pulverized coal injection - seaisiseaisi.org/seaisi2017/file/file/presentation-file/12a-1.pdf ·...

© Paul Wurth IHI 2017 1 SEAISI 2017 – Paul Wurth's PCI Technology

Pulverized Coal Injection

-

Paul Wurth’s Technology for New Installations and Plant Upgrades

P. Mahowald, Head of Injection Technologies, Paul Wurth S.A. - Luxembourg

E. Censi, Senior Project Engineer, Paul Wurth S.A. - Luxembourg

D. Michels, Technical Manager, Paul Wurth IHI Co., Ltd. - Japan

Presenter: D. Michels, Paul Wurth IHI Co., Ltd. - Japan

© Paul Wurth IHI 2017 2 SEAISI 2017 – Paul Wurth's PCI Technology

• Basics of pneumatic conveying Dilute vs. dense phase conveying

Cost comparison

• Distribution types Static vs dynamic distribution

Gritzko flow rate control valve

• Plant upgrades ROI case study for upgrade from static to dynamic distribution

• Upgrade of dilute phase PCI plants General

PWIHI R&D program

Results

• Recent references

Contents

© Paul Wurth IHI 2017 3

Basics of Pneumatic Conveying

SEAISI 2017 – Paul Wurth's PCI Technology

Gas retention Fluidization


Dilute vs. Dense Phase Conveying


Dilute phase

- High speed (pipe wear )

- More pneumatic power per

coal unit mass

- More N2 required

- Lower combustion eff.

+ Low operating pressure

Dense phase

+ Low speed (pipe wear )

+ Less pneumatic power per

coal unit mass

+ Less N2 required

+ Higher combustion eff.

- Higher operating pressure


Cost Comparison


• Reduced operational cost for dense phase conveying Less pneumatic power per coal unit mass

Less N2 required

• Lower lifecycle costs despite higher initial capital cost

Time

Total costs

100%

7 months in recent project


Static Distribution

• Same equivalent pipeline length (same flow resistance) of all injection lines

• Improved distribution accuracy by installing a calibrated nozzle (sub-critical expansion tuyere) in each Injection Line

• Equal distribution onto all the Injection Lines by means of a coal flow rate measurement device, a coal flow rate control valve and a closed loop control installed in each Injection Line

• Best distribution accuracy through individual flow rate control

Dynamic Distribution

Static vs Dynamic Distribution



Static vs Dynamic Distribution


With individual flow rate control

Individual flow rate control switched off

BF 6 – Cockerill Sambre Seraing - Belgium


Dynamic Distribution


• Closed-loop-control with GRITZKO® flow rate control valve and flow rate measurement device installed in main conveying line and in each injection line.

• Excellent accuracy

Global flow ± 2 % *

Distribution accuracy ± 2.5 % *

• High availability

• Proven and reliable technology

* On 5 minute average


Upgrade ArcelorMittal Gent - Results

ArcelorMittal Gent, BF B – Belgium: Equal distribution with average deviation below 1.5% on 5 minutes average

0.0 %

0.5 %

1.0 %

1.5 %

2.0 %

2.5 %

3.0 %

3.5 %

4.0 %

4.5 %

5.0 %

1500

1550

1600

1650

1700

1750

1800

1850

1900

1950

2000

0 1000 2000 3000 4000 5000 6000 7000

Time (s)

Ave

rage

De

viat

ion

(%

)

Ind

ivid

ual

Co

al F

low

Rat

e (

kg/h

)

AM Gent BFBEqual Distribution of the Global Flow onto the Injection Lines

Average Deviation



GRITZKO® Flow Rate Control Valve


• High resistance to abrasive material

• Used for global flow control on conveying line or individual flow control in injection lines

• Usually linked to a Cabloc device


Plant Upgrades


• Increase of grinding and drying capacities

• Increase of storage capacities

• Intermediate transports

• Increase of conveying flow rates

• Increase of injection rates

• Increase of accuracy of global injection flow rate control

• Upgrade to dynamic distribution: increase of accuracy of the equal distribution of global injection flow onto the injection lines For existing dense phase plants

For existing dilute phase plants

© Paul Wurth IHI 2017

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Cu

mu

late

d s

avin

gs

[Mio

. €]

