2005 yokota_ aspen plusfactsagechemapp interface.pdf

Morihisa Yokota

Ube Research LaboratoryCorporate Research & Development

UBE Industries, Ltd.

Aspen Plus/FactSage/ChemApp interface for Cement Production Process Simulation

7th GTT WORKSHOP 2005 AACHEN GERMANY

Contents

Why Cement Plant ?

Problems in Cement Plant Operation

Modeling Cement Plant with Aspen/ChemApp/Fact

Cement Plant with Chloride Bypass System

Conclusions

Future WorksOther High Temperature Process in UBE INDUSTRIES,LTDEstimation of Miner Components Behavior in Cement Making(Henrian Solution Model)


Clinker Burning Process

Counter Current Process

12or more)System ElementsFe-Ca-K-Cl-S-Si-Al-Mg-Na-O-N-C

Formation of clinker phasesAlite 3CaO*SiO2Belit Ca2SiO4,Fe2SiO4,Mg2SiO4Aluminat 3CaO*Al2O3Ferrite Ca2Al2O5 Ca2Fe2O5

Solid FlowGas Flow

Cooler

C4

C3

C2

C1

SP fan

Pre-Calciner

Rotary KilnClinker

Fuel(Coal)

Raw Meal


Waste and Byproduct Utilization in Cement Factories

Inorganic Waste(Raw)SewagePublic refuse incineration ashWater supply sludgeCoal ashGypsumSlag Controlled soilHydraulic cake

Organic Waste(Alternative Fuel)Waste plasticsWaste oilWaste tireWaste pachinko panelsWaste tatami matsBone meal


Cyclone clogging caused by Chloride and Sulfate accumulation

5/26

Raw Meal

C4

C3C2

C1

Coating Build up

Accumulation of Chloride and Sulfate

Formation of low melting point component

Cyclone clogging

Plant Operation Shutdown !

Chloride Conc. Sulfate Conc.

Raw Meal 60ppm 200ppm C4 430ppm 2,000ppm C3 840ppm 4,900ppm C2 1,630ppm 11,100ppm C1 11,880ppm 35,000ppm Clinker 70ppm 4,400ppm

Chloride KCl, NaCl

Sulfate K2SO4,CaSO4 etc


Cement Process Simulation with Aspen/ChemApp/FactSage

1990~ In-House Program (Gibbs Energy Minimization)

