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
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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?
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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!
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Places of evaporation and condensation
of chloride
Thermal evaporation in the burning zone
Condensation in calciner and lower cyclones
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Bypass Installation Pictures
Installation of Bypass @ Al Khaleez Cement, Qatar
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Differences between by-pass and filter
dust
Preheater Dust
By-pass dust
Chloride Salts
Raw m eal
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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.
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Flame Theory/ Burners
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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
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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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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
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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.
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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
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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.
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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
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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)
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Lecture 05-13 Theory
FL
Hi, fuel Heat value of the fuel (Kcal/Kg)
C Carbon, H Hydrogen, O Oxygen,
S Sulphur & N Nitrogen.
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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
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Lecture 05-13 Theory
FLSmid
th
2010,
all
rights
Flame formation in Duoflex and Traditional
Burners
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Duoflex Burner
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Duoflex Burner
Primary air inlet
Burner trolley
Burner pipe with
refractory
Valve for radial air
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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
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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
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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
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High
temperature
ILC Low NOx
Calciner
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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
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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
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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
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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
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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??
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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
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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???
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Emissions
Direct toxicity
Dioxins, CO, heavy metals
Global warming
CO2, CH4, N2O
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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
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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
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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
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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
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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
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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
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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
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How to convert ppm to mg/Nm3 and
correct for Oxygen
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The Most effective NoX reduction measures
SNCR injection.
Low Primary Air Burners (LOW NOX BURNER)
High temperature Combustion in the PC
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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
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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
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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
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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)
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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
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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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HOTDISC Site Pictures
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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
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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
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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
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Latest development in Cross-Bar cooler
technology
FLSmidth Cross-Bar
cooler
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Benefits from the unique design features
Consistently high thermal efficiency
High reliability / availability
Fast, low cost installation
Low, predictable maintenance
tons
kcal
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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
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Mechanical Flow Regulator (MFR)
Constant airflow to
clinker bed,
irrespective of
conditions above the
grate line
kcal
Air through
idle hole
Air through gaps
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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
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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
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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
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First installation of the new FLSmidth Cross-Bar
cooler in Texas, USA
8-grate wide rated for 2000 t/d
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Results achieved at Capitol
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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!
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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
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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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MFR & ABC Inlet
Mechanical Flow Regulator
Air Blast Controlled Inlet
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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
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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
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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.
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Back to normal operation with consistent low air supply.
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Zone division
PLC control with pre-programmed sequences of varying intensity
(frequency, volume, area)
Inlet divided in sections.
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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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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
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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
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
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Fig1. Cooler Operation without hot air recirculation
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Fig2. Cooler Operation with hot air recirculation
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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
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HRB MID-COOLER TYPE -Benefits
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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 %
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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
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