schenck process americas s.a.s / fct combustion pty

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HeavyLightMiningPowerTransport Automation

FICEM APCAC COSTA RICA 2012

Schenck Process Americas S.A.S / FCT Combustion Pty

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1Schenck Process Americas S.A.S

Presentation

2FCT Combustion Pty Ltd

Presentation

CONTENTS

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Efficient and Optimum Cement Production with Alternative Fuels

ByBy

Sanjiv Dhanjal (FCT Combustion, USA) Sanjiv Dhanjal (FCT Combustion, USA) and and

Fernando Garcia (Schenck Process Americas S.A.S, Colombia)Fernando Garcia (Schenck Process Americas S.A.S, Colombia)

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Your partner in cement IndustryProducts: Belt weigher Weighfeeder Loss in weigh feeder

MECHATRON FlowmeterMULTISTREAM Bin weighing Mass flow feeders

MULTICOR Screens Truck and train

scales Loading automation Alternative fuels.

Cement-mill

Cement

Separator

Bucket elevator

Bucketelevator

Returngrits

Homogeni-zation

Alternative:

Flow gates

Separator

Raw mill

Lime-stone

Clay Sand

Return grits

Cement Cement

Blaine valueMeasurement

Clinker Gypsum Additive

Cooler

Belt weigher to beinstalled in apronconveyor

MULTICOR-K - Feedingof pulverized coal(10 bar pressure proof)

Store

Kiln

SCHENCK Fuel MasterFeeding of Alternative Fuels

MECHATRONFE2SO4

Limestone SandClay

Reclaimer wheel

Limestonecrusher

ClaySand

Apron feeder

Crusher reliefscreen

SCHENCK Fuel MasterFeeding of Alternative Fuels

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The goal:

Reduce the operation costs in cement kilns by substituting of: More expensive primary fuels (Coal, Oil, Gas) for alternative low cost fuel.

– Clinker quality

– Production capacity

– stability of kiln

– and atmosferic emisions.

... Giving the less impact on:

Feeding systems FUEL-Mastersolutions for alternative fuels

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Design requirements for fuel systems:

They must feed a wide range of materials.

Hi accuracy and high feeding constancy.

High reliability and high availability.

Capacity of manage very big sizes of material.

Easy integration on existing installations.

Easy maintenance

Cheap return cost


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3 golden rulesfor design of alternative fuels plants:

1. Specifying robust equipment despite low density! Ensure high availability of systems.

2. Avoid bottleneck - Alternative fuels tries to create bridges. Avoid dead times for plugging.

3. Design a wide range of densities and flow properties.

Makes sure high flexibility using several materials.


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60502400

60006000

1500

1800

±0 = 314,000

6900

8500

20000 30000

50000

+ 0,450

+ 12,100

- 4,300

Reception Storing and transport Weighing and feeding


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FCT TURBU-JETFOR REGULAR AND ALTERNATIVE FUEL

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GaseousNozzle design is based on flow and pressure. Typically multiple holes

LiquidAtomization required for efficient combustionPressure atomization requires up to about 40 barg (600 psig)Air and steam also used for atomization, typically at about 6-8 barg (90-120 psig)

SolidGrind coal or coke to about 90% through 75 micron sieveFinal size depends on volatile fraction

Purpose is to facilitate fuel and air mixing

FUEL COMBUSTION

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ALTERNATIVE FUELS COME IN ALL SHAPES AND SIZES

Rice HusksWood Waste Paper and Plastics

Cherry StonesTire ShredsDiapers

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TESTING AND MODELING TO DETERMINE BEST WAY TO FIRE ALTERNATIVES

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FCT ALTERNATIVE FUEL NOZZLE

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KILN MINERALOGICAL REACTIONS

C3SC2SC3A,C4AF

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FCT MODELING FOR BURNER DESIGN

Water Bead Acid/Alkali Mathematical

Physical Modelling

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1650 TPD kiln firing coal/coke/gas can only fire 30% coke before high CO and build up

Model shows The burner provides incorrect momentum to entrain the combustion air.The burner position and angle in the kiln cause flame impingement.The kiln is operated with too little excess air.Flame length is excessive at all reasonable excess air levels.

EXAMPLE – PROBLEM

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Model used to design new burner

New burnerShorter flame length at all excess air

levels, can operate at 2% oxygenPerforms best when aligned with the kiln

axis Has correct burner momentum for short

flame.

EXAMPLE - SOLUTION

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The benefits to the plant are

Petcoke usage has now increased to 100% - previously 30%

Clinker quality has improved dramatically, with 28 day strengths increasing by 10%

Almost no build up has been experienced in the kiln and riser duct, where previously build up was restricting kiln performance even with 30% petcoke

A fuel saving of about 45 kcal/kg cli was seen by the plant, partly attributable to a change in the coal dosing system and partly to the new burner

EXAMPLE - BENEFITS

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COSMA OUTPUT IN REAL TIME

On-Line X-Ray Diffraction Analyzer

Measures mineral phases directly, like alite, belite, gypsum de-hydration and free lime

Data sent to process control system for automatic quality control and process optimization

Continuous mineral analysis in Real TimeReal Time

Control quality continuously

Increase limestone or pozzolan addition

Reduce free lime variability, lower fuel, reduce NOx, less grinding energy

Ensure clinker quality, especially when burning alternatives

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1. MATERIAL HANDLING2. COMBUSTION EFFICIENCY3. PRODUCT QUALITY CONTROL

SUMMARY

schenck process americas s.a.s / fct combustion pty

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