JANAF TABLE, NBS TABLE1993~ MALT, MALT21997~ HSC, TAPP

MINEQEL for windows

1988~ Aspen PlusStand-Alone Data Base or Programs Process Simulator

Barin for in-organics

Cement Process Simulation1997 ~

2003~ Kiln-Simu for rotary kiln

2002~Cement Process Simulation withAspen+ChemApp+FactSage

2001~ FactSage2002~ ChemApp RSTOICDRYREACWET-COALNITROGEN FLASH2DRYFLSHEXHAUSTDRY-COAL

RYIELD

DECOMPINBURNER

Q-DECOMP

RGIBBS

KBURN1

1ST-AIR

KB1G

KB11KB1S

KB12

KSBC6

KB1M

KGBC6

RGIBBS

KBURN2

KB2G

KB6SKB61 KB62

KSBC1

KB6M

KGBC1

G-PAS

KGASOUT

RGIBBS

SLDR1

KSLDIN

SINTERQ1

KC11

KC1S

KC12COOL1

COOLG1

COOLSLD1

2ND-GAS

COOL3

COOLG3

COOLSLD2

CLINCA

GASOUT

CASPLIT1COOLAIR COOLG12

AIR-SEP

KB3G KB4G

C1CMIXC1MJK

C1MNK

SEP

C1MNSEP

C1MN

C1MNC2

C1CYC

C1MJC2

BYPSEPC1

PGASOUT

C1BYPASS

RGIBBS

C1R

C1SLDIN

SEP

MJMNC1

C1GASMIX

C1BYPVPR

C1GASOUT

BYPSEPC2C2LEAK C2RIN

C2BYPASS

C2CMIXC2MNC1

C2MJC1

PSLDIN

RGIBBS

C2R

C2SLDIN

C2ROUT

SEP

MJMNC2

SEP

C2MNSEP

C2MNC3

C2CYC

C2MJC3

C2GASMIXC2BYPVPR

C2GASOUT

C3CMIX

C3MJC2

BYPSEPC3C3GASIN

C3BYPASS

SEP

C3MNSEP

C3MN

C3ROUT

C3MNC4

SEP

MJMNC3

C3SLDIN

C3MJC3RIN C3CYC

C3MJC4

C3GASMIXC3BYPVPR

C3GASOUT

C4CMIX

C4MJC3

C4GASMIX

C4MNFAN

C4MJFAN

C4BYPVPR

C4GASOUT

SEP

MJMNC4

SEP

C4MNSEP

C4CYC

FLVPR

BYPSEPC4C4FLSHIN

C4BYPASS

HEAT

HEATINHEATOUTFILTER

SYGASOUT

FLASH

SFLSHIN

MIX

SOURCE

RGIBBS

C3R

SEP

KC6SKC61

RSTOIC

DRYREAC2PCOAL

PN2PINDRY

FLASH2

DRYFLSH2

EXHSTP

PDRYCOAL

RYIELD

DECOMP2PBURNIN

QDECOMPP

RGIBBS

PBURN

PASPIN

P1STAIR

PB11

RGIBBS

PREFR

PBC1

PROUT

PBSPB12

PMIX

PBC2

PGPAS

PCS

P-PASPBYPASS

C4BYPS2

C3BYPS2

C2BYPS2

C1BYPS2

RGIBBS

SLDR2

SINTERQ2

KSBC2

KC21

Q

FSPLIT

QSEP1

SINTER-Q

Q

SINTERQ3

SINTERQ4

COOL2

COOLG2

CASPLIT2

RGIBBS

KBURN5

RGIBBS

KBURN6

RGIBBS

SLDR3

KSBC5

KC22

RGIBBS

SLDR6

KB4M

KGBC5

KB5M

KGBC2

KB2SKB5S

KC2SKC5S

RGIBBS

KBURN3

RGIBBS

KBURN4

RGIBBS

SLDR5

RGIBBS

SLDR4

KB2M KB3S KB3M KB4S

KC41KC51

KGBC3

KGBC4

KSBC4 KSBC3

KB5GKB6G

SINTERQ5SINTERQ6

KC3SKC4S

Rotary kiln(6 blocks)