Months of plant operation after upgrade

ROI of a Plant Upgrade from Static to Dynamic Distribution - Case study: Nom. BF prod. = 4 500 [tHM/d] - Price Delta between Coke and Coal* = 60 [€/t] - Coal-Coke-Replacement ratio = 0,85 *including OPEX for GAD & PCI Savings at an injection rate increased by 10 kg/tHM PCI rate

Savings at an injection rate increased by 8 kg/tHM PCI rateSavings at an injection rate increased by 6 kg/tHM PCI rate

Savings at an injection rate increased by 4 kg/tHM PCI rate

Savings at an injection rate increased by 2 kg/tHM PCI rate

CAPEX range for Upgrade from static to dynamic

distribution

12

ROI for Upgrade to dynamic distribution



Upgrade of Dilute Phase PCI Plant


• PW has proven track record for new installations & plant upgrades in dense phase More than 100 references

More than 1.000 GRITZKO® valves installed

• Next step: adopt GRITZKO® valves to existing dilute phase plants Upgrade of existing dilute flow PCI plants from static distribution to

dynamic distribution

For reaching significantly better equal distribution accuracy between individual injection lines

• PWIHI undertook a significant R&D program in this regard Test campaign conducted by operating a physical test plant with

two GRITZKO® valves in dilute phase environment

CFD analysis


PWIHI Test Installation


• Located at IHI R&D centre, Yokohama, Japan

• Main characteristics:

Two full size GRITZKO® valves installed

Testing in actual operating conditions

Flow rate of up to 1.000 kg/h of coal

Dilute load level from 10 to 20 kg coal/N2


• Main results from test plant:

Excellent controllability of GRITZKO® valves in dilute phase

Clear relationship established between differential pressure and opening position as well as flow rate

15

PWIHI Test Installation


Dif

fere

nti

al p

ress

ure

bet

wee

n u

pst

ream

an

d d

ow

nst

ream

of

GR

ITZK

O®

val

ve (k

Pa)

GRITZKO® valve opening position (%)


CFD Analysis


• Main results from CFD analysis

Good correlation with physical tests

Definition of necessary wear protection upstream and downstream of GRITZKO® valves

Dense phase

Dilute phase


References for Individual Flow Control


Dense phase dynamic distribution ArcelorMittal Gent (Belgium)

BF ‘A’ & BF ‘B’

ArcelorMittal Liège (Belgium)

BF ‘B’ & BF ‘6’

ArcelorMittal Fos-sur-Mer (France)

BF ‘1’ & BF ‘2’

ArcelorMittal Gijón (Spain)


Trinecke (Czech Republic)

BF ‘4’ & BF ‘6’

DMKD (Ukraine)

BF ‘1M’, BF ‘8’, BF ‘9’ & BF ‘12’

Kardemir (Turkey)

BF ‘5’

NSSMC Kashima (Japan)

BF ‘1’ & BF ‘3’

NSSMC Wakayama (Japan)

BF ‘1’ & BF ‘2’

Dense phase distribution hopper with individual flow control ThyssenKrupp (Germany)

BF ‘1’, BF ‘2’, BF ‘4’ & BF ‘9’

ROGESA (Germany)

BF ‘3’, BF ‘4’ & BF ‘5’

Salzgitter (Germany)


ArcelorMittal Dunkirk (France)

BF ‘2’, BF ‘3’ & BF ‘4’

Hyundai Steel (Korea)

BF ‘1’, BF ‘2’ & BF ‘3’

Dilute phase upgrade from static to dynamic distribution NSSMC Kashima (Japan)

BF ‘1’& BF ‘3’

NSSMC Nagoya (Japan)

BF ‘1’ & BF ‘3’ (upcoming)


Paul Wurth IHI Co., Ltd. Toyosu Center Building, 3-3, Toyosu 3-chome, Koto-ku,

Tokyo 135-6009 Japan Phone: +81-3-6630-4786

[email protected]

Daniel Michels Phone: +81-3-6630-4786 Fax: +81-3-3536-4014

Mobile: +81-90-2455-2932 e-mail: [email protected]

18 SEAISI 2017 – Paul Wurth's PCI Technology

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pulverized coal injection - seaisiseaisi.org/seaisi2017/file/file/presentation-file/12a-1.pdf ·...

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