bereichskennung oder produktname process instrumentation and analytics januar, 2003 folie 1 a&d...

Bereichskennung

oder Produktname

Process Instrumentation and Analytics

Januar, 2003 Folie 1 A&D PI2 SE1

Siemens Process Analytics in the Cement Industry

Process Analytics

Solutions for the Cement IndustryApplications

FLK sampling system

Kiln inlet

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process Analytics

Applications of gas analysis systems in Cement PlantsApplications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process Analytics

Gas analyzer equipment in cement works must be able to withstand a very tough environment:

high gas temperature up to 1400 C

high dust concentration up to 2000 g/m3

high content of Alkalis, Sulfates and Chlorides

in addition, high level of mechanical stress and strain

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname



Process Analytics


Conventional gas sampling systems with water cooling have a number of serious weak points:

they block up easily because of the condensation thatforms due to the low operating temperature

lime deposits and corrosion with water as coolant

caking of material on the probe causes excessivemechanical stress

High cost for maintenance and low reliability

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process Analytics

The problems with the gas analysis in cement rotary kilns can be minimized or eliminated by using our patented gas sampling system

The Problem and our Solution

Formation of condensation

The operating temperature of 200 C at which our probe operates is above the dew point of the flue-gas and the acid.

Lime deposits and corrosion with water as coolant

Using a special synthetic liquid as coolant prevents lime deposits and corrosion

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process Analytics

Caking of material on the probe

Minor deposits are removed during regular automatic retraction and cleaning with compressed air.

High maintenance costs

Thanks to the high operating temperature and the effective method of cleaning our system can achieve periods of maintenance free operation up to three months

The Problem and our Solution

The problems with the gas analysis in cement rotary kilns can be minimized or eliminated by using our patented gas sampling systemApplications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process AnalyticsFLK Gas Sampling System

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process AnalyticsGas Sampling probe

for gas temperatures up to 1400 C

gas sample temperature up to 200 C lateral intake chamber to reduce entry of dust

self-cleaning of dust deposits during retraction and insertion

variable probe length to meet the customer requirements

high mechanical stability due to oval design

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process AnalyticsAutomatic Retraction unit

in case of faults the probe is retracted automatically from the kiln

redundant motorized retraction due to electrical and pneumatic motor

heavy duty and maintenance free mechanical design

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process AnalyticsDedusting Filter

electrically heated operation

operating temperature controlledby thermostat

maintenance free sinter metal filter

preheating of compressed air

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process AnalyticsPurge unit

automatical cleaning of gas paths

adjustable cleaning cycles

minimum pressure recognition

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process AnalyticsHeat exchanger

synthetic coolant high boiling point environmentally friendly

closed coolant circulation, pressure free operation

monitoring of temperature, flow and level

operating temperature adjustabel (130C – 220 C)

fast and easy installation and commissioning

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process AnalyticsHeat exchanger

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process AnalyticsControl- and monitoring unit

Compact cabinet with SIMATIC S7-300 or Allen Bradley SLC500 central power distribution

Function controlling of purge cycles

and gas sampling monitoring of temperature, flow and level automatical probe retraction in case of faults

easy to change parameter settings without programming expertise

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process AnalyticsGasflow and cooling circuit

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




Process AnalyticsGas treatment and Analysis

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname



Process Analytics


Up to 3 IR absorbable gas components plus oxygen

Easy-to-use menu driven operation

AUTOCAL with ambient air

Up to 8 gas components in one analyser cabinet with theMulti-Component gas analyser ULTRAMAT23

Gas treatment and Analysis Process Analytics

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname



Process Analytics


Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname




FLK Gas sampling system Process Analytics

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname



Process Analytics


FLK Gas sampling system

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname



Process Analytics



Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname



Process Analytics


FLK Gas sampling system / Benefits

Synthetic heat transfer liquid instead of water

Gas sample temperature up to 200 C no condensation-build up in the sampling probe

no lime deposits and corrosion

no freeze over of the coolant

high availability and less maintenance compared with water cooled

systems Short commissioning time

the system comprise just 6 components

components ready to connect

typical commissiong time: 3 to 5 days

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname



Economic performance analysis of typical Customer benefits

Optimized burning process

1% excess of Oxygen means: 10 kcal of extra energy consumption per kilo of clinker

In the case of a kiln with a capacity of 3000 tons/dayoperating 300 days a year, this means:

9.000.000.000 kcal of extra energy consumption perannum

or

1.097.560 kg of extra coal consumption assuming an energy content of 8200 kcal per kilo of coal

Process Analytics


Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname



Process Analytics




With a coal price of $ 45 per ton this means:

1.097,560 tons of extra coal x $ 45 = $ 49.365 higher energy costs

This saving means that the payback period on the investment in FLK GAS is less than 2 years

And remember too that this does not even take into account the savings that can be made on maintenance compared with water-cooled systems

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

Bereichskennung

oder Produktname



Process Analytics




0102030405060708090

100

0 3 6 9 12 15 18 21 24

Months

USD

Investment Saving

Applications

Kiln inlet

FLK sampling system

Gas flow

Gas conditioning

Installation

Benefits

ROI

bereichskennung oder produktname process instrumentation and analytics januar, 2003 folie 1 a&d...

Documents

analytics januar

high gas temperature

cement works

cement rotary kilns

high operating temperature

high maintenance costs

high content of alkalis

c high dust concentration