Transcript Slide 1
20 Stirling Street Thebarton SA 5031 AUSTRALIA Tel: Fax: +61 8 8352 9999 +61 8 8352 9988 5 Great Valley Parkway Malvern PA 19355 USA Tel: Fax: +1 610 725 8840 +1 610 725 8846
Complete Alternate Fuel Solution
Optimising Combustion with Alternate Fuels and Monitoring with On-line XRD
Con Manias, Sanjiv Dhanjal & David Retallack
FCT-ACTech P/L
Corporate Context
FCT Holdings FCT-ACTech
On-line Plant Optimisation
FCT-Combustion
Process Mineral Process Industries Combustion Products & Consulting
Agenda
INTRODUCING FCT
About FCT-Combustion PL
About FCT – ACTech PL
The FCT Process and Applications
FCT-Combustion
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Design and supply of kiln and calciner burner systems. Combustion System Consultancy and problem Solving Cement process Consultancy
FCT-Combustion
Since 1984
23 years in Business
FCT-Combustion
FCT-Combustion
FCT-Combustion
Multi Channel Burners
Coal/Gas/Waste Kiln Burner
Burner Face after 1 year in Cement Kiln
Valve trains & Burner Management Systems
Kiln Ignition/Pilot Systems
Burner Carriages
FCT Critical Projects
FCT Critical Projects
FCT Critical Projects
FCT Critical Projects
FCT Critical Projects
Cement Process
Limestone, Shale, Sand, Ironstone Pre-heater Kiln Blending Silo Quarry Raw feed Proportioning Raw Mill
Quarrying Blending Raw Milling
Clinker Storage
Kiln Burning
Flyash Gypsum Cement Mill Storage
Cement Milling
Kiln Mineralogical Reactions
Flame Effects on Clinker Crystals
1600 1500 1400 1300 1200 Short Flame Belite Long flame Alite 1100 1000 0 5 10 15 20 25 30
D istance from firing end, (m)
35 40 45 50 Short strong Long strong
Factors Affecting Burner Operation
Type of fuel
Excess oxygen in the kiln
Momentum ratio between the burner jets and secondary air
Kiln, cooler and hood aerodynamics and relative burner position
Nozzle Design (Atomizer, Gas Nozzle etc.)
Burner Design
Combustion and Heat Transfer
Fuel Nozzles
Primary Air Flow and Pressure
Secondary Air Aerodynamics
Mechanical Considerations
Suitable for harsh environment
Accessible for maintenance
FCT Combustion
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Kiln Burner Impacts on:
► Fuel Consumption ► Product Quality ► Production Rate ► Kiln Operational Problems ► Emissions
FCT Combustion
► FCT goes to extraordinary lengths to get the burner design correct for each kiln.
► FCT custom designs burners for each individual application to optimise performance
Air Flow Management
Primary Air
Axial
Swirl length and mixing width and stability
Secondary Air
Uncontrolled
Burner designers only have control over primary air
Types of Modelling
Physical Modelling Water Bead Acid/Alkali Mathematical
Water Bead Modelling
Kiln Hood Aerodynamics
Acid/Alkali Modelling
Click image to start/stop video Existing Condition Click image to start/stop video Optimised Solution
Mathematical Modelling
120 100 80 60 40 20 0 0
Kiln Wall Heat Flux
Existing Burner Multichannel Burner 10 20 30 40 50
Axial Distance from Burner Tip, m
60 70 70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
0 New Flame Length, m Existing Flame Length, m 10 20 30
Excess Air, %
40 50 60 Heat Release Flame Length
Combustion Summary
► Fuel is a major cost for industry, and optimisation will give rapid payback ► Trial and Error is a slow and high risk path to optimisation and could be costly ► Combustion Optimisation benefits the economy AND the Environment
Combustion Design Summary
Modelling is a cost effective tool to improve plant combustion performance.
