aberthaw - report mission july 2007 - v 25 07 07

8/18/2019 Aberthaw - Report Mission July 2007 - V 25 07 07

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From :Caroline JennyHenri Veyrenche

To : Alan RuxtonDai MorganChris Simms

Kenny HarrisonNorman CreightonFranc !ruggemanTom Freeman

ABERTHAWJuly 2007

CONTENTS

Summary .........................................................................................................................................................................2

1. Safety..............................................................................................................................................................................3

2. Operating cn!itin".................................................................................................................................................4

"#$ Ra% material &uality...............................................................................................................................................4

"#" Main !urner ..............................................................................................................................................................5

"#' Com(ustion..............................................................................................................................................................5

#. Ne$ analy"er c%%i""ining..................................................................................................................................6&. '( )an.............................................................................................................................................................................7

*. By+,a""..........................................................................................................................................................................8

)#$ *as (y+,ass.............................................................................................................................................................8

)#" Material (y+,ass to, o- C......................................................................................................................................9

-. Air 'nlea"....................................................................................................................................................................10

Anne/................................................................................................................................................................................12

Aberthaw – July 2007 – TCEA Report 1/12


2/12

Summary

Air Inleak!

That i the main problem o" the kiln# E""ort mut be "o$ue% on the re%u$tion o" theeinleak& epe$ially at the rier %u$t#

'iln (a$k)en% analyer!

The new analyer are properly runnin* an% *i+e reliable in"ormation#,ow internal trainin* i nee%e% "or operator to how them the interet o" u$h ameaurement an% to train them to operate the kiln with thi new tool#

Air $on%itione% houl% be intalle% in the analyer $abinet#

(etter tan%ar% *a houl% be ue% to $alibrate thi analyer#

Sin$e we $ame& the %ata tranmiion problem ha been ol+e%#

Combution!

The burner *eometry houl% be $he$ke% at ea$h no--le reno+ation# .e u**et animpro+ement o" the $amera intallation in or%er to ha+e a better +iew o" the "lame

I an!

The I an %oent operate on it $ur+e# It $on%ition houl% be $he$ke% at net toppa*e#

(y)pa!

There i no notable *a or material by)pa# .e a%+ie a re*ular $he$kin* at ea$h plah

bo#

Aberthaw ) 3iion July 2007 )2/12 17/04/2015


3/12

1. Safety

//0 are %ell use1#/roce1ure o- locout o- air (laster is %ell a,,lie1#

02en i- huge ,rogress ha2e (een o(ser2e13 there is a remaining ga, o- ,rogress as -ar asti1iness o- the ,lant is concerne1: many e&ui,ments %ere lea2ing a-ter the %ors -rom theiln sto,,age#

Se2eral 1oors o- the riser 1uct are not ,ro,erly close14 some o- them o,en %ith air (laster -lo%# Riss o- (urning %ith hot gases -lo% must (e consi1ere1#


ate" ene!


4/12

2. Operating cn!itin"

2.1 Ra$ %aterial uality

There is not a s,eci-ic ,re+homogenisation: 5imestone -rom South 6uarry3 slag an1 7ronare roughly ,remixe1 in the &uarry#/antsone3 /FA an1 /a,er Ash are a11e1 at the ra% mill#

5SF8$9'#. SR8 "#; AF8$#;)

The ra% meal is 2ery -ine#

The iln -ee1 (urna(ility is 2ery goo1 < excellent as sho%n on the -ollo%ing chart3summari=ing tests con1ucte1 recently :2007.174.2AberthawKiln feed

Refus à200µm

Refus à100µm

Refus à90µm

CaOlcuit

elta!C

"#$ A%$ 'ndiceK14(0

A)titude

*chantill+n

% % %

11/11/2006 0.2 2.6 3.8 1.61 2.5 98.8 2.4 3.3 107 Très Bon

02/12/2006 0.2 2.6 3 0.85 4.1 96.5 2.1 3.1 127 Très Bon

11/01/2007 0.2 2.2 3.4 3.24 -0.5 102.7 2.0 3.3 91 Bon

24/01/2007 0.2 3.4 4.8 0.75 7.6 92.0 2.2 3.2 86 Bon

11/02/2007 0.2 2.8 4 1.41 1.7 99.8 2.1 3.0 135 Très Bon

23/02/2007 0.2 2.4 3.2 0.91 2.3 98.8 1.9 3.0 162 Excellent

03/03/2007 0.4 3 4.6 0.76 3.0 98.0 2.1 2.9 157 Excellent

14/03/2007 0.69 1.8 99.5 1.7 2.7 217 Excellent

20/03/2007 0.2 2.5 3.7 1.05 2.7 98.7 2.4 3.0 140 Excellent

>e can clearly see that the K is getting (etter %ith a lo%er silica ratio#



5/12

These results can ex,lain ,rocess 1i--iculty 1uring the ,erio1 the MS %as high#

2.2 ain Burner

Visual -lame ins,ection is 1i--icult an1 the camera is ,artly (loce1 (y cliner 1e,osit# A (etter 2isi(ility %ill lea1 to a (etter checing o- the -lame as con-irmation o- themeasurement o- the settings#

The last measurements con1ucte1 (y the ,lant gi2e the -ollo%ing results

7s 8 #"? S% 8 9#9;;@%ith a11ition o- $99C -or axial air tem,erature to tae into account the real tem,eratureat the no==leBThe last calculation o- the (urner 1esign gi2es a (ias coe--icient o- $39? -or the Ra1ial Air#/re2iously @calculation o- ")


