more than 50 years of expertise. reducing emissions by monitoring the gas composition at the kiln...
TRANSCRIPT
More than 50 years of expertise
Reducing emissions by monitoring the gas composition at the kiln inlet
= Saving Money
INTERNATIONAL NETWORK
ITECA SOCADEI SAS445 Rue Denis PapinEuropôle de l’ArboisCS 3047813592 Aix en Provence Cedex 3 FRANCE + 33 (0)4 42 97 77 00 + 33 (0)4 42 97 77 33 [email protected] www.iteca.fr
Europe - North, Central & South America - Asia - Middle East - Africa
Aix en Provence
Paris
ITECA SOCADEI - TODAY
CEMENT- Analysers for on line process control
- Centralised laboratories
- Production equipments (kiln seals…)
ColourOn line analysis
INSTRUMENTATIONDedicated to the solid bulk industry
(food, calcium carbonate, sugar, cement…)
3 DIVISIONS
Process optimization ON LINE CONTROLS
Quality control CENTRALIZED LABORATORIES
SUSTAINABILITY ENERGY SAVING PRODUCTION EQUIPMENTS
CEMENT DIVISION PRODUCTS RANGE
Quality
Sustainability
Process optimizatio
n
The most important gases to be monitored for kiln control are:
Oxygen : too low fuel may not be burning correctly wasting energy. too high possible to increase fuel input and raw material input and
therefore possible to increase production
CO : This gas is created in the flame, when the flame is not burning correctly
Dangerous, toxic loss of energy (incomplete combustion)
NOx : This gas is also created in the flame. Flame Surface T° NOx creation . NOx = indicator of the temperature of the clinkering zone in the kiln = indicator of the end quality of the clinker that is manufactured. All these gases can be measured using our sampling system, and the measurement of these gases already provides a great deal of valuable information on the operation of the kiln.
Kiln Inlet Gas Sampling & Analysis: WHY?
O2CO
NOx
Cooler
Precalciner
Kiln
Gas sampling
Output
Analyser
Our experience: all cement plants are facing the same
trouble Clogging of the sampling
probe in the Fume Box
Different sampling locations
Gas Sampling and Analysis
Requirements for an efficient kiln back end gas sampling
Low Maintenance - High availability
Withstand high dust concentration without blockage
Withstand high temperatures
Quick response time : high gas flow rate
Sturdy construction to withstand build-up fall
Gas Sampling and Analysis
Traditional technology : basic principle
Gas Sampling and Analysis
Gas is sampled and then filtered through a ceramic/metal/glass filter
The gas sampling is stopped and the filter and the probe are cleaned using compressed air
Filter
Traditional technology : limitations
Clogging problems (probe and filter): high maintenance
Sample contamination due to purge air : low availability
High maintenance on the membrane pump
Low gas flow rate (max 120 l/h) : slow response time
Bending due to blocks falling from the tower
Gas Sampling and Analysis
Gas Sampling and Analysis
Case study 1– ReliabilityContinuous operation for 20 consecutive days
4300 TPD Line with 63% alternative fuels
Gas Sampling and Analysis
O2 Drop
CO Rise
O2 no change
Tower
Iteca
Gas Sampling and Analysis
Tower
O2 no change
Iteca
O2 Drop
CO Rise
ITECA’s system: principleWet sampling
Closed circuit double cooling
system
Analysis CellCO, O2, NOx, CH4
Gas conditioning
Dryer
Gas analysis
Gas Sampling and Analysis
The sampled gas passes through the water spray, dust is trapped outside the probe before entering the line
Water spray 3 bars-30 l/h
Cooled jacket
Cooled probe
Cooled jacket
GAS
ITECA’s Wet sampling probe
No ceramic filter to clean or to replace
Gas Sampling and Analysis
Efficient probe cleaning system
Every 10-20 min (adjustable), high pressure
water (8 bars) is sent through the sampling line
to clean the probe
High pressure
water pulses
(4 to 5 l)
Efficient cleaning
+
No sample contamination from air purge
Cooled jacket
Cooled probe
Cooled jacket
Gas Sampling and Analysis
Sturdy sampling probeResistance to accidental fall of blocks
Sampling end
Connections to suction gas pump and
water Jacket Ø 168 mm
Sampling line Ø 34 mm
Weight (without water): 150 to 200 kg (depends on probe’s length)
Double cooling system: jacket + sampling line
Gas Sampling and Analysis
The probe is installed so that its tip is at least 500 mm beyond the inlet seal
Sampling Probe installationAvoid inlet seal false air influence
Gas Sampling and Analysis
Sampling Probe
Gas Sampling and Analysis
3D design to check the feasibility and find optimum probe location
Sampling Probe Automatic Extraction
High torque extraction
Secured system for the extraction of the probe in case of any problem on the power supply or the cooling circuit
Prevention system on a regular basis used to remove the coating
around the probe
Gas Sampling and Analysis
ITECA’s Sampling Probe Automatic ExtractionSafe and Reliable
Gas Sampling and Analysis
Secured system for the extraction of the probe in case of any problem on the power supply or the cooling circuit
Prevention system on a regular basis used to remove the coating around the probe
HIG
H T
OR
QU
E EX
TRAC
TIO
N
Gas Sampling and Analysis
ITECA’s Sampling Probe Automatic ExtractionSafe and Reliable
Oversized capacity closed cooling circuit (water T° < 65°C)
+ High cooling water flow rate : 2 500 l/h
Sampling probe really protected
Close loop cooling circuit
Gas Sampling and Analysis
No hot fluidNo high pressure
Persons really protected
Electrical control
Gas Analysis Gas Conditioning
Gas Conditioning and Analysis
Gas Sampling and Analysis
Gas Sampling and Analysis
Water / gas separation
circuit
Liquid ring pump
Gas suction : 1800 litres/hour
Water / gas separator : most of the water is
removed here
Cyclone separator :any remaining wateras liquid is removed
here
Water + Gas
Water
Gas
The gas is then dried inthe gas dryer by reducing
its temperature to 3°C
Dust filter
Gas flow regulators - One for each analyser (70 l/h /analyser)
+ evacuation
Command and display
Paramagnetic oxygen analyser
Infrared analyser : CO, NO, CO2
Gas dryer
Gas Analysis
Gas Sampling and Analysis
Working temperature : max 1400 °C
Working dust concentration : up to 2 kg/m3
Gas sampling flow rate : 1800 litres/hour
Response time (sampling and conditioning): 5
to 10 s
No sample contamination from air purge
No wear parts on the liquid ring pump
Heavy duty probe able to withstand build-up fall
Performances - Advantages
Gas Sampling and Analysis
Case study 2 – cement plant
Gas Sampling and Analysis
Pre-calciner kiln
Kiln capacity 4200 tpd
Partial fuel substitution with pet coke
The Iteca system was installed in parallel
with an existing traditional probe
Tests were conducted over an 8 month
period
Case study – cement plant
Gas Sampling and Analysis
Traditional
OXYGEN READING
ITECA
Air purges
Case study – cement plant
Gas Sampling and Analysis
NOx
ITECA GAS READING
CO
O2
Case study – cement plant
Gas Sampling and Analysis
ITECA
CO READING
TRADITIONAL
Case study – cement plant
Gas Sampling and Analysis
The reliability factor achieved was greater than 95% over an 8 month period
The gas sampling provided accurate and reliable data for O2, CO and NOx
The plant decided to purchase 2 more gas sampling systems from ITECA
Reduction of emissions, reducing consumption while increasing production:
BENEFITS ON BOTH SUSTAINABILITY and PROFITS
CONCLUSION