Kraft-Värme 17./ Saltsjö-Boo. Mokesys tiling systems potential for process optimisation Examples. Karl-Ulrich Martin Mokesa AG, Switzerland

Transcription

1 Kraft-Värme 17./ Saltsjö-Boo Mokesys tiling systems potential for process optimisation Examples Karl-Ulrich Martin Mokesa AG, Switzerland

2 Mokesa Office Building

3 Mokesa Today Mokesa AG Today Office: Personnel: Success: Success factors: Birsfelden near Basel; Switzerland 50 employees of which 30 experienced foremen and masons Today Mokesa is one of the world's leading refractory material specialists for waste incineration, hazardous waste and high temperature furnaces and chimneys. state-of-the-art refractory products professional engineering-concepts 24/7 complete refractory maintenance and service highly-qualified employees 1

4 Ankeba AG Holding Mokesa AG Switzerland, Europe Mokesys AG Sales Mokesys Tile System Worldwide Mokesa BLX Belgium & Netherlands Local Partners Germany, Italy, UK, 2

5 Content of this presentation Why do we need to optimize the process with refractory systems? Reliable long term life to protect membrane walls against corrosion High quality products for tiles, back filled materials and hangers Complete system design INNOVATION in products and systems Process Know How, and Realization and benefit 5

6 Mokesa Tiles Sexy??? For insider in refractory business YES! But there is a long way to go with continuous on-going improvement 6

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8 Overview development Steps in the corrosion protection systems Systems Ceramic refractory - SiC pin tubes with cap masses/tubes and pins concretes - Initial tests with bonded tiles - First larger-area bonded tile systems - Nitride bonded tiles - Initial tests air-ventilated systems - Initial tests backfilled systems - Large panels with backfilled tiles** State of the art - High quality requirements for tiling production Warranty/ statistical lifetime 6 months / 8 months 12 months / 24 months 24 months / 48 months 8

9 Overview development Steps in the corrosion protection systems Systems /13 Ceramic refractory warranty /lifetime - Optimisation back-filled system - Large area of airventilated system - State of the art - Initial test with extremely thin tiles - highly qualified, professional installation - Systems and installations from a single source - Large area of thin backfilled system for the furnace/ first pass (high heat transfer) - Thin tiles for high heat transfer - 2nd Generation airventilated system* 24 months / 48 months 24/36 months / 60 months 24/36 months / 60 months 9

10 Overview incinerator Segments of incinerator; lifetime refractory Areas of the incinerator Refractories maintenance Stat. Lifetime conserv. eng Refractory maintenan ce D A = Feeding, drying, start of pyrolysis. water vapour, abrasion, compensation of boiler expansions. conservation of energy Low, but special 10 years Low, but special B = Burnout zone, hoppers low temperature, low corrosion None 10 years None A C B1 B2 C = Combustion chamber, high energy and temp. slag, ash build up, attack on ceramic matrix, corrosion. high heat transfer, stress due to expansion between ceramic and tubes D = Upper part of boiler 1st. Pass 2 sec. at 850 C heat transfer ash build up, slag, low stress between ceramic and tubes, low corrosion, low temperature inlet 2nd. pass High-Low 3-5 years High Low 6-9 years Low 10

11 Product Mokesys Air 2E + Mokesys back filled (same tile design) 2 or 3 tube tiles, anchor mounted 2 or 4 anchors All anchors are located away from the tile joints for maximum protection 11

12 Product & System Mokesys systems Mokesys back-filled (patented) Mokesys Air 2E (patent pending) 12

13 Product & System System Mokesys Air 2E Safe air supply Pressurised air (1-2 mbar) is transported through horizontal and vertical channels across the tiling inner surface openings Air duct tile Ventilator 13

14 Product & System System Mokesys Air 2E Wall distance adjustable Holder behind the tile is protected air channel 14 14

15 Product & System After 4 years service life Distance between the air duct/inlet and holder 5 m ; 60 % industrial waste, hight salt content, high corrosion potential Proof: 0 corrosion VIDEO 15

16 O Corrosion 16

17 Product & System Mokesys back filled system m² installed, approx m² each year Service life 5-8 years, 1st. Pass 17

18 Product & System Mokesys back filled system double protection of the membrane wall Picture after an explosion Slag Mokesys tile SiC concrete 5-10 mm, very low porosity, very low gas permeability 18

