tecnicelpa lime kiln what are the newest projects using?
TRANSCRIPT
TECNICELPA
Lime kilnWhat are the newestprojects using?March 04, 2015 Golegã
TECNICELPA conferenceMarch 04, GolegãLime Kiln: 11.15 – 12.45
� Valmet continues the FLS Lime kiln technology.� Lime kiln sizing� Cooler technology� Flash dryer technology� Kiln supports� Trust� Refractory� Modern emission levels� New instrument� Questions?
The Valmet lime kiln
License agreementwith FLS
Valmet lime kiln technology
In July 2013, Valmet acquired anexclusive license to use FLSmidth’slime kiln and recausticizingtechnology
The acquisition complementsValmet’s portfolio as a full-scopesupplier to the pulp & paper industry
The acquisition involves resources inDenmark, USA, India and China
Pulp millSödra Cell, Värö, Sweden
Valmet lime kiln technology
A new technology center has beenestablished in Copenhagen.
30 key-persons from FLS continuesin Valmet from all functions includingSpare parts and Service.
The acquisition involves resources inDenmark, USA, India and China
ValmetCopenhagen, Denmark
Name: John Middelhede
Education:
- Bachelor degree in Mechanical/process Engineering
Professional Experience:
- Valmet (2013 – now):
* Sales Manager Lime Reburning Kilns
- FLSmidth (2003 – 2013):
* Sales Manager Lime Reburning Kilns
- FLSmidth (1989 – 1997):
* Process engineer Lime reburning kilns (5 years)
* Process engineer Flue Gas Cleaning (3 years)
Contact: [email protected]
Cellular: +45 6023 8812
The modern Pulp mill
Getting bigger
120 tDS/24h1933
1,500 tDS/24h1976
2,000 tDS/24h1986
3,800 tDS/24h1996
7,000 tDS/24h2006
15 t/d1905
1.8 × 22 m
450 t/d1991
4.15 × 120 m
600 t/d1992
4.15 × 95 m
1,050 t/d1996
5.0 × 115 m
1,250 t/d2014
5.5 × 140 m
Ready for next-generationrecovery boilers withstandard kiln components
Getting biggerRecovery boilers and lime kilns
The Valmet lime kiln
Cooler technology
Until 1991:FLSmidth Unax™
From 1992:FLSmidth Compax™
Now:FLSmidth Cross-Bar™ cooler
3% less fuel 3% less fuel
Cooler technology reduces fuel consumption
Valmet Rotating Cooler compared to Satelite Cooler
Plusses:� Less radiation� Less noise� Improved fuel economy� Shorter burner
Minusses:� Higher investments cost� More complex� Max. 900 MTPD
FLSmidth Cross-Bar™ cooler for large lime kilns
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FLSmidth Cross-Bar™ cooler for large lime kilns
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FLSmidth Cross-Bar™ cooler for large lime kilns
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• Self-adjusting air flow regulators• Compensates for variations in bed resistance• Ensures even air distribution throughout the cooler
CB Cooler versus rotating coolers
• CB cooler has no need for nose ring.
• CB cooler has no restrictionsbetween the kiln and the cooler
CB Cooler versus rotating coolers
• CB cooler has norestrictions for thelime to pass throughthe cooler
CB Cooler versus rotating coolers
• No risk of material build-up in CB cooler.• Free passage of balls andpieces of ring formation
FLSmidth Cross-Bar™ cooler for large lime kilns
� Even better thermal efficiency
� Product temperature <150 °C
� Rigid mechanical construction
� High reliability & availability
� Low, predictable maintenance
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The Valmet lime kiln
Kiln supports
Kiln support – base plate
Rigid support
Kilns < 4.35 m
Semi-rigid support
Kilns ≥ 4.35 m
Features:• Always a full line contact• Avoid hardening anddamages on components• Designed for heavy loads• Proven in operation (> 100)
Flexible support (semi-rigid suspension)
Alignement
Normal Rollermisaligned
Tyremisaligned
Flexible support (2)
Fixed
Flexible support, example
Other supplier Semi rigid support
Flexible support, Stendal, Germany
Flexible support, Suzano, Brazil
The Valmet lime kiln
Trust
Thrust roller
Kiln with 3 supports
Kiln with 4 supports
Trust in the middle of the kiln
Trust at support #3.
