Process Optimization & Plant Safety

Transcription

1 Engineering Solution for Cement Industry Process Optimization & Plant Safety By : Teoh Wen Han Venue : Forest Hill Resort, Saraburi, Thailand Date : 12 September 2006

2 Presentation Contents Optimized Integrated Solution 1. Gas & Dust Analysis Application in Cement Industry Processes 2. Gas Analysis at Pre-heater / Pre-calcinator 3. Gas Analysis at Kiln Inlet 4. Gas Analysis & Level Measurement at Coal Mill / Silo 5. Gas & Dust Analysis before Electrostatic Precipitator 6. Gas & Dust Analysis before CEMS for Cement Plant 7. Questions & Answers

3 Optimized Integrated Solution Gas/Dust Analysis Application in Cement Industry 9th TCMA Technical Workshop

4 Reasons of Gas Analysis in Cement Process Saving of energy By optimized burning process control Measuring Points : Pre-calcinator, Kiln Inlet Constant high production quality Constant kiln operation control Measuring Points : Pre-heater, Pre-calcinator, Kiln Inlet Plant safety Protection of the electrostatic precipitator Protection of the coal grinding plant Measuring Points : Before E.P., Coal grinding mill

5 Reasons of Gas Analysis in Cement Process Reduction of the operating costs High availability of the plant equipment Early recognition of critical situations Reduced emission / Environmental protection Emission control by monitoring the burning process Emission monitoring and data acquisition

6 Gas Analysis at Preheater / Precalcinator Measurement Task CO, O 2 Combustion optimization of secondary furnace CO 2 Degree of calcination CaCO 3 (lime) CaO + CO 2

7 Gas Analysis at Preheater / Precalcinator Process Condition 850 C (1562 F) 200 g/m³ dust Components: CO, O 2 and CO 2

8 Gas Analysis at Preheater / Precalcinator Sampling Probe System

9 Gas Analysis at Preheater / Precalcinator Sampling Probe Sampling Conditioning System with Analyzer Pre-heater Tower

10 Gas Analysis at Kiln Inlet Optimized Integrated Solution Measurement Task CO, O 2 Combustion optimization SO 2, NO Quality of cement CO 2 Degree of calcination CaCO 3 => CaO + CO 2

11 Gas Analysis at Kiln Inlet Optimized Integrated Solution Process Condition 1400 C (2552 F) g/m³ Dust Components: CO, O 2, NO, CO 2, SO 2

12 Gas Analysis at Kiln Inlet Optimized Integrated Solution Gas Sampling Probe KIP 1000R

13 Gas Analysis at Kiln Inlet Optimized Integrated Solution KIP 1000R System Solution consist of 1. Gas Sampling Probe System 2. Cooling System & Heat Exchanger System 3. Gas Conditioning and Analyzer System 4. Integrated Hybrid Control System

14 Gas Analysis at Kiln Inlet Optimized Integrated Solution ANIMATION OF KIP 1000R

15 Gas Analysis at Coal Mill / Silo Optimized Integrated Solution Measurement Task 1 : Coal bunker is filled with ambient air CO Measurement Detection of smouldering Measurement Task 2 : Coal bunker is filled with Inert gas (Example : N 2 ) O 2 Measurement N 2 leak detection

16 Gas Analysis at Coal Mill / Silo Optimized Integrated Solution O2 O2 Gas Cooler Purging System Purging System Coal Mill Inlet Mill Filter Outlet CO Gas Cooler Sample Switching System Purging System Mill Filter Outlet Configuration of Sample Switching System Coal Silo Purging System Switching 3-way solenoid Coal Silo Purging System

17 Gas Analysis at Coal Mill / Silo Optimized Integrated Solution Photos showing an Analyzer Panel with Sample Switching System

18 Gas Analysis at Coal Mill / Silo Optimized Integrated Solution Sampling on top of the coal silo Coal mill with analyzer cabinets on Level 5 (Silo) and Level 6 (Filter)

19 Level Measurement at Coal Mill / Silo Measurement Methods / Installation 1. Vertical from top, rigid shaft. 2. Vertical from top flexible shaft or cable boom. 3. Horizontal,lateral of bin 4. Horizontal, lateral of bin with inclined flange 5. Inclined