► Low risk ► Examine plant operation off line ► No disruption to plant ► Well proven ► Solutions can be found off line ► Payback can be as short as a few months
Alternative Fuels
Numerous types
Petroleum Coke
Tires
Liquid Hazardous waste
Hog fuel sawdust
Wood municipal waste
Sewage Sludge
Maximum benefit when fired as is, because processing costs money
Large and irregular particles
Variable heat value
Undesirable chemicals
Alternative Fuel must have optimised burner
Pipe for Solids Pilot
FCT Multi-Fuel Burner Nozzle
Axial Air Coal Channel Guide Pipe for Waste Sprayer Swirl Air Gas Ports
Alternative Fuel Issues
Due to the combustion nature of alternative fuel, burner design becomes extremely critical. Even so, as the % substitution increases, a point can be reached when the flame is unsatisfactory for clinkering Also, waste materials and waste fuels can often alter the clinker mineralogy and cement behaviour A continuous knowledge of the clinker quality is the best information by which to control the use of waste.
FCT offers On-Line XRD (COSMA) to provide this very information, thereby allowing the OPTIMAL use of alternative fuel or other waste materials
Waste Fuel Effects
Control of Waste Fuel
Chemistry & Bogue calculations do not accurately reflect true mineralogy
On average
Actual Alite 13% higher than calculated by Bogue Actual Belite 6% lower than calculated by Bogue Actual Aluminate & Ferrite 2% lower than calculated
Bogue errors unpredictable with alternative fuels
COSMA On-Line XRD measures true mineralogy in all conditions allowing the plant to maximise alternative fuel usage
COSMA
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Direct Mineral Phase Analysis
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Continuous Real Time Analysis
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In Plant On-Stream Location
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Linked to Plant PLC
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Data Trending
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Elemental Analysis also
1
COSMA - Field Installation
2 3 4 XRD
COSMA for CLINKER
1. Clinker sampling point 2. Clinker sampler 3. Crusher 4. RSD 5. Grinder (P50 50 microns) 6. Sample receival hopper 7. Sample return (pneumatic)
1 2 7 4
Sample Prep Station
5 7 6
COSMA - Sample Presentation
Feedscrew Turntable Moving sample maximizes number of particles analyzed
COSMA - Continuous XRD Scanner
X-Ray Diffraction
WHY XRD?
The performance of a Cement Plant and Cement Product is Governed by
Mineralogy
NOT
Chemical Composition
COSMA
WILL DIRECTLY ANALYSE CLINKER C 3 S, C 2 S, C 3 A, C 4 AF, CaO, and their various forms Other Crystalline Minerals if required CEMENT C 3 S, C 2 S, C 3 A, C 4 AF, CaO, Ca(OH) 2 , CaCO 3 , CaSO 4 .2H2O, CaSO 4 .
1 / 2 H2O, Other Crystalline Minerals if required
COSMA
WHY CONTINUOUS ON LINE?
On-Line Analysis allows
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plant control action from COSMA in real time
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largely reduced sampling problems
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better XRD count statistics - better accuracy
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Trended data
Mineral Trends
70.0
65.0
60.0
55.0
50.0
45.0
40.0
05-N ov 09-N ov XR D Alite 13-N ov 17-N ov Lab Bog ue C 3S 21-N ov
Mineral Trends
30.0
25.0
20.0
15.0
10.0
5.0
0.0
05-N ov 09-N ov XR D Belite-b eta 13-N ov Belite-g am m a 17-N ov 21-N ov Lab Bog ue C 2S
XRD vs Bogue
18.0
16.0
14.0
12.0
10.0
8.0
6.0
4.0
2.0
0.0
5-Nov 6-Nov 7-Nov Aluminate 8-Nov Aluminate 9-Nov 10-Nov Bogue_C3A 11-Nov Ferrite 12-Nov Ferrite 13-Nov 14-Nov Bogue_C4AF 15-Nov
COSMA vs XRF
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
5-Nov 6-Nov 7-Nov SO3 8-Nov 9-Nov 10-Nov 11-Nov 12-Nov Averaged XRD SO3, RMSD = 0.18, Std Dev = 0.16 13-Nov Lab_SO3 14-Nov 15-Nov
Gypsum Analysis
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
6-Nov 7-Nov 8-Nov 9-Nov 10-Nov XRD Gypsum 11-Nov
Date
12-Nov XRD Hemihydrate 13-Nov Exit Temp 14-Nov 15-Nov 16-Nov 260 250 240 230 220 210 200 190 180 170 160
Cement Analysis
Mill exit cement after a power trip, July 28,2004
4 3.5
3 2.5
2 1.5
1 0.5
0 20:00 20:30 21:00 21:30 22:00
Time
22:30 23:00 23:30 60 50 80 70 40 30 20 0:00 10 SO3 Portlandite Gypsum Hemihydrate Anhydrite Lime Alite-tricl Alite-monoc
Limestone Addition
CM3 XRD Calcite and Loss
5 4 3 2 1 0 03-Nov 00:00 03-Nov 12:00 04-Nov 00:00 04-Nov 12:00
Date
05-Nov 00:00 05-Nov 12:00 06-Nov 00:00 Calcite Loss
Free lime excursion
60 50 40 30 20 10 25-Jan 26-Jan Alite 27-Jan Belite-b 28-Jan 2.5
2 1.5
1 0.5
0 29-Jan Free Lime
Cement Plant Control
Free Lime
150% 130% 110% W.r.t.