Mechanical trust
Hydraulic trust
• For heavy loads• ”Soft” contact• Kiln can be moved• Overpressure valveprevents damage on shaft• Compensation of tyrewobbling• Proven in operation (120 +)
Hydraulic thrust roller
Thrust roller w. Accumulator
Fixed thrustroller
Hydraulicroller w. accu
Hydraulic thrust roller, Stendal, Germany
The Valmet lime kiln
Flash dryer technology
Flash dryer technology
� Purpose:
– Reduce kiln length for new installations– Increase capacity of existing installations
Flash dryer is not a fuel saving item!
3.rd. Generation Flash dryer with recirculation
Hot kiln gas
Exhaust gas andlime mud
Dryer
Mud feeder
fdprincp
Flash dryingprinciple
Flash dryer
Tight seal preventsdusting and false
air
No mechanicalparts or flow
obstructions in thehot gas
Round riser, nocorners
Inclined ductprevents dustaccumulation
Backwall flushed bymud; prevents lime
deposits
No feed pipeinside the hot gas
Compact 2-diameter cyclone w.
high efficiency
Mechanical gate: nodrive, no
maintenance
Flow by gravity, nodrive, no
maintenance
Smoke gas chamber
No internals
Round design
Back wall cleaned by hot lime
Smoke gas chamber
� Specially designedfor high temperatureapplications
Dryer features
� No mud going directly to the kiln� Flow control outside hot gas� No need for scoops in smoke chamber
Water injection, typical P&I
Water injection system
� Objective:
– To cool the kiln gases, protecting ESP and ID fan– To reduce urgency of operator intervention– To maintain operation with abnormal feed (extreme LMDS
etc.)
The Valmet lime kiln
Refractory
RefractoryAs used today
No drying zone in a flash kiln.
Heating zone(approx. 44 %)
Calcination zone(approx. 16 %)
Burning zone(approx. 40 %)
Big kilnSingle layer 220 mm≈ Refraterm 150
Big kilnSingle layer 300 mmChamotte (≈ 40 % Al2O3)
Big kilnSingle layer 300 mmHigh Alumina (≈63 % Al2O3)
Small kilnSingle layer 220 mm≈ Refraterm 150
Small kilnDouble layer 200+65 mmChamotte (≈ 40 % Al2O3)+ insulation
Small kilnDouble layer 200+65 mmHigh Alumina (≈63 % Al2O3)+ insulation
The Valmet lime kiln
Emission levels
Modern emission levels
Dust H2S SO2 NOx
Oil
20-50mg/Nm3.
10 mg/Nm3, dry,8 % O2, basedon 0.2 % WSAas NaOH.
50 mg/Nm3 , dry,8 % O2, based on2 % S in the oil.
250 mg/Nm3 ,dry, 8 % O2,based on 0.4 %N in the oil.
Naturalgas
5 mg/Nm3, dry, 8% O2.
360 mg/Nm3,dry, 8 % O2.
The ACS 820
Fully automatedresidual CaCO3analyzer
ACS 820AUTOMATIC CARBON/SULPHUR
ANALYSER
ACS 820On-line sampling
Crusher BB200 (option)
Sampler A-17.2
APT-40P
Chute
Transport Tube(max.75m)
Analyzer ACS820Cabinet
APT-40L + Filter
Crusher MK25
Transport Blower
Mill CM800 (option) Vacuum cleaner
Screw Doser
ACS 820Site housing
Reference list for the ACS 800/810/820
� FLSA - IC Limerick Ireland ACS800 2005� FLSA - IC Platin Works Ireland ACS800 2007� Italcementi Sarche Italy ACS800 2007� Aalborg cement Denmark ACS800 2008� FLSA - Xstrata Canada ACS810 2008� Suzano Pulp & Paper Brazil ACS810 2011� CMPC Guiaba Brazil ACS820 2014
Advantages of a fully automated CaCO3 analyzer
� Frequent results within minutes delivered to theoperator� Optimizes the lime kiln operation� Will produce the most optimal quality continuously
for the recaust plant� Can prevent lining damage due to over fueling� Reduces work load in the laboratory
ACS 820Optimized kiln control
ProductionKiln speed
Feed
Fuel
1st control: Kiln speed as a function of Production (PID regulator)Production * X (individual constant) = kiln speed
2nd control: Variable parameter controlled by ACS 820Y = 6300 kJ/kg (individual) * ACS 820 control
3rd control: Fuel as a function of productionProduction * Y (limited to 7000 kJ/kg) = fuel flow