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“Optimized Integrated Solution…”

www.bnf.com9th TCMA Technical Workshop

Process Optimization & Plant

Safety

Engineering Solution for Cement Industry

By : Teoh Wen Han

Venue : Forest Hill Resort,

Saraburi, Thailand

Date : 12 September 2006



7. Questions & Answers

Presentation Contents

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



Gas/Dust Analysis Application in Cement Industry



Reasons of Gas Analysis in Cement Process

Plant safety• Protection of the electrostatic precipitator• Protection of the coal grinding plant• Measuring Points : Before E.P., Coal grinding mill

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



Reduced emission / Environmental protection

• Emission control by monitoring the burning process

• Emission monitoring and data acquisition

Reasons of Gas Analysis in Cement Process

Reduction of the operating costs

• High availability of the plant equipment

• Early recognition of critical situations



Measurement Task

• CO, O2 Combustion optimization of secondary furnace

• CO2 Degree of calcinationCaCO3 (lime) CaO + CO2

Gas Analysis at Preheater / Precalcinator




Process Condition

≤ 850 °C (1562 °F)

≤ 200 g/m³ dust

Components: CO, O2 and CO2



Sampling Probe System




Sampling ProbeSampling Conditioning System

with Analyzer Located @ Pre-heater Tower




• CO, O2 Combustion optimization

• SO2, NO Quality of cement

• CO2 Degree of calcinationCaCO3 => CaO + CO2

Gas Analysis at Kiln Inlet

Measurement Task



Process Condition

≤ 1400 °C (2552 °F)

≤ 200 - 2000 g/m³ Dust

Components: CO, O2, NO, CO2, SO2




Gas Sampling Probe KIP 1000R




1. Gas Sampling Probe System

2. Cooling System & Heat Exchanger System

3. Gas Conditioning and Analyzer System

4. Integrated Hybrid Control System

KIP 1000R System Solution consist of





ANIMATION OF KIP 1000R



Measurement Task 1 : Coal bunker is filled with ambient air

Measurement Task 2 :Coal bunker is filled withInert gas (Example : N2)

• CO Measurement – Detection of smouldering

• O2 Measurement – N2 leak detection

Gas Analysis at Coal Mill / Silo



O2

O2

COGas

Cooler

Gas

Cooler

Sample SwitchingSystem

Switching3-way

solenoid

PurgingSystem

Coal Mill Inlet

PurgingSystem

Mill Filter Outlet

PurgingSystem

Coal Silo

PurgingSystem

Mill Filter Outlet

PurgingSystem

Coal Silo

Configuration of Sample Switching System




Photos showing an Analyzer Panel with Sample Switching System




Coal mill with analyzer cabinets onLevel 5 (Silo) and Level 6 (Filter)

Sampling on top of the coal 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

2 1

3

4

5

Level Measurement at Coal Mill / Silo



Process Condition

≤600 °C (1112 °F)

≤ 12 g/m³ dust (Before EP)

≤ 50 mg/m³ dust (After EP)

Components: CO, O2

Gas & Dust Analysis before Electrostatic Filter



Dust Monitors

Stack gas in front of E-Filter

Dust < 12 g/m³

Stack gas after E-Filter

Dust < 50 mg/m³

Dust Monitors

Add. quick CO measurementto avoid explosions


OVERVIEW

Gas Analyzer



Dust

Measurement

Dustmg/m3

Triboflow

Extinction Ringelmann

Bacharach

Scatter lightTransmission

TransmissionOpacity

Beta Ray Gravimetric comparison

Flicker lightScintillation

Methods in Determination of Dust Concentration




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




reflection

diffraction

absorption

Ligh

t

refraction

Different effects occurring when illuminating a particle



Dust Analysis


1. In-situ Cross Stack System• Typically used before EP ( High Dust )

• Dual path measurement

• Wide measuring range ( 0 – 12 g/m3 )

2. In-situ Probe Type

• Typically installed after EP ( Low Dust )

• Laser scattered light measurement

• Sensitive for low dust measurement ( 0 – 200 mg/m3)




Gas Analysis

2. In-Situ System

• Permeation Probe for fast and accurate measurement

• 2 sec response time

1. Extractive System

• The sampling line must be as short as possible

• Design is similar to Coal Mill Application



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



Process Condition

200 °C (Main Stack)

≤ 400 mg/m³ (Dust)

~ 30 Vol% (Moisture Content)

Components: CO, CO2 , O2 , SO2 , NOX ,THC, HCl

System MUST Comply to Local Environmental Regulation

Gas & Dust CEMS for Cement Plant



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

Measurement Techniques for Gas

In-Situ System

- Cross Stack Type

- Probe Type




• 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

Features of Extractive 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 H2O 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

Features of In-situ Gas CEMS System




1. Cross Stack Version•• For use in medium to high dust measurementsFor use in medium to high dust measurements

•• Capable of catering large ducts, up to 15 m dia. Capable of catering large ducts, up to 15 m dia.

•• Able to use in high temperature (up to 600 Able to use in high temperature (up to 600 OOC) C)

exhaust points such as Cooler Stackexhaust points such as Cooler Stack

2. Probe Version•• For use in low to medium dust measurementsFor use in low to medium dust measurements

•• OneOne--side installationside installation

•• Typically used to measure after EP or bag filterTypically used to measure after EP or bag filter

Measurement Techniques for Dust

In-situ Measurement




3. Heated Bypass Version

•• For use in measuring of dust in wet gasFor use in measuring of dust in wet gas

•• Flue gas maximum temperature 200 Flue gas maximum temperature 200 OOCC

•• Measuring cell & thermoMeasuring cell & thermo--cyclone in one cyclone in one compact designcompact design

•• PTFE probe to withstand corrosionPTFE probe to withstand corrosion




Thank You For Your Attention…

Questions…?

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