C4 Cyclone

AirFuel

Raw meal Exhaust

Fuel

Pre-Calciner

AirClinker

C3 Cyclone

C2 Cyclone

C1 Cyclone

RSTOIC

DRYREACWET-COAL

NITROGEN FLASH2

DRYFLSH

EXHAUST

DRY-COAL

RYIELD

DECOMPINBURNER

Q-DECOMP

RGIBBS

KBURN1

1ST-AIR

KB1G

KB11KB1S

KB12

KSBC6

KB1M

KGBC6

RGIBBS

KBURN2

KB2G

KB6SKB61 KB62

KSBC1

KB6M

KGBC1

G-PAS

KGASOUT

RGIBBS

SLDR1

KSLDIN

SINTERQ1

KC11

KC1S

KC12COOL1

COOLG1

COOLSLD1

2ND-GAS

COOL3

COOLG3

COOLSLD2

CLINCA

GASOUT

CASPLIT1COOLAIR COOLG12

AIR-SEP

KB3G KB4G

C1CMIXC1MJK

C1MNK

SEP

C1MNSEP

C1MN

C1MNC2

C1CYC

C1MJC2

BYPSEPC1

PGASOUT

C1BYPASS

RGIBBS

C1R

C1SLDIN

SEP

MJMNC1

C1GASMIX

C1BYPVPR

C1GASOUT

BYPSEPC2C2LEAK C2RIN

C2BYPASS

C2CMIXC2MNC1

C2MJC1

PSLDIN

RGIBBS

C2R

C2SLDIN

C2ROUT

SEP

MJMNC2

SEP

C2MNSEP

C2MNC3

C2CYC

C2MJC3

C2GASMIXC2BYPVPR

C2GASOUT

C3CMIX

C3MJC2

BYPSEPC3C3GASIN

C3BYPASS

SEP

C3MNSEP

C3MN

C3ROUT

C3MNC4

SEP

MJMNC3

C3SLDIN

C3MJC3RIN C3CYC

C3MJC4

C3GASMIXC3BYPVPR

C3GASOUT

C4CMIX

C4MJC3

C4GASMIX

C4MNFAN

C4MJFAN

C4BYPVPR

C4GASOUT

SEP

MJMNC4

SEP

C4MNSEP

C4CYC

FLVPR

BYPSEPC4C4FLSHIN

C4BYPASS

HEAT

HEATINHEATOUTFILTER

SYGASOUT

FLASH

SFLSHIN

MIX

SOURCE

RGIBBS

C3R

SEP

KC6SKC61

RSTOIC

DRYREAC2PCOAL

PN2PINDRY

FLASH2

DRYFLSH2

EXHSTP

PDRYCOAL

RYIELD

DECOMP2PBURNIN

QDECOMPP

RGIBBS

PBURN

PASPIN

P1STAIR

PB11

RGIBBS

PREFR

PBC1

PROUT

PBSPB12

PMIX

PBC2

PGPAS

PCS

P-PASPBYPASS

C4BYPS2

C3BYPS2

C2BYPS2

C1BYPS2

RGIBBS

SLDR2

SINTERQ2

KSBC2

KC21

Q

FSPLIT

QSEP1

SINTER-Q

Q

SINTERQ3

SINTERQ4

COOL2

COOLG2

CASPLIT2

RGIBBS

KBURN5

RGIBBS

KBURN6

RGIBBS

SLDR3

KSBC5

KC22

RGIBBS

SLDR6

KB4M

KGBC5

KB5M

KGBC2

KB2SKB5S

KC2SKC5S

RGIBBS

KBURN3

RGIBBS

KBURN4

RGIBBS

SLDR5

RGIBBS

SLDR4

KB2M KB3S KB3M KB4S

KC41KC51

KGBC3

KGBC4

KSBC4 KSBC3

KB5GKB6G

SINTERQ5SINTERQ6

KC3SKC4S

Rotary kiln(6 blocks)

C4 Cyclone

AirFuel

Raw meal Exhaust

Fuel

Pre-Calciner

AirClinker

C3 Cyclone

C2 Cyclone

C1 Cyclone

Barin DatabasePure Solids,Liquids and Gas


Chloride and Sulfate at High Temperature (FactSage)

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

800 900 1000 1100 1200 1300 1400 1500

3K2Ca2(SO4)3

CaSO4 Slag-CaSO4

Slag-MgSO4

Slag-K2SO4 Slag-Na2SO4

Liq. or Solid K2SO4

Temperature C

S

c

o

m

p

o

u

n

d

s

i

n

S

o

l

i

d

+

S

l

a

g

m

o

l

5.0vol% O2

Chloride

Sulfate


Oxygen Partial Pressure on Sulfate Decomposition


Process Simulation Tools

+

PCOS Windows 2000 proCPU XEON 2.4GHzRAM 2GB


Components considered in Cement Process Simulation

Gas;116components

Pure Solids;155 components

Slag;28components

Solid Solution

Pure Liquids;3 components

Ferrite phase

Belit phase


Save *.cst file from FactSage


Databanks and Definition of Fact Componentsin ASPEN

Selection of DatabankDefinition of Componentsin case of SiO2


Single Stage Equilibrium Calculation

ASPEN PLUS GUI

ChemApp Block

Any number


Specification of ChemApp Block

1; P,T2; P,dH(W), incase of dH=0 adiabatic3,4; Target calc.

