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“Optimized Integrated Solution…”
www.bnf.com9th TCMA Technical Workshop
Process Optimization & Plant
Safety
Engineering Solution for Cement Industry
By : Teoh Wen Han
Venue : Forest Hill Resort,
Saraburi, Thailand
Date : 12 September 2006
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7. Questions & Answers
Presentation Contents
1. Gas & Dust Analysis Application in Cement Industry Processes
2. Gas Analysis at Pre-heater / Pre-calcinator
3. Gas Analysis at Kiln Inlet
4. Gas Analysis & Level Measurement at Coal Mill / Silo
5. Gas & Dust Analysis before Electrostatic Precipitator
6. Gas & Dust Analysis before CEMS for Cement Plant
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Gas/Dust Analysis Application in Cement Industry
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Reasons of Gas Analysis in Cement Process
Plant safety• Protection of the electrostatic precipitator• Protection of the coal grinding plant• Measuring Points : Before E.P., Coal grinding mill
Saving of energy
• By optimized burning process control
• Measuring Points : Pre-calcinator, Kiln Inlet
Constant high production quality
• Constant kiln operation control
• Measuring Points : Pre-heater, Pre-calcinator, Kiln Inlet
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Reduced emission / Environmental protection
• Emission control by monitoring the burning process
• Emission monitoring and data acquisition
Reasons of Gas Analysis in Cement Process
Reduction of the operating costs
• High availability of the plant equipment
• Early recognition of critical situations
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Measurement Task
• CO, O2 Combustion optimization of secondary furnace
• CO2 Degree of calcinationCaCO3 (lime) CaO + CO2
Gas Analysis at Preheater / Precalcinator
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Gas Analysis at Preheater / Precalcinator
Process Condition
≤ 850 °C (1562 °F)
≤ 200 g/m³ dust
Components: CO, O2 and CO2
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Sampling Probe System
Gas Analysis at Preheater / Precalcinator
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Sampling ProbeSampling Conditioning System
with Analyzer Located @ Pre-heater Tower
Gas Analysis at Preheater / Precalcinator
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• CO, O2 Combustion optimization
• SO2, NO Quality of cement
• CO2 Degree of calcinationCaCO3 => CaO + CO2
Gas Analysis at Kiln Inlet
Measurement Task
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Process Condition
≤ 1400 °C (2552 °F)
≤ 200 - 2000 g/m³ Dust
Components: CO, O2, NO, CO2, SO2
Gas Analysis at Kiln Inlet
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Gas Sampling Probe KIP 1000R
Gas Analysis at Kiln Inlet
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1. Gas Sampling Probe System
2. Cooling System & Heat Exchanger System
3. Gas Conditioning and Analyzer System
4. Integrated Hybrid Control System
KIP 1000R System Solution consist of
Gas Analysis at Kiln Inlet
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Gas Analysis at Kiln Inlet
ANIMATION OF KIP 1000R
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Measurement Task 1 : Coal bunker is filled with ambient air
Measurement Task 2 :Coal bunker is filled withInert gas (Example : N2)
• CO Measurement – Detection of smouldering
• O2 Measurement – N2 leak detection
Gas Analysis at Coal Mill / Silo
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O2
O2
COGas
Cooler
Gas
Cooler
Sample SwitchingSystem
Switching3-way
solenoid
PurgingSystem
Coal Mill Inlet
PurgingSystem
Mill Filter Outlet
PurgingSystem
Coal Silo
PurgingSystem
Mill Filter Outlet
PurgingSystem
Coal Silo
Configuration of Sample Switching System
Gas Analysis at Coal Mill / Silo
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Photos showing an Analyzer Panel with Sample Switching System
Gas Analysis at Coal Mill / Silo
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Coal mill with analyzer cabinets onLevel 5 (Silo) and Level 6 (Filter)
Sampling on top of the coal silo
Gas Analysis at Coal Mill / Silo
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Measurement Methods / Installation