20 Gas & Dust Analysis before Electrostatic Filter Process Condition 600 C (1112 F) 12 g/m³ dust (Before EP) 50 mg/m³ dust (After EP) Components: CO, O 2

21 Gas & Dust Analysis before Electrostatic Filter OVERVIEW Dust Monitors Dust Monitors Stack gas in front of E-Filter Dust < 12 g/m³ Stack gas after E-Filter Dust < 50 mg/m³ Gas Analyzer Add. quick CO measurement to avoid explosions

22 Gas & Dust Analysis before Electrostatic Filter Methods in Determination of Dust Concentration Extinction Transmission Opacity Ringelmann Dust mg/m 3 Triboflow Dust Measurement Bacharach Flicker light Scintillation Beta Ray Scatter light Transmission Gravimetric comparison

23 Gas & Dust Analysis before Electrostatic Filter Measuring principle Type Procedure Gravimetric measurement extractive discontinuous Beta Ray extractive discontinuous Scatter light wet gas extractive discontinuous Scatter light dry gas in - situ continuous Triboflow in - situ continuous Flickerlight in - situ continuous Transmission in - situ continuous

24 Different effects occurring when illuminating a particle reflection diffraction Light absorption refraction

25 Gas & Dust Analysis before Electrostatic Filter Dust Analysis 1. In-situ Cross Stack System Typically used before EP ( High Dust ) Dual path measurement Wide measuring range ( 0 12 g/m 3 ) 2. In-situ Probe Type Typically installed after EP ( Low Dust ) Laser scattered light measurement Sensitive for low dust measurement ( mg/m 3 )

26 Gas & Dust Analysis before Electrostatic Filter Gas Analysis 1. Extractive System The sampling line must be as short as possible Design is similar to Coal Mill Application 2. In-Situ System Permeation Probe for fast and accurate measurement 2 sec response time

27 Gas & Dust Analysis before Electrostatic Filter Purpose Of Measuring To monitor the efficiency of Electrostatic Precipitator (or broken bag filter) For plant safety ( high CO concentration can cause explsion on the EP ) For emission monitoring

28 Gas & Dust CEMS for Cement Plant Process Condition 200 C (Main Stack) 400 mg/m³ (Dust) ~ 30 Vol% (Moisture Content) Components: CO, CO 2, O 2,SO 2, NO X,THC, HCl System MUST Comply to Local Environmental Regulation

29 Optimized Integrated Solution Gas & Dust CEMS for Cement Plant Measurement Techniques for Gas Extractive System - Hot Wet Measurement (HW) - Cold Dry Measurement (CD) - Permeation Drying Measurement (PD) - Gas Dilution Measurement Technology - Depending on gas component, utilities availability, etc In-Situ System - Cross Stack Type - Probe Type 9th TCMA Technical Workshop

30 Gas & Dust CEMS for Cement Plant Features of Extractive Gas CEMS System Require Sampling System, more component CD and PD need Sampling Conditioning System Possible Time Sharing for multi stacks Easy Auto or Manual System Calibration by Reference Gas Dual Measurement Range is possible Analyzer should be placed as close as possible to the sampling point

31 Gas & Dust CEMS for Cement Plant Features of In-situ Gas CEMS System No Sampling System Fast Response (not dependent of SCS tube length) No Time Sharing for Multi Stacks Multi gas in one analyzer is possible Wet Measurement need H 2 O measurement for dry value reporting Difficult to conduct system calibration by gas cylinder Dual Measurement Range may not be possible Gas Measurement can be influenced by stack moisture

32 Gas & Dust CEMS for Cement Plant Measurement Techniques for Dust In-situ Measurement 1. Cross Stack Version For use in medium to high dust measurements Capable of catering large ducts, up to 15 m dia. Able to use in high temperature (up to 600 O C) exhaust points such as Cooler Stack 2. Probe Version For use in low to medium dust measurements One-side installation Typically used to measure after EP or bag filter

33 Gas & Dust CEMS for Cement Plant 3. Heated Bypass Version For use in measuring of dust in wet gas Flue gas maximum temperature 200 O C Measuring cell & thermo-cyclone in one compact design PTFE probe to withstand corrosion

34 Thank You For Your Attention Questions?