19 Design & Hanger/Holder Construction of the tiling systems holder corrosion? Holder in the gap between 2 tiles Holder protected behind the tile tile holder Membrane wall Corrosive flue gas C Membrane wall Non-protected holder up to 800 C Protected holder up to 400 C 19

20 Innovation Innovation in conjunction with TU Dresden First project Oftringen ; over 4 years measuring project see Prewin Basel 2011 analyzing heat transfer of different refractory systems and different fouling Second project beginning in autumn 2013, subject not official published 20

21 Innovation Innovation in conjunction with TU Dresden Currently 18 heat flow measurements 46 temp. measurements Sealing air rate and temp. 21

22 Innovation Innovation: thermal element in the tile Thermal element Thermal element 22

23 Innovation & Prozess Membrane wall outside Heat flow measuring points fin pipe Thermal element Temp. measurement Tile inner face 23

24 Process optimazation Adapted heat transfer in the range of high heat transfer to almost adiabatic Version: Mokesys backfilled Backfilled concrete: Basis SiC or AI 2 O 3 Thickness: 5-30 mm 24

25 Process optimazation Mokesys back filled system Specially designed concrete basis of SiC or Al 2 O 3 gives different heat transfers and adds 2 nd protection-layer against corrosion Video 25

26 Specially designed concrete basis of SiC or Al 2 O 3 gives different heat transfers and adds 2 nd protection-layer against corrosion 26

27 Process optimazation Mokesys refractory concept backfilled / air-ventillated 3mm Mokesys tile >90 % SIC, 7 % nitride bond, double fired, 27mm thick, with backfilled concrete of SIC 60% and AI 2 O 3 60% with variable thicknesses Feuerfest W/(m 2 K) mm Layer thickness backfilled concrete S 5mm S 15mm S 30mm S 15mm S 30mm K mm Mokesys Air, range for high & low flue gas temp Mokesys with SiC 60% 30mm Air 15mm 30mm Mokesys with 60% Al 2 O 3 1/K=s/lambda+s/lambda+.. Backfilled concrete, 6W/(mk) Backfilled concrete, 1,5W/(mk) 27

28 Realization Example: Controlled heat transfer results in max. throuput and minimized add. energy Gathering data to establish an CFD Model Optimize the process in theory by using the model and feed it with different parameters Match the new model with appropriate refractory lining SiC tiles with different backfilled refractory Build it!!! 28

29 Realization Refractory concept according to CFD-Model Mokesys SiC nitrided, Double fired 24,5m height, 410 C tile, RG 810 C Mokesys with 5mm SiC 60% Approx. 170m² 16,6m height, 550 C tile RG 920 C With Mokesys ; 13 mm Al 2 O 3 Approx. 35m C tile Mokesys with 26mm Al 2 O 3 Approx. 95m² 29

30 Realization Comparison temperature modelling and actual > y = 24,545 y = 21,745 y = 16,65 Part load & ash T tile= 410 C T Measure = 811 C T Simulation = 818 C T Measure = 828 C T Simulation = 842 C T tile = 550 C T Measure = 917 C T Simulation = 919 C Cut through the boiler center as built /

31 Realization Small difference in refractory but substantial effect!! > 1400 Mokeflow AL 2 O 3 or SiC 700 Al 2 O 3 SiC area-weighted average temperatures: area-weighted average temperatures: 0 Outlet T = 1011 C Outlet T = 980 C H = +15,2 m T = 1080 C T = 1146 C H = +12,2 m T = 1062 C T = 1129 C H = +9,2 m T = 1231 C T = 1221 C 31

32 Realization Comparision different refractory lining inconel Inconel+tiles inconel Refractory tiles Mokesys tiles Mokesys tiles area-weighted average temperatures: Outlet T = 861 C T = 888 C H = +27 m area-weighted average temperatures: T = 821 C Outlet T = 799 C area-weighted average temperatures: T = 821 C Outlet T = 798 C T = 957 C H = +22 m T = 886 C T = 886 C T = 1032 C H = +17 m T = 972 C T = 971 C 32

33 Mokesys extra thin tiles thin backfill high heat transfer Protection of the corroded/defected inconel no negative effect to the heat transfer

34 Process optimazation with low cost High benefit 1. Best refractory system and quality reliable lifetime direct cost and less consequential cost by unplanned shutdown, corrosion 2. Controlled heat transfer by process-designed Refractory systems more throughput and less additional energy 3. Increased heat transfer in first pass results in lower temp input 2nd pass which causes lower corrosion at superhearter. 34

35 Reliable Systems Swiss Quality 35