COMPANY BOOKLET YOUR PARTNER. for economic and innovative engineering solutions for cement and minerals industry

Transcription

1 COMPANY BOOKLET YOUR PARTNER for economic and innovative engineering solutions for cement and minerals industry

2 We are an engineering company that is active in plant engineering for the cement industry and in selected areas of the minerals industry. The company was founded in April Reliable and flexible, experienced and innovative - we design and implement customized solutions in all fields of plant engineering and for each project phase. Whether complete plant or plant unit, whether reconstruction of existing plants or design and construction of new plants as a competent partner, we have the necessary size and strength also to implement large projects into reality. Our staff has decades of experience in plant engineering and is worldwide in personal contact with our customers. ZEMDES has its operational headquarter in Dessau and is your partner for innovative and economic solutions in all aspects of plant engineering for the cement industry and the minerals industry. ZEMDES - BOOKLET

3 Cement Industry What ZEMDES does for you: - professional consultancy service complete plants on turn-key basis and Greenfield solutions, plant units, individual equipment reconstruction of existing plants, upgrading and efficient production solutions spare parts service Zemdes services starts with the examination of the raw materials, go about the process-engineering, the design and construction of the plant and end with the commissioning of the project. In addition, Zemdes advise and assist customers in optimizing of production and in maintenance and repair of facilities. Even if Zemdes does not supply equipments, you can engage the services of the company. Goals of Upgrading: Current Technologies: Increase clinker production High efficient dedusting cyclone Reduce of the heatconsumption Process cyclone with low pressure drop Reduce of fuel costs Calciner technology state of the art Improving the environmental performance NOx-reduction technology Combustion of alternative fuels BOOKLET - ZEMDES

4 Preheater and Calciner ZEMDES - BOOKLET

5 ZEMDES Preheater & Calciner ZEMDES cyclone preheaters and calciners are designed modular and they allow by combining the different modules a consistently procedure oriented figuration. If the conditions are changing later (e.g. other raw materials and fuels or higher environmental standards) the ZEMDES cyclone preheaters and calciners can be aligned by exchanging or adding modules for the respective conditions. For example: A calciner was dimensioned for fuel oil. The conditions for the use of coal as a fuel could be created by removing standard modules and inserting Low-NO x Module for a relative simple way by concurrent reduction of the NO X contents in the exhaust gas or it shall be used for difficult inflammable alternative fuels. This requirement can also be complied by adding a combustion chamber in the available calciner. ZEMDES cyclone preheaters could be one- or more-stringed. The one-stringed execution is used up to a throughput of t/d. For larger throughputs, the cyclone preheaters are usually two-streamed. The 1st stage (top stage) of each preheater is a module WEZ.D. The module WEZ.D is a double cyclone, designed as dedusting cyclone. Characteristic features of the ZEM- DES-dedusting cyclones are: one from the dip tube undisturbed inlet flow a long immersion depth of the dip tube a diameter ratio of cyclone and dip tube of 2: inlet spiral with an inclined bottom surface a cyclone cone with 70 wall inclination ZEMDES Double Cyclone 1st Stage The dust content in the exhaust gas after preheater is max. 25 g/m³. The double cyclones, including the riser ducts, are provided with a refractory lining. Therefore, a wall temperature of about 90 C will be aspired. The aspired wall temperature is independent of the used fuel. There will be no action with regard to the wall temperature with the use of alternative fuels. BOOKLET - ZEMDES

