On-line quality control Instrumentation For the cement industry. Sylvie VALERO ITECA - France

Transcription

1 On-line quality control Instrumentation For the cement industry By Sylvie VALERO ITECA - France

2 CENTRALISED LABORATORY Quarry Additives Blending Silos Precalciner Additives Cement Silo Preblending Crusher Raw Mill Kiln Cooler Clinker Silo Cement Mill Sampling tower Chute Screw sampler Air cooling Homogenisation hopper Piston sampler Sending station Electrical cabinet Diverter Quarry sampling Raw Mix sampling Hot Meal sampling Cement sampling To the lab

3 CENTRALISED LABORATORY CO2/SO3 analyser Receiving station Loss of Ignition analyser Rotative distributing arm Raw Mix Manual sample introduction Cement Supervision Composite samples storage Press Mill Automatic conveyor Dedusting XRD XRF Automation cabinet

4 ON LINE PROCESS CONTROL Quarry Additives Blending Silos Precalciner Additives Cement Silo Preblending Crusher Raw Mill Kiln Cooler Clinker Silo Cement Mill FX 3000 Al -Fe -Ca -Si S - P K-Cl Ignition Loss Free Lime CO2 -SO3 Particle Size 10/h RAW MIX 2/h HOT MEAL 5/h CLINKER 4/h Continuous CEMENT

5 ON LINE PROCESS CONTROL Advantages over centralised automatic laboratory Analysis at a higher frequency energy savings and more stable quality Cheaper systems Simpler to operate Independent systems no risk of having no analysis at all in the whole plant

6 PROBLEM : RAW MIX IS UNSTABLE SOLUTION : ON LINE RAW MIX CONTROL

7 RAW MIX CONTROL RAW MIX ANALYSER FX 3000

8 RAW MIX CONTROL Requirements for an efficient i raw mix control system Representative & reliable sampling system High quality sample preparation p Repeatable & reliable analysis High frequency control

9 RAW MIX CONTROL Representative and reliable sampling system Screw sampler with variable pitch & speed PREC 100 Rotating Spoon sampler PGR Homogenisation hopper Homogenisation hopper Piston sampler P11 Piston sampler P11 To the analyser or transport system Vl Valves

10 RAW MIX CONTROL Automatic raw mix sampling system LAFARGE Tetouan (Morocco)

11 RAW MIX CONTROL High quality sample preparation p Patented grinding system High density Tungsten Carbide Grinding vessel No grinding aid required Short grinding time: 90s Results Average particle size: 3μ 90 % of particles < 16μ

12 RAW MIX CONTROL Raw Mix Analyser FX3000

13 RAW MIX CONTROL Raw Mix Analyser FX3000 Volumetric dosing system Puck and mill grinder Variable frequency drive

14 RAW MIX CONTROL Raw Mix Analyser FX drops of alcohol are added directly into the grinder The ground material is then The ground material is then prepared and analysed using a Labx3500 from Oxford Instruments

15 RAW MIX CONTROL Integrated XRF from Oxford Instrument Labx3500

16 RAW MIX CONTROL Results obtained by Italcementi for the Borgo San Dalmazzo plant raw mix Unground Fused bead Mill and press FX3000 On line analyzer R Std Err R Std Err R Std Err R Std Err SiO2 0,957 0,688 0,999 0,091 0,998 0,136 0,998 0,129 Al2O3 0,927 0,142 0,997 0,032 0,986 0,063 0,975 0,084 Fe2O3 0,962 0,085 0,996 0,029 0,996 0,027 0,994 0,035 CaO 0,988 0,257 0,998 0,099 0,998 0,097 0,997 0,119 Regression on the analysis of 20 different samples

17 RAW MIX CONTROL Raw Mix Analyser FX analysis per hour Standard deviation on main elements : Ca : 0.1 Si : 0.1 Al : 0.03 Fe : 0.01

18 PROBLEM : CALCINATION STABILZATION SOLUTION : ON LINE HOT MEAL CONTROL

19 HOT MEAL CONTROL IGNITION LOSS ANALYSER PF1K

20 HOT MEAL CONTROL Hot Meal Sampler

21 HOT MEAL CONTROL Ignition loss Analyser High T sampling (± 950 C) Air cooling to stop decarbonation Measurement of rate of decarbonation 2 analysis/h

22 PROBLEM : CLINKER IS OVERBURNT OR FREE LIME IS UNSTABLE SOLUTION : ON LINE FREE LIME ANALYSER

23 CLINKER CONTROL FREE LIME ANALYSER KLC3

24 CLINKER CONTROL Representative and reliable sampling system Directly at kiln discharge: High T sampler PHT 100 In the 3 rd or 4 th compartment of a grate cooler: Under grate sampler PT 103 At the cooler discharge: After clinker crusher PP 101

25 CLINKER CONTROL Representative ti and reliable sampling system Kiln Discharge Sampler 2 pneumatic cylinders Air cooling Bulk pneumatic transport