300 2 /kg G R I N D A B I I L T Y 50 45 S T R E N G T H 55 MPa
Schematic Optimum Free Lime vs. 28 Day Strength and Grindability
O v r e b u r n I n g Incre asing C 3 S(the oretic al st rengt h) Optimum %Free Lime Grin dabil ity ( a ctual) Cem ent S treng th (a ctual) 0.5
1.0
1.5
% Free Lime 2.0
3.0
Strength1-2.ppt
COSMA Benefits in Kiln control
Kiln Control
► Increase Average Free Lime ► 0.1% increase in av = 1% fuel saving = 1% increased Production ► Optimise Alite/Belite percentages and forms ► Make more Monoclinic Alite?
► Optimise Aluminate percentage and forms ► Make more Cubic Aluminate?
COSMA Payback
FOR TYPICAL PLANT
Average Free Lime is 0.7% (say) Optimum is 1.2% (say) Fuel saving approx. 5% Production Increase approx. 5% For 1,000,000 tpa plant, with $7/t fuel costs, this represents $350,000 p.a. fuel saving, and 50,000t more clinker by controlling free lime better. Additional benefits with clinker reactivity, cement strength, improved grindability. Could lead to 5 -10% increased finish mill production & reduced kwh/t.
COSMA Benefits in Kiln control
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Kiln Control / Optimization
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Effective use of optimization & expert systems
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Fuel Savings / Increased Production
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Reduced NOx emissions
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Prolonged Refractory life
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Reduced Laboratory Testing
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Improved Product Quality
Summary
FOR CLINKER APPLICATIONS
► Monitor Free Lime Continuously ► Monitor C3S, C2S, C3A, C4AF etc Continuously ► Feed information into kiln controller continuously ► Produce more uniform free lime with minimum fuel
WILL RESULT IN
► Fuel Savings ► Electrical Power Savings ► Increased Production ► Better Refractory life ► Lower NOx ► More Uniform Product
Capabilities
FCT has distinctive competencies in combustion science and process engineering
► Unique ability to physically model combustion and heat transfer – design or diagnostic ► Cement & Lime Process expertise - Plant design and Optimisation ► Patented Real Time Continuous On-LineMineral Analysis
Cement Lafarge Buzzi-Unicem Heidelberg Group Blue Circle Southern CIMA Adelaide Brighton Cement OYSA Nigde Cimento Akcansa Cimento Kars Cimento Cimsa Ashgrove cement Baticim Cimento Adocim Cimentas Baticim
Recent Customers
Other (industrial) Alcoa Georgia Pacific Global Stone Graymont Tolko Manitoba PT Inco American Colloid PCS Phosphate Metso Queensland Nickel Alcoa BHP Billiton Queensland Alumina
20 Stirling Street Thebarton SA 5031 AUSTRALIA Tel: Fax: +61 8 8352 9999 +61 8 8352 9988 5 Great Valley Parkway Malvern PA 19355 USA Tel: Fax: +1 610 725 8840 +1 610 725 8846