6 Depending on requirements of raw material drying, there are used 4-, 5- or 6-stage cyclone preheater. For process cyclones of the stages 2 up to 6, modules of the type WPZ.X are used. The selection of the modules is made according to each stage calculated amounts of gas out of process calculations. The modules of the type WPZ.X are process cyclones, which are optimized in their geometry concerning high filtration efficiency and low pressure drop. Characteristic features of the ZEMDES process cyclones are: one from the dip tube undisturbed flow an immersion depth of the dip tube of about 50% of the height of the inlet spiral the 270 inlet spiral with an inclined bottom surface a cyclone cone with 70 wall inclination The process cyclones, including the riser ducts, are provided with a refractory lining. In the normal case (use of standard fuels) wall temperatures of about C will be aspired. The aspired wall temperatures are dependent of the use of fuel. There are used 4-, 5- or 6-stage cyclone preheater. ZEMDES Process Cyclones At the using of alternative fuels, it have to adapt once the used grades of refractory materials, but also the value of the wall temperatures of the cyclones on this application. At the qualities of the refractory materials, the primary intension is to avoid the destruction of the lining by diffusing pollutants. At specifying the value of the wall temperatures, the destruction of the metal shell by corrosion from the inside (below acid dew point) shall be prevented. Therefore, by using of alternative fuels, wall temperatures of about C for the cyclones of stages 4, 5 and 6 are aspired. ZEMDES - BOOKLET

7 ZEMDES calciners ZD-C.SD are stream-duct reactors. Depending on the size of the plant, one or two calciners are used. All ZEMDES calciner can be equipped with a Low-NO x Module and / or a combustion chamber. Due to the modular design, a further upgrading can also be made by relatively little effort. The basic concept of the flow tube reactor offers a high stage of operational safety and combining a simple design with high flexibility for changes of process parameters. The particular shape of the deflection at the top of the calciner provides disintegration of any remaining streak and for a complete mixing of raw meal, gas and fuel. This is the precondition for complete combustion and optimum heat transfer between gas and solids up to entering the lowest cyclone stage. Degrees of calcination of the raw meal can be achieved by up to 95%. The Low-NO x Module operates on the principle of staged combustion. The complete Low-NO x Module consists of 2 parts. The lower section begins just above the orifice (transition from the kiln inlet chamber into the calciner). In this area, a subset of fuel and for control of the temperature also a subset of raw meal of second lowest cyclone stage is offered. The combustion takes place substoichiometric, that means so much fuel is supplied to that in relation to the furnace exhaust gas oxygen present an air excess number (λ) of about 0,8. There is an initial reduction of NO x -content in exhaust gas. In the transition from lower to upper part of the Low-NO x Module, the first supply of tertiary air is carried out and the remaining task of the fuel and the raw meal of the second lowest cyclone stage. Also in the upper part of the Low-NO x Module, the combustion is substoichiometric, that means it is only so much tertiary air supplied, that a number of excess air (λ) is about 0,8. It is a further reduction of NO x -content in exhaust gas. ZEMDES Calciner At the end of the upper part of the Low-NO x Module is the second supply for tertiary air. The amount of tertiary air, which is incorporated, depends on the oxygen content which is envisaged at the end of calciner (before entering the lowest cyclone). The target is 2 3 % oxygen. BOOKLET - ZEMDES

8 To observe the limit value for the NOx- content in the exhaust gas, an additional SNCR system has to be installed mostly. The range for the injection location of the reducing agent is above the Low-NOx Module to the deflection at the top of the calciner. In this area it is expected with temperatures between C. This temperature range is an optimum value for the SNCR process. The complete calciner is designed so that depending on the characteristics of the fuels a gas residence time is achieved by 3,0 6,5 seconds. The calciner is provided with a refractory lining. For the execution of the refractory lining, it is the same, which was already explained to the process cyclones. The wall temperatures should be about C with the use of alternative fuels. The modular whole concept of the ZEMDES preheater and calciner is designed, that at a later date an extension of the calciner or retrofit with a combustion chamber are possible options. This may be required if the characteristics of the used fuels in the future a reliable ignition and / or complete burn out with the original calciner-configuration is not allowed. ZEMDES Preheater 2 String, 4 Stage with Low-NOX Module ZEMDES - BOOKLET ZEMDES Preheater with Tower Structure 2 String, 5 Stage with Low-NOX Module

9 Rotary Kiln BOOKLET - ZEMDES

10 The ZEMDES Rotary Kiln One of our special engineering product is the ZEMDES rotary kiln. The engineers of ZEMDES have already designed several of rotary kilns, constructed, installed and successfully commissioned. The rugged and reliable construction, high reliability and low specific investment and operating costs are the characteristics of the modern ZEMDES rotary kiln. By using modern precalcination process under optimal thermal total solution, rotary kilns can today be dimensioned much smaller, despite the high flow rates. Basis of any dimensioning of a ZEMDES-kiln are, in addition to the experience of the engineers, the laboratory analysis of raw materials and fuels, and realization of small-scale technical combustion experiments. The result of the subsequent calculations is an optimal kiln geometry. ZEMDES Main Drive ZEMDES Tyre Fastening Arrangement ZEMDES Roller Station ZEMDES - BOOKLET

