schenck process americas s.a.s / fct combustion pty
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Schenck Process Americas S.A.S / FCT Combustion Pty. FICEM APCAC COSTA RICA 2012. CONTENTS. 1. Schenck Process Americas S.A.S Presentation. 2. FCT Combustion Pty Ltd Presentation. Efficient and Optimum Cement Production with Alternative Fuels By Sanjiv Dhanjal (FCT Combustion, USA) - PowerPoint PPT PresentationTRANSCRIPT
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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
Feeding systems FUEL-Mastersolutions for alternative fuels
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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.
Feeding systems FUEL-Mastersolutions for alternative fuels
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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
Feeding systems FUEL-Mastersolutions for alternative fuels
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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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FCT GYRO-THERM BURNERFOR GAS AND COAL
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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
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THANK YOU VERY MUCH.