Schenck Process Americas S.A.S / FCT Combustion Pty

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5 Νοε 2013 (πριν από 3 χρόνια και 7 μήνες)

168 εμφανίσεις

©

Schenck Process 2012

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FICEM APCAC COSTA RICA 2012

Schenck Process Americas S.A.S / FCT Combustion Pty

©

Schenck Process 2012

2

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1

Schenck Process Americas S.A.S

Presentation

2

FCT Combustion Pty Ltd

Presentation

CONTENTS

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3

Efficient and Optimum Cement Production with Alternative Fuels


By


Sanjiv

Dhanjal

(FCT Combustion, USA)

and

Fernando
Garcia (Schenck
Process Americas S.A.S,
Colombia)


©


Schenck Process GmbH 2006


Seite
4


Your partner in cement Industry

Products:


Belt
weigher


Weighfeeder


Loss in weigh feeder
MECHATRON


Flowmeter

MULTISTREAM


Bin weighing


Mass flow feeders
MULTICOR


Screens


Truck and train
scales


Loading automation


Alternative

fuels
.

Cement
-

mill

Cement

Separator

Bucket elevator

Bucket

elevator

Return

grits

Homogeni
-

zation

Alternative:

Flow gates

Separator

Raw mill

Lime
-

stone

Clay

Sand

Return grits

Cement

Cement

Blaine value

Measurement

Clinker

Gypsum

Additive

Cooler

Belt weigher to be

installed in apron

conveyor

MULTICOR
-
K
-

Feeding

of pulverized coal

(10 bar pressure proof)

Store

Kiln

SCHENCK Fuel Master

Feeding of Alternative Fuels

MECHATRON

FE2SO4

Limestone

Sand

Clay

Reclaimer wheel

Limestone

crusher

Clay

Sand

Apron feeder

Crusher relief

screen

SCHENCK Fuel Master

Feeding of Alternative Fuels

©


Schenck Process GmbH 2006


Seite
5


The goal:

Reduce the operation costs in cement kilns by substituting of:

More expensive primary fuels (Coal, Oil, Gas) for alternative low cost

fuel.




Clinker quality



Production capacity



stability of kiln



and
atmosferic

emisions
.



... Giving the less impact on:

Feeding systems FUEL
-
Master

solutions for alternative fuels

©


Schenck Process GmbH 2006


Seite
6


Design requirements for fuel systems:



They must feed a wide range of materials.



Hi accuracy and high feeding constancy.



High reliability and high availability.


Capacity of manage very big sizes of material.



Easy integration on existing installations.


Easy maintenance


Cheap return cost


Feeding systems FUEL
-
Master

solutions for alternative fuels

©


Schenck Process GmbH 2006


Seite
7


3 golden rules

for design of alternative fuels plants:



1.
Specifying robust equipment despite low density!



Ensure high availability of systems.

2.
Avoid bottleneck
-

Alternative fuels tries to create bridges.



Avoid dead times for plugging.

3.
Design a wide range of densities and flow properties.




Makes sure high flexibility using several materials
.



Feeding systems FUEL
-
Master

solutions for alternative fuels

©


Schenck Process GmbH 2006


Seite
8


6050
2400
6000
6000
1500
1800
±0 = 314,000
6900
8500
20000
30000
50000
+ 0,450
+ 12,100
- 4,300
Reception

Storing and transport

Weighing and feeding

Feeding systems FUEL
-
Master

solutions for alternative fuels

©

Schenck Process 2012

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©

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9

FCT
TURBU
-
JET

FOR REGULAR AND ALTERNATIVE FUEL

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Schenck Process 2012

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Gaseous

Nozzle design is based on flow and pressure. Typically multiple holes


Liquid

Atomization required for efficient combustion

Pressure
atomization requires up to about 40
barg

(600 psig)

Air and steam also used for atomization, typically at about 6
-
8
barg

(90
-
120 psig)

Solid

Grind coal or coke to about 90% through 75 micron
sieve

Final size depends on volatile fraction



Purpose is to facilitate fuel and air mixing


FUEL COMBUSTION

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11

ALTERNATIVE FUELS COME IN ALL SHAPES AND
SIZES

Rice Husks

Wood Waste

Paper and Plastics

Cherry Stones

Tire Shreds

Diapers

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12

TESTING AND MODELING TO DETERMINE BEST
WAY TO FIRE ALTERNATIVES

©

Schenck Process 2012

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FCT ALTERNATIVE FUEL NOZZLE

©

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14

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KILN MINERALOGICAL REACTIONS


C3S

C2S

C3A,

C4AF

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FCT MODELING FOR BURNER DESIGN

Water Bead


Acid/Alkali Mathematical


Physical Modelling

©

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16

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1650 TPD kiln firing coal/coke/gas can only
fire 30% coke before high CO and build up


Model shows

The burner provides incorrect
momentum to entrain the
combustion air.

The burner position and angle

in

the

kiln cause flame impingement.

The kiln is operated with too little
excess air.

Flame length is excessive at all
reasonable excess air levels.

EXAMPLE


PROBLEM

©

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17

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Model used to design new burner


New burner

Shorter
flame length at all excess air
levels, can operate at 2% oxygen

Performs
best when aligned with the
kiln axis

Has
correct burner momentum for
short flame.

EXAMPLE
-

SOLUTION

©

Schenck Process 2012

18

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The benefits to the plant are

Petcoke

usage has now increased to 100%
-

previously 30%

Clinker quality has improved dramatically, with 28 day strengths increasing by 10%

Almost no build up has been experienced in the kiln and riser

duct
, where previously
build up was restricting kiln performance even with 30%
petcoke

A fuel saving of about 45 kcal/kg

cli

was seen by the plant, partly attributable to a
change in the coal dosing system and partly to the new burner

EXAMPLE
-

BENEFITS


©

Schenck Process 2012

19

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FCT GYRO
-
THERM

BURNER

FOR GAS AND COAL


©

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20

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COSMA OUTPUT IN REAL TIME


On
-
Line X
-
Ray Diffraction
Analyzer

Measures mineral phases directly, like
alite
,
belite
,
gypsum de
-
hydration and free lime

Data
sent to process control
system for automatic
quality
control and process
optimization

Continuous mineral analysis in
Real Time


Control quality continuously


Increase limestone or
pozzolan

addition


Reduce free lime variability, lower fuel, reduce
NOx
, less grinding energy


Ensure clinker quality, especially when burning
alternatives

©

Schenck Process 2012

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©

Schenck Process 2012

21

1.
MATERIAL HANDLING

2.
COMBUSTION EFFICIENCY

3.
PRODUCT QUALITY CONTROL


SUMMARY

©

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©

Schenck Process 2012

22

THANK YOU VERY MUCH.