6/12

#. Ne$ analy"er c%%i""ining

The ,ro(e seems to ha2e3 u, to no%3 no ,ro(lem o- (uil1+u,#"3 C an1 S" signals are ali2e#During our 2isit3 the analysers 1ata trans-er nee1e1 a mo1i-ication to -ree=e the 2alue1uring the se&uential ,urge to gi2e a (etter rea1a(ility to the o,erators# Since that time3the ,ro(lem has (een -ixe1#N Value is %ell measure1 (ut the transmission to Control Room: the signal %as constant(et%een " ,urges# @,ro(lem has (een sol2e1 since %e control itBThe ne% analyser is %ell ,ositione1 an1 gi2es results that are coherent %ith our analysers#

The gas analyser ca(inet is not air con1itione1: (y a tem,erature o- $)C outsi1e3 it %as

alrea1y 2ery hot @')CB insi1e# That coul1 (e 1amaging -or the electronic com,onent o- the analyser -or higher external tem,eratures# At least 2entilation or (etter3 air con1itione1 shoul1 (e installe1#

The set o- stan1ar1 gases3 ase1 (y A!! -or their -irst cali(ration is not %ell a1a,te1 -or the current le2els o(ser2e1 at the iln (ac en1#

*enerally %e use to cali(rate %ith stan1ar1 gas at "


7/12

&. '( )an

>e measure1 the 7D Fan -lo%#

(ate Hur 4 O2 Te%p 5C)l$

N%#6 )l$ %#6 )l$ %#6"

9'


8/12

Then %e 1ra%3 on the same chart3 the same cur2es in the current o,erating con1itions@s,ee1 o- the -an3 tem,eratureB# These ne% cur2es are calculate1 (y the xls chart#

7t gi2es the -an cur2e in the current con1itions3 (lue#7- the -an runs correctly the ,oint measure1 shoul1 (e at the cross ,oint o- the (lue cur2es#

For the ,lant 7D Fan it is not the case: the o,erating ,oint is (elo% an1 seems to (e on acur2e -or ")r,m s,ee1 o- the -an (ut the control room 2alues gi2e 9r,m#- course3 this -irst measurement must (e cross+chece13 as the measuring ,oints %erenot ,er-ectly locate1 @the measuring ,oints shoul1 (e as close as ,ossi(le -rom the 7D -anan1 %e use1 existing holes locate1 a (it -ar -rom the -anB# Ho%e2er the result got issigni-icantly -ar -rom its theoretical ,osition#

That ,ro(a(ly means either that a -raction o- the -umes is internally recycle1 (y the -an%hich lea1s to a 1ra-t ca,acity re1uction or that the -an is e--ecti2ely running slo%ly#

At the next sto,,age air tightness o- the -an shoul1 (e checout an1 ne% ,oint o- measurement create1 Gust (e-ore an1 Gust a-ter the -an in or1er to 2ali1ate easily thee--iciency o- the -an#

*. By+,a""

*.1 a" 3y+pa""

0*60762007 0&60762007

:&* :&* 10H1* 102* 10&* 1000 101*

at. Enter. C2fr% C1 Ea"t

at. Enter. C2fr% C1 We"t

at. Enter. C#fr% C2

at. Enter. C&fr% C#

aterial ut f C& t te iln

aterial .?I .". ?.'#) III ". 9C $)C

a" .) .$ ?.9#) II? $'# I;'C I;'C

0ach time the material %as hotter than the gas: no hot gases go trough the material 1uct#>e conclu1e that there is no signi-icant gas (y+,ass#



9/12

*.2 aterial 3y+pa"" tp f C&

Sam,ling ,ointsLs ,osition

)'cm ,1 .)cm ,2 .$cm ,# ))cm ,& .cm

Ma,,ing starts .9 cm -rom the e1ge then e2ery "9cm#

9#' 9;#" $9#) I'#$

$'#. 9I#; $9#I I;9#$

$I 9#' 9I#$ 9)#I

$#I 9?#I 9; 9I#.

;iln $)#" 9?#; 9?#I 9I#$)#) $"#' 9.#? 9)#)

$I#I $I#. 9? 9;#$

$I#? $I#' $.#) $9#

$#' $# $.#$ $"#)

,* $$#) $. $9#; 9)#. I; I;?#" I'#? I;)#' 99#.

$"#. $' $$# 9;

,1 ,2 ,# ,&

This ma,,ing re2eals no C" material (y+,ass 1irectly toC.4


,* @?9cm to the e1geB

Spla" 3/$$cm a(o2e the,oints /$ to /.


10/12

-. Air 'nlea"

>e ha2e 1one a ma,,ing o- oxygen through the to%er to 1etermine the entry o- -alse air#

For each le2el %e calculate1 the ,ercentage o- air in leas com,are1 %ith the total to%erexit gas -lo%# >e use1 the a2erage o- the !e-ore 7D Fan -lo% %e measure1#

For the Kiln !ac+0n13 %e use1 the 1ata gi2en the ne% analyser#

0*607607

10#* 10#*

a" ut f C& ;iln Bac+En!

Te%p


11/12

0#607607 0*607607

1*#0 11 :#*

Befre '()an Befre '()an a" ut f C2

Te%p e coul1nLtmeasure the " le2el at the C$ cyclones#

0#607607 0*607607

17#0 1*#0 11

After '()anBefre'()an

;ilnBacEn!

After '()anBefre'()an

;ilnBacEn!

Te%p


12/12

Anne/

!y+,ass ma,,ing sheet7D Fan ,itot sheet7D Fan cur2es


aberthaw - report mission july 2007 - v 25 07 07

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