11 In plants with precalcination processes, the 2-support kiln is now the standard solution. ZEMDES provides the 2-support kiln with 16 different diameters of 3.00 m to 6.00 m. The length / diameter ratio (L / D I ratio) is about 13. ZEMDES can provide the 2-support kiln to an L / D I ratio of 15. If this value is exceeded, then the 3-support kiln is the technically and economically better solution. The 3-support kiln has by same diameter as the 2-support kilns, an L / D I ratio of about 17. One of the most important criteria for determining the required length of a rotary kiln is on the reactivity of the raw meal. In very good to good reactivity, an L / D I ratio of 11 can be sufficient. At very unfavorable conditions, it can be required an L / D I ratio greater than 17. Whatever the specific conditions are: ZEMDES always delivers the right rotary kiln. More characteristics of the ZEMDES-rotary kiln are: floating kiln tires with axial fixing compact roller station with floating bearing drive by gear rim and pinion frequency-controlled single- or double drive hydraulic thrust roller station pneumatically kiln inlet sealing spring plates- or pneumatically kiln outlet sealing air cooled kiln inlet trough air cooled kiln outlet section graphite- or grease lubrication for kiln roller surface Pneumatically Kiln Inlet Sealing Kiln Inlet Trough BOOKLET - ZEMDES

12 Kiln Hood with Tertiary Air Duct of a t/d Rotary Kiln 2-Support Kiln for a Plant with t/d ZEMDES 2-SUPPORT KILN Diameter Length (inside steel) L / DI (inside lining) Size of lining Clinker production Volumetric load Acceptable specific burning zone load nom. capacity max. capacity [mm] [t/d] [t/d] [t/d x m³] [Gcal/m² x h] 13, ,96 3, , ,99 3, , ,99 3,75 3, , ,92 3,95 3, , ,90 4,15 ZD-RK.K , , ,02 4,35 ZD-RK.K , , ,03 4,60 ZD-RK.K , , ,05 4,85 ZD-RK.K , , ,08 5,05 ZD-RK.K , , ,05 5,30 ZD-RK.K , , ,10 5,60 ZD-RK.K , , ,17 5,90 ZD-RK.K , , ,26 6,00 ZD-RK.K , , ,33 6,00 ZD-RK.K , , ,32 6,00 ZD-RK.K , , ,26 6,00 Designation D L [m] [m] ZD-RK.K ,00 35 ZD-RK.K ,20 ZD-RK.K ,40 ZD-RK.K-3643 ZD-RK.K-3845 ZEMDES - BOOKLET

13 ZEMDES 3-SUPPORT KILN Diameter Designation Length (inside steel) L / DI (inside lining) Size of lining Clinker production Volumetric load Acceptable specific burning zone load [t/d] [t/d x m³] [Gcal/m² x h] nom. capacity max. capacity [mm] [t/d] D L [m] [m] ZD-RK.N , , ,94 3,40 ZD-RK.N , , ,95 3,60 ZD-RK.N , , ,92 3,75 ZD-RK.N , , ,91 3,95 ZD-RK.N , , ,80 4,15 ZD-RK.N , , ,87 4,35 ZD-RK.N , , ,87 4,60 ZD-RK.N , , ,86 4,85 ZD-RK.N , , ,94 5,05 ZD-RK.N , , ,84 5,30 ZD-RK.N , , ,93 5,60 ZD-RK.N , , ,95 5,90 ZD-RK.N , , ,96 6,00 ZD-RK.N , , ,06 6,00 ZD-RK.N , , ,03 6,00 ZD-RK.N , , ,03 6,00 Kiln Shell Cooling at the Burning Zone Kiln Outlet Section Cooling BOOKLET - ZEMDES

