FLSmidth. All Rights Reserved

Pet coke


solid residue that remains after extraction of all valuable liquid and
gaseous components from crude oil.

The volatile content range is typically 5 - 15%, depending on the


coking process.

The main challenges in burning petcoke

low reactivity due to this low volatile content

high sulfur content.

Low reactivity - finer grinding - high momentum can help????.

Adjusting the Raw Mix

2016 FLSmidth. All Rights Reserved

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Pet coke firing Benefits vs Challenges


Benefits

Challenges

High calorific value

Low volatile content

-Low ash content

Blending with coal often necessary

More chemically stable than coal

Finer grinding

-low tendency of spontaneous


combustion

Slow combustion

-low explosion tendency in the mill


system

High sulphur content

Less production cost

2016 FLSmidth. All Rights Reserved

28

Pyro Operation with Petcoke


S.
No.
1

Problems
Recommendations
because of Pet
coke
High CO (due to Fine grinding based
Low volatility)
volatility.
Operation
Calciner

as

HOT

on

the

BOTTOM

High Momentum Burner.


Coating issues due Optimum sulfur alkali ratio ~ 1.1
to
High
Sulfur
content
Raw mix to be made easy
burnable by making,
Raw Mix with less SM
Finer Raw meal
Operate with less Burning zone
temperature.
Maintain higher O2 at Kiln inlet

2016 FLSmidth. All Rights Reserved

29

Pyro Operation with Pet coke


Hot Bottom calciner:




Why we need ? Slow burning - more retention time??.


Combustion rate proportional to Temperature
localized hot zone requires in the calciner to promote faster combustion.

High Momentum Burner:





Why we need?
A high momentum burner -quick burnout.

Easy burnable Raw Mix:


Why it is required? Volatility of the sulfur will increase with critical
temperature. Consequently, hard burning mix or long retention time increases
the volatile nature of sulfur.
Higher O2 at Kiln Inlet:
Why? Hence high O2 will help in reducing the disassociation of alkali sulfate
and CaSO4.
CaSO4 CaO + SO2 + O2

2016 FLSmidth. All Rights Reserved

30

Pyro Operation with Pet coke




Kiln refractory conditions - application with high momentum operation.

Adjusting Radial and axial air for good amount of fuel intermixing done in
the flame.

Higher O2-Reducing atmosphere in the burning zone should be avoided--???

Air blasters to take care???

Why we need to divert some material from 3rd bottom cyclone to the
middle of calciner?

The challenge in the hot zone operation??

Finer clinker??.

Cross bars and grate plates- high fluidization??

2016 FLSmidth. All Rights Reserved

31

Pyro Operation with Pet coke -Quality




High sulfur content

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

2016 FLSmidth. All Rights Reserved

32

Coal Mill Operation Pet Coke




Coal mill operation and recommendations

Recommended to operate at 85-90% of table speed.

Separator speed

Additional water spray due to???

Chances of high vibration???

2016 FLSmidth. All Rights Reserved

33

Emissions

Direct toxicity

Dioxins, CO, heavy metals

Global warming

CO2, CH4, N2O


2016 FLSmidth. All Rights Reserved

Respiratory
problems

Smog, particles, NOx, VOC, SO2

Harmful to nature

NOx, SO2, NH3, HCl, toxins,


halocarbons, heavy metals

Emissions


Positions at which emission measurements are made

Emission level of pollutant


measured in stack gas

Flue gas plume gradually


dispersing

Urban area
Process gas
measurement

2016 FLSmidth. All Rights Reserved

NOx Emissions & Reduction process


What are Nitrogen Oxides ?

NOx emissions are the product of every air-fed combustion process

Cars

Industrial processes

Solid waste disposal

Nitric oxide and Nitrogen Dioxide are a product of high temperature


combustion.

How do they effect us?