26 CLINKER CONTROL Representative and reliable sampling system Kiln Discharge Sampler Cooling nozzle Sampling slots Discharge jack Sampler after 15 years of operation

27 CLINKER CONTROL Representative and reliable sampling system Under Grate Sampler Cooler Residues Excess Clinker 300 cm 3 valves

28 CLINKER CONTROL Representative and reliable sampling system Under Grate Sampler Centering spout under drilled grates Fine particles elimination

29 CLINKER CONTROL Bulk pneumatic transport Maximum distance: 200 m Diverter Receiving cyclone Sending station

30 CLINKER CONTROL Bulk Pneumatic transport

31 CLINKER CONTROL Free Lime Analyser KLC3 Grinding Analysis Automation

32 CLINKER CONTROL Free Lime Analyser KLC3 5 analysis/h Analysis cell Mill Weighing of clinker and glycol Heating Mixing clinker + glycol Conductivity measurement

33 CLINKER CONTROL Free Lime and Kiln Data Tokuyama Soda Japan

34 CLINKER CONTROL Free Lime and Kiln Data A high frequency free lime measurement is required (< 20 mn) Free Lime / Burning Zone T / Kiln Amps and NOx are closely correlated over the short term Over the long term the relation between Free Lime / BZT/ Kiln Amps and NOx changes

35 CLINKER CONTROL Operational experience Lafarge Ravena NY USA % free lime Free lime % 1 0,9 08 0,8 0,7 0,6 0,5 04 0,4 0,3 0,2 0, K-1 K-2 Date 1 : Analysis not used to control the kiln (over burnt clinker) 2 : Manual control of kiln using free lime (higher h free lime rate but unstable) 3 : LinkMan connected to the analyser (stable and higher free lime rate)

36 CLINKER CONTROL Direct Savings A 0,5 % increase in free lime results in : 15 Kcal / Kg CK of fuel savings 1 KWh / Ton CK of electricity savings Indirect Savings Manual analysis labour cost Cost of handling production rejects Post production incident costs

37 CLINKER CONTROL On Line XRDAnalysis Solid state detector

38 CLINKER CONTROL On Line XRDAnalysis It is possible with this analyser to determine all the phases of clinker determine the real clinker quality, not the one calculated by Bogue increase the use of alternative fuels, and determine their effects on clinker, real time.

39 CEMENT CONTROL CARBON SULPHUR ANALYSER PARTICLE SIZE ANALYSER

40 PROBLEM : GYPSUM / LIMESTONE ADDITIONS ARE UNSTABLE AND NOT OPTIMZED SOLUTION : ON LINE C/S CONTROL

41 CEMENT CONTROL Representative and reliable sampling system Screw sampler PREC 100

42 CEMENT CONTROL Carbon Sulphur Analyser Measurement of limestone and gypsum additives

43 CEMENT CONTROL Carbon Sulphur Analyser 200 crucible storage system

44 CEMENT CONTROL Carbon Sulphur Analyser Integrated ELTRA Analyser CS800 4 analysis/h

45 PROBLEM : FINENESS AND STRENGTHS ARE UNSTABLE SOLUTION : ON LINE PARTICLE SIZE CONTROL

46 CEMENT CONTROL Particle Size Analyser Continuous measurement

47 CEMENT CONTROL Particle Size Analyser Sampling in a vertical chute MALVERN Insitec Vertical chute at classifier outlet ITECA Sampling system

48 CEMENT CONTROL Particle Size Analyser Cement Schematic MALVERN Insitec Vertical chute at separator outlet ITECA Sampling system

49 CEMENT CONTROL Particle Size Analyser In situ installations LAFARGE Milaki (Greece) ITALCEMENTI Rombas (France)

50 CEMENT CONTROL Particle Size Analyser Application: Ashgrove Leamington USA

51 CEMENT CONTROL Particle Size Analyser Application: Ashgrove Leamington USA

52 CEMENT CONTROL Particle Size Analyser Grinding optimisation Q1-Q4 Q during manual control Q3-Q during automatic control 50 0 Production increase Ciments Calcia : + 5 % Grasim Bathinda : + 5% Ash Grove : +8% Consumption decrease : 4 to 8 % Production stability : standard deviation reduced by 20 to 40 % Return on investments

53 ON LINE PROCESS CONTROL Conclusions Complete On Line instrumentation to control the cement manufacturing process Higher frequency results, means that it is possible to better control the process, and therefore save energy costs Typical payback for each of these instruments is < 1 YEAR

54 ON LINE PROCESS CONTROL References Raw Mix control: 15 analysers Hot Meal control: 10 analysers Clinker control: 95 analysers Cement control: 80 analysers Customers: LAFARGE, ITALCEMENTI, HOLCIM, VICAT, CIMPOR, CEMEX, TITAN, ASHGROVE, BUZZI, HEIDELBERG, VOTORANTIM

55 THANK YOU FOR THANK YOU FOR YOUR ATTENTION