14 Alternative fuels in Cement Industry ZEMDES - BOOKLET

15 Alternative Fuels in Cement Industry Worldwide, an increasing usage of alternative fuels is noted in the cement industry. ZEMDES faces this challenge with its facilities and offers solutions for a wide range of cases of operation. Alternative fuels can be used in the incineration process of rotary kiln plants in supplementation of fossil fuels, as long as their use does not adversely affect to the kiln-preheater-system. Generally, alternative fuels should comply with the following requirements: Steady and preferably low-pollution composition Calorific value, ignition temperature, density, combustion behavior, etc. must ensure a continuous energy utilization Treatment, storage, transport and proportioning must be relatively inexpensive and simple. Using alternative fuels, which are typical in the cement industry, are listed in the table below. Alt. Fuels Cement Plant Dotternhausen - Alternative Fuels Storage The advantages of using alternative fuels are the saving of fossil fuels like coal, oil and gas and thus a reduction of production costs and also an environmentally friendly disposal of waste. The disadvantages are the increased amounts of exhaust gas and radiation losses from the usage of alternative fuels compared to the ordinary usage of fossil fuels. Furthermore, in the kiln inlet and in the calciner riser duct there must be estimated with amplified build up coatings. Tires Rubber Animal meal Plastics Paper Petcoke Sewage sludge Domestic refuse Waste oil Solvent NCV [kj/kg] Moisture [%] , , ,1-0, Because with the usage of alternative fuels often an increased entry of chlorine and sulfur compounds is accompanied, in many cases the usage of a bypass system or calcium hydrate injection is estimated. Mostly the use of alternative fuels has a positive influence to the NOX - emissions. BOOKLET - ZEMDES

16 When using alternative fuels, longer burn-up times must be expected. These depend on particle size and oxygen content. For this reason, the design of a system with secondary fuels, the fuel treatment and proportioning, and the selection of the proper calciner are important. Liquid alternative fuels can usually be applied in a standard calciner reactor (ZD-C.SD-S) with elongated tubular part. For solid and lumpy alternative fuels it must be decided on the basis of grain size and responsiveness, whether an ordinary Low-NOx calciner (ZD-C.SD-LN) or a calciner with additional combustion chamber (ZD-C.SD LN.CC) will be used. In this case, the treatment of alternative fuels has a significant part. A finer treatment of the fuels results in a simple calciner design. But also environmental regulations have an influence on the technology of the calciner, if certain given temperatures and retention times are required for the combustion of alternative fuels. When designing a system with alternative fuels, it is exactly noted on the following points: Stable kiln operation Quality of clinker Production capacity of kilnmissions at chimney ZEMDES - BOOKLET Scheme of Storage and Transport Alternative Fuels

17 Minerals Industry BOOKLET - ZEMDES

18 Minerals Industry The long-year experience of our employees in different areas of plant design is the foundation to be able to offer practice oriented solutions for our customers. MATERIAL FEEDING DESLIMING PROCESS FLOTATION PROCESS DEWATERING GRINDING PROCESS CONCENTRATELOADING We are closing the CONCEPTION CIRCUIT ENGINEERING of ENGINEERING. REALISATION Analyses Basic Engineering Supply Process Design Detail Engineering Erection Process Development ZEMDES - BOOKLET Project Management Commissioning

19 We deliver INNOVATIVE and INDIVIDUAL engineering solutions ZEMDES in the field of pyroprocessing systems, we can offer directly or indirectly heated rotary kilns in metallurgical and chemical industry. e.g. ore pelletizing /// pet coke processing bauxite processing /// aluminium fluoride - production dust recycling from steel works and galvanising plants ZEMDES delivers electrical basic engineering. e.g. compilation of electrical consumer lists and measuring point lists individual design to related technology ZEMDES delivers environmental, hazardous material and storage management corresponding to the actual regulations and guidelines with focus to e.g. storage of chemical products storage conception /// Substances Hazardous to water dosing systems /// laboratory design BOOKLET - ZEMDES

20 Erich-Köckert-Str Dessau-Roßlau Germany info@zemdes.com YOUR PARTNER for economic and innovative engineering solutions for cement and minerals industry