NOx emissions are suspected of contributing directly and indirectly


to several atmospheric process that are known to be degrading the
environment

Acid rain

Forest and vegetable decline

Changes to ozone layer

Green house gas (GHG) & Global warming

2016 FLSmidth. All Rights Reserved

NOx Sources

Thermal NOx

Fuel NOx

Thermal NOx (From atmospheric N2)


Created by reaction of N2 and O2 molecules in air at temperature >1300 oC (i.e. Kiln)

Above reaction is influenced by temperature, 3X for every 55oC in gas temperature

Factors influencing thermal NOX formation


High combustion temperature

high NO

High O2 concentration

high NO

Long residence time @ high temp

high NO

2016 FLSmidth. All Rights Reserved

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

2016 FLSmidth. All Rights Reserved

NO
Fuel-N + O2
N2

Sources of Nox (ILC Kiln system)


Raw meal

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

2016 FLSmidth. All Rights Reserved

39

Factors determining NOx formation in the burning zone

Fuel type

Excess air

Flame shape and temperature

Necessary material temperature

NOx reduction strategies


Reducing kiln NOx by:
Avoiding temperature and O2 peaks (automatic kiln control)
Replacing a simple burner with a modern burner
Kiln burner settings (momentum, primary air, swirl etc.)
Improving raw meal burnability

2016 FLSmidth. All Rights Reserved

40

NOx reduction strategies (Contd)


SNCR - Selective Non Catalytic Reduction (Injecting ammonia solution in the
preheater)

NOx reduction reactions

(1)

2CO + 2NO

2CO2 + N2

(2)

C + 2NO

CO2 + N2

(3)

2N + 2NO

2N2 + O2

The Above Reactions Are:


Favored By Higher Temperature

2016 FLSmidth. All Rights Reserved

41

How to convert ppm to mg/Nm3 and


correct for Oxygen

2016 FLSmidth. All Rights Reserved

42

The Most effective NoX reduction measures




SNCR injection.

Low Primary Air Burners (LOW NOX BURNER)

High temperature Combustion in the PC

2016 FLSmidth. All Rights Reserved

43

NOx Reduction - SNCR


The most effective NOx Reduction measures

SELECTIVE NON CATALYTIC REDUCTION - SNCR




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

NOX reduction reaction occurs at the temperature 900- 1000 oC

At the proper temperature , the SNCR reagent selectively reduces NO to


molecular nitrogen , which results in NOX reduction , typically 35% to 65%

Agent used here is a <25(% w/w) aqueous solution of ammonia.

Ammonia slip may results from higher molar ratios & Location: Calciner
outlet

2016 FLSmidth. All Rights Reserved

SNCR Reactions


NH3 + NO + O2  N2 + H2O Reduction Reaction

Ideal Temperature Window: 900-1000C

If <850C: Ammonia slip

If >1000C: O2 + NH2  NO + H2O Oxidation Reaction

2016 FLSmidth. All Rights Reserved

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

Dramatically reduce the fuel costs in energy intensive


CO2 emissions
can be reduced
industries
Dramatically reduce the fuel costs in energy intensive industries

Achieve Zero fuel costs if feasible


Achieve Zero fuel costs if feasible

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

2016 FLSmidth. All Rights Reserved

46

Why Use Alternative Fuels?


Attractive for society
 CO2 emissions can be reduced
 Use of local resources creates local jobs.
 Waste problems are reduced.
Attractive for cement producers
 Can dramatically reduce fuel costs
 Environmental profile (Green cement)

2016 FLSmidth. All Rights Reserved

47

HOTDISC Technology
A HOTDISC Reactor:







Burns solid waste, e.g. whole truck tires


Co-feeding of different waste material
Longer retention time
Substitutes Calciner fuel
Residues are incorporated in the clinker
Emission control
Calciner

Cold Raw
Meal Bin

Raw Meal
to Calciner
& HOTDISC
Triple Flap Sluice /
AF feed point
Tertiary Air

HOTDISC

2016 FLSmidth. All Rights Reserved

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.

2016 FLSmidth. All Rights Reserved

HOTDISC Site Pictures

2016 FLSmidth. All Rights Reserved

50

Burns just about anything




Refuse Derived Fuel (produced from


municipal garbage), loose or compacted

Old Tyres (whole, shredded or cut into


pieces)

Bleaching earth

Paper sludge

Lime-stabilised oil sludge (from tanker


cleansing)

Old car fragments(upholstery, dashboards,


etc)

Impregnated wood waste

50% possible Calciner thermal substitution


rate.