1. Vertical from top, rigid shaft.
2. Vertical from top flexible shaft or cable boom.
3. Horizontal,lateral of bin
4. Horizontal, lateral of bin with inclined flange
5. Inclined
2 1
3
4
5
Level Measurement at Coal Mill / Silo
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Process Condition
≤600 °C (1112 °F)
≤ 12 g/m³ dust (Before EP)
≤ 50 mg/m³ dust (After EP)
Components: CO, O2
Gas & Dust Analysis before Electrostatic Filter
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Dust Monitors
Stack gas in front of E-Filter
Dust < 12 g/m³
Stack gas after E-Filter
Dust < 50 mg/m³
Dust Monitors
Add. quick CO measurementto avoid explosions
Gas & Dust Analysis before Electrostatic Filter
OVERVIEW
Gas Analyzer
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Dust
Measurement
Dustmg/m3
Triboflow
Extinction Ringelmann
Bacharach
Scatter lightTransmission
TransmissionOpacity
Beta Ray Gravimetric comparison
Flicker lightScintillation
Methods in Determination of Dust Concentration
Gas & Dust Analysis before Electrostatic Filter
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Measuring principle Type Procedure
Gravimetric measurement extractive discontinuous
Beta Ray extractive discontinuous
Scatter light wet gas extractive discontinuous
Scatter light dry gas in - situ continuous
Triboflow in - situ continuous
Flickerlight in - situ continuous
Transmission in - situ continuous
Gas & Dust Analysis before Electrostatic Filter
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reflection
diffraction
absorption
Ligh
t
refraction
Different effects occurring when illuminating a particle
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Dust Analysis
Gas & Dust Analysis before Electrostatic Filter
1. In-situ Cross Stack System• Typically used before EP ( High Dust )
• Dual path measurement
• Wide measuring range ( 0 – 12 g/m3 )
2. In-situ Probe Type
• Typically installed after EP ( Low Dust )
• Laser scattered light measurement
• Sensitive for low dust measurement ( 0 – 200 mg/m3)
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Gas & Dust Analysis before Electrostatic Filter
Gas Analysis
2. In-Situ System
• Permeation Probe for fast and accurate measurement
• 2 sec response time
1. Extractive System
• The sampling line must be as short as possible
• Design is similar to Coal Mill Application
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Purpose Of Measuring
Gas & Dust Analysis before Electrostatic Filter
• To monitor the efficiency of Electrostatic Precipitator (or broken bag filter)
• For plant safety ( high CO concentration can cause explsion on the EP )
• For emission monitoring
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Process Condition
200 °C (Main Stack)
≤ 400 mg/m³ (Dust)
~ 30 Vol% (Moisture Content)
Components: CO, CO2 , O2 , SO2 , NOX ,THC, HCl
System MUST Comply to Local Environmental Regulation
Gas & Dust CEMS for Cement Plant
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Extractive System- Hot Wet Measurement (HW)
- Cold Dry Measurement (CD)
- Permeation Drying Measurement (PD)
- Gas Dilution Measurement Technology
- Depending on gas component, utilities availability, etc
Measurement Techniques for Gas
In-Situ System
- Cross Stack Type
- Probe Type
Gas & Dust CEMS for Cement Plant
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• Require Sampling System, more component
• CD and PD need Sampling Conditioning System
• Possible Time Sharing for multi stacks
• Easy Auto or Manual “System” Calibration by Reference Gas
• Dual Measurement Range is possible
• Analyzer should be placed as close as possible to the sampling point
Features of Extractive Gas CEMS System
Gas & Dust CEMS for Cement Plant
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• No Sampling System
• Fast Response (not dependent of SCS tube
length)
• No Time Sharing for Multi Stacks
• Multi gas in one analyzer is possible
• “Wet” Measurement need H2O measurement for dry value reporting
• Difficult to conduct “system” calibration by gas cylinder
• Dual Measurement Range may not be possible
• Gas Measurement can be influenced by stack moisture
Features of In-situ Gas CEMS System
Gas & Dust CEMS for Cement Plant
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1. Cross Stack Version•• For use in medium to high dust measurementsFor use in medium to high dust measurements
•• Capable of catering large ducts, up to 15 m dia. Capable of catering large ducts, up to 15 m dia.
•• Able to use in high temperature (up to 600 Able to use in high temperature (up to 600 OOC) C)
exhaust points such as Cooler Stackexhaust points such as Cooler Stack
2. Probe Version•• For use in low to medium dust measurementsFor use in low to medium dust measurements
•• OneOne--side installationside installation
•• Typically used to measure after EP or bag filterTypically used to measure after EP or bag filter
Measurement Techniques for Dust
In-situ Measurement
Gas & Dust CEMS for Cement Plant
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3. Heated Bypass Version
•• For use in measuring of dust in wet gasFor use in measuring of dust in wet gas
•• Flue gas maximum temperature 200 Flue gas maximum temperature 200 OOCC
•• Measuring cell & thermoMeasuring cell & thermo--cyclone in one cyclone in one compact designcompact design
•• PTFE probe to withstand corrosionPTFE probe to withstand corrosion
Gas & Dust CEMS for Cement Plant
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Thank You For Your Attention…
Questions…?