Pressure;PaTemperature(K) in type1, dH(W) in type2Number of Phasein this case only Slag-liquid was considered

definition of cst file name

Name of Phase

Number of Componentsin this case 273 compounds were considered


Aspen Plus Model for Cement Process

ChemApp Equilibrium Block

Coal

ProductRaw

Off-Gas

Rotary Kiln and Cooler

Pre-heater+Pre-Calciner

Burner

Coal


Calculation Sequence in Process Simulation

ASPEN PLUS creates Calculation Sequence Automatically

IterationLoop

ChemApp Block

Iteration vs. Residue(Loop)


Calculated Example of Cl, SO3 Circulation in Process

Chloride and Sulfate accumulation in bottom Cyclone


Calculated Clinker Phase

Alit Belit Aluminat Ferrite

3CaO*SiO2 3CaO*Al2O3Ca2Al2O5Ca2Fe2O5

Ca2SiO4Fe2SiO4Mg2SiO4


Chloride Bypass System

Dust Collector

Pre-Heater

Fuel

Clinker Cooler

KilnChloride Circulation

Raw Meal

Bypass


Cement Processwith Chloride Bypass System

Clinker Cooler

Bug filterfan

Cooling fan

Bypass DustMixing Chamber

Quench at Mixing ChamberKCl(Gas) KCl(liq) KCl(Solis)


Aspen Plus model with Chloride Bypass System

ChemApp Equilibrium Block

Coal

ProductRaw

Off-Gas

Rotary Kiln and Cooler

Pre-heater +Pre-Calciner

Bypass Gas Recycle LineChloride Bypass

Burner


Effect of Chloride Bypass System

Dust Collector

Pre-Heater

Fuel

Clinker Cooler

KilnChloride Circulation

Raw Meal

Bypass


Conclusion

Aspen/ChemApp/Fact interface was applied to Cement Process

Counter Current and Complex System 12 System ElementsFormation of clinker phases Sintering in liquid phase

Cement Process was modeled as a series of Equilibrium Reactors(ChemApp) by Aspen Plus

Accumulation of Chloride and Sulfate in Cement Process were successfully estimated in this Model


Future Works

9Application of Aspen/ChemApp/Fact interface toCoal Gasification PlantsOrganic Waste Gasification PlantsCoal fired Power Plants

9Linking ChemApp/Fact with CFD Calculation

9Behavior of Trace Elements in Cement Plants

rotary kiln

Coal Fired Power Plant

25/25


Some Processes with High Temperature in UBE25/25

EUP

Coal Fired Power Plant

Ube Ammonia Coal

Coal Gasification Waste Plastics Gasification

Behavior of Ash in GasifierGasification Modeling

CFD+Fact?

Behavior of Ash in BoilerCoal Combustion Modeling

CFD+Fact?


Application of Advanced feature of FactSage

Major Elements in Cement ProcessAl-Ca-Fe-Si-Mg-Na-K - Cl-S-O

Miner or Trace Elements in Cement ProcessPb-Zn-Se-Cd-Hg-Tl

Wed like to know (estimate) the behavior of Miner or Trace Elements in the Process !!

In FACT-SLAG, Zn and Pb are included.

Se,Cd,Hg,Tl are created as dilute Henrian solution, and then merge it into the FACT-SLAG solution phase.


Aspen Plus version 12.1.12&Technical Tip ID 115127(19-Jan-2005)

ChemApp version 5.3.2

FactSage version 5.3.1

Handling of dilute solutions in the Aspen Plus/FactSage/Chemapp interface


25/25 Al-Ca-Fe-Si-Mg-Na-K-Cl-S-O-F-Pb-Zn Systemwith Dilute Components(Se-Cd-Hg-Tl)

Dilute Components added to FACT-SLAG

Ftoxide System(FACT-SLAG)

In Fact53, some compounds have in its chemical formula,then, these compounds must be re-defined in ASPEN-PLUS

MG*S*O4, zn*cl2, etc

These compounds are addedto a User Databank


2005 yokota_ aspen plusfactsagechemapp interface.pdf

Documents

ppm clinker

ppm c4

ppm c3

ppm c2

ppm c1

ppm chloride kcl

caso4 etc7th gtt workshop

aachen germanyclinker