Reduces Coal consumption

2016 FLSmidth. All Rights Reserved

51

Key benefits


Lower fuel costs by replacing


fossil fuels with coarse
alternative fuels

Flexibility to use a wide variety


of alternative fuel qualities

High substitution rates with


difficult alternative fuels (e.g.,
whole tyres)

Controlled emissions

Guaranteed performance

Robust technology, maintaining


high kiln availability with
alternative fuels

2016 FLSmidth. All Rights Reserved

52

References

 Norcem A/S, Kjopsvik Plant , Norway

 Holcim Slovensko A/, Rhozonik, Slovakia.

 Ciment Quebec , Quebec Plant , Canada

 S.A.Industries Votorantium , Brazil

 Salonit Anhovo , Slovenia

 Vasavadatta Cements* , India

 Cimsa Eskisekir-Turkey

2016 FLSmidth. All Rights Reserved

53

Latest development in Cross-Bar cooler


technology

FLSmidth Cross-Bar
cooler

2016 FLSmidth. All Rights Reserved

54

Benefits from the unique design features

Consistently high thermal efficiency


High reliability / availability
Fast, low cost installation
Low, predictable maintenance

tons

kcal

2016 FLSmidth. All Rights Reserved

55

Separation of clinker conveying and air


distribution systems
kcal

Clinker conveying via


cross bars effectively
convey, mix and
shear clinker layer
Air distribution system

Gradual wear on cross bar


elements has no effect on cooler
operation

2016 FLSmidth. All Rights Reserved

56

Mechanical Flow Regulator (MFR)

Constant airflow to
clinker bed,
irrespective of
conditions above the
grate line

kcal

Air through
idle hole
Air through gaps

2016 FLSmidth. All Rights Reserved

Air through
holes in
tongue

57

Supplied standard with an ABC (Air Blast


Controlled) cooler fixed inlet for snowman
elimination

Internal
check valve

MFRs

Cast grates on
sloped profile

Flexible control of
blasting area

Air blaster
manifold and
pipes

2016 FLSmidth. All Rights Reserved

blasting frequency
blasting intensity

58

Horizontal design with optimized


transport method

Step 1.
All cross bars
move forward

ton
s
Step 2.
Every other line
moves backwards

Step 3.
Remaining lines
move backwards

Shuttle motion with independent,


finite control across the cooler
width

2016 FLSmidth. All Rights Reserved

59

Comparison of SF and FLSmidth Cross-Bar


coolers

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

2016 FLSmidth. All Rights Reserved

60

First installation of the new FLSmidth Cross-Bar


cooler in Texas, USA

8-grate wide rated for 2000 t/d

2016 FLSmidth. All Rights Reserved

61

Results achieved at Capitol

2016 FLSmidth. All Rights Reserved

62

Summary




FLSmidth is the originator of 3rd generation cooler technology


More Cross-Bar coolers sold than all other 3rd generation cooler suppliers combined
Cross-Bar cooler design evolution
SF and MMC FLSmidth Cross-Bar

Result is one of the most competitive and high performance coolers on the market

The latest generation in Cross-Bar cooler technology




Superior reliability / availability







Low, predictable maintenance


Consistently high thermal efficiency
Low operating cost
Fast, simple installation
Great flexibility for retrofits

At an extremely attractive
installed cost!

2016 FLSmidth. All Rights Reserved

63

First SF upgrade project






Arabian Cement Co., Ramliya I plant


6000 t/d FLS plant, SF 4x6
Kiln shutdown 18 January 2010
Feed on 11 February 2010

2016 FLSmidth. All Rights Reserved

64

Ramliya SF upgrade
Before
upgrade
6150 t/d
22 spm

After upgrade
6800+ t/d
11-12 spm

2016 FLSmidth. All Rights Reserved

65

MFR & ABC Inlet


Mechanical Flow Regulator
Air Blast Controlled Inlet

2016 FLSmidth. All Rights Reserved

66

FAN with FLOW CONTROL

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Mechanical Flow Regulators

HIGH BED
RESISTANCE

LOW BED
RESISTANCE

LOWER

HIGHER

VALVE dP

VALVE dP

C O N STANT

2016 FLSmidth. All Rights Reserved

AIR

FLOW

68

Snowman A Big Threat ????

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Air Blast Controlled Inlet (ABC Inlet)


Benefit: eliminates snowmen and
prevents dead zones





Ensures uniform clinker distribution


Introduces flexible control of air blasting
Based on well-proven Mechanical Flow Regulator
(MFR) system
Consistent MFR cooling process supplemented by a
shock blast of compressed air released directly to
the grates and the clinker bed

2016 FLSmidth. All Rights Reserved

70

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72

During normal operation, the mechanical flow regulators


control the supply of air.

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Short periods of high air supply are necessary to lift or fluidise


the clinker bed.

2016 FLSmidth. All Rights Reserved

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Back to normal operation with consistent low air supply.

2016 FLSmidth. All Rights Reserved

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Zone division
PLC control with pre-programmed sequences of varying intensity
(frequency, volume, area)

Inlet divided in sections.

2016 FLSmidth. All Rights Reserved

Sectionalized piping underneath


inlet.

76

Flexible control of blast area and intensity

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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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83

Hot air Recirculation in FLS CB cooler for


increased WHR Potential

Increase in Boiler inlet temperature.

Increase in energy potential.

increase in heat potential of the WHR is an added advantage.

In turn, the corresponding vent-air volume will be reduced. The model


calculations show that the thermal energy available for WHR increases due
to hot air recirculation.

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

2016 FLSmidth. All Rights Reserved

84

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

Without hot air


recirculation

30 C

390 C

65 C+ amb

3 MW

0 kW

3 MW

With hot air


recirculation

120 C

445 C

125 C+ amb

4 MW

370 kW

3.6 MW

2016 FLSmidth. All Rights Reserved

85

Fig1. Cooler Operation without hot air recirculation

2016 FLSmidth. All Rights Reserved

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Fig2. Cooler Operation with hot air recirculation

2016 FLSmidth. All Rights Reserved

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88

HYDRAULIC ROLL BREAKER


HRB (HYDRAULIC ROLLER BREAKER) :


A combination of transport and


crushing rolls in series

Permits fines to pass through


predetermined gaps

Coarse is transported to the


crushing rolls

Over-size material is broken into


the required size by two heavy
crushing rolls

BENEFITS


Red rivers are stopped at the roller breaker

Minimal dynamic impact and wear on adjacent areas

Dust reduction

Long service life

2016 FLSmidth. All Rights Reserved

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HRB MID-COOLER TYPE -Benefits

2016 FLSmidth. All Rights Reserved

Improved heat transfer and cooling of


clinker

Red rivers are stopped at the roll breaker

Improved control of clinker discharge


temperatures

Better handling of kiln upset conditions

Large lumps do not interrupt kiln operation

Reduced dust to vent air

Improved particle size conditions

Longer service life/reduced maintenance


costs

Jetflex Burner

FACTS ABOUT THE JETFLEX BURNER




Improved performance, matching or exceeding the best in class

Reduced weight and fabrication cost

Reduced delivery time.

Superior control on flame.

Increased productivity for our customers due to better availability (less maintenance)
and better fuel economy.

Primary air consumption of 4-6 %

2016 FLSmidth. All Rights Reserved

92

JETFLEX Burner

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Jetflex Burner


Installation at Rohoznik Cement Plant, Slovakia


Based on the presentations, Rohoznik (former Holcim plant, now a
CRH plant) agreed to collaborate in the industrial test. An existing
Pillard burner at the plant was delivered to Denmark for
modification to the JETFLEX burner design. The customer was
already using a large percentage of RDF in the existing burner
which can be considered their main fuel. Additional to the RDF
they use ~25 % of petcoke, gas is also available, but mainly used
for heating up.

The fuel distribution and retention time


The mixing of primary and secondary air
The velocity profiles across the kiln
Stability and widest possible adjustability
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Jetflex Burner

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Thank you
for your attention

2016 FLSmidth. All Rights Reserved

98

2016 FLSmidth. All Rights Reserved

99

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