Process Optimiaztion & Plant Safety PDF

Optimized Integrated Solution
Engineering Solution for Cement Industry
Process
Optimization & Plant
Safety
By : Teoh Wen Han

Venue : Forest Hill Resort,
Saraburi, Thailand
Date : 12 September 2006
9th TCMA Technical Workshop
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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
7. Questions & Answers
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Gas/Dust Analysis Application in Cement Industry
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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
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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
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Gas Analysis at Preheater / Precalcinator
Measurement Task
CO, O2 Combustion
optimization of secondary
furnace
CO2 Degree of calcination
CaCO3 (lime) CaO + CO2
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Process Condition
850 C (1562 F)
200 g/m dust
Components: CO, O2 and CO2
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Sampling Probe System
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Sampling Probe
Sampling Conditioning System

with Analyzer Located @
Pre-heater Tower
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Gas Analysis at Kiln Inlet

Measurement Task
CO, O2 Combustion optimization
SO2, NO Quality of cement
CO2 Degree of calcination
CaCO3 => CaO + CO2
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Process Condition
1400 C (2552 F)
200 - 2000 g/m Dust
Components: CO, O2, NO, CO2, SO2
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Gas Sampling Probe KIP 1000R
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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
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ANIMATION OF KIP 1000R
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Gas Analysis at Coal Mill / Silo

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 : N2)
O2 Measurement N2 leak
detection
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Coal Mill Inlet
O2
O2
Purging
System
Gas
Cooler
Mill Filter Outlet

Purging
System
CO
Gas
Cooler
Sample
Switching
System
Mill Filter Outlet

Purging
System
Configuration of Sample Switching System
Coal Silo
Purging
System
Switching
3-way
solenoid
Coal Silo
Purging
System
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Photos showing an Analyzer Panel with Sample Switching System

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Sampling on top of the coal silo
Coal mill with analyzer cabinets on

Level 5 (Silo) and Level 6 (Filter)
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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
4
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Gas & Dust Analysis before Electrostatic Filter
Process Condition
600 C (1112 F)
12 g/m dust (Before EP)
50 mg/m dust (After EP)
Components: CO, O2
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OVERVIEW
Dust
Monitors
Dust
Monitors
Stack gas
in front of E-Filter
Stack gas
after E-Filter
Dust < 12 g/m
Dust < 50 mg/m

Gas
Analyzer
Add. quick CO
measurement
to avoid explosions
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Methods in Determination of Dust Concentration
Transmission
Opacity
Extinction
Ringelmann
Dust
mg/m3
Bacharach
Dust
Measurement
Flicker light
Scintillation
Triboflow
Gravimetric
comparison
Beta Ray
Scatter light
Transmission
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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
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Different effects occurring when illuminating a particle

reflection
Light
diffraction
absorption
refraction
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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)
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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
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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
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Gas & Dust CEMS for Cement Plant

Process Condition
200 C (Main Stack)
400 mg/m (Dust)
~ 30 Vol% (Moisture Content)
Components: CO, CO2 , O2 , SO2 , NOX ,THC, HCl
System MUST Comply to Local Environmental
Regulation
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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
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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
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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 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
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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 OC)
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
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3. Heated Bypass Version

For use in measuring of dust in wet gas
Flue gas maximum temperature 200 OC
Measuring cell & thermo-cyclone in one
compact design
PTFE probe to withstand corrosion
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Thank You For Your Attention
Questions?
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Process Optimiaztion & Plant Safety PDF

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Optimized Integrated Solution

Engineering Solution for Cement Industry

By : Teoh Wen Han

Optimized Integrated Solution

Optimized Integrated Solution

Gas/Dust Analysis Application in Cement Industry

9th TCMA Technical Workshop

Optimized Integrated Solution

Reasons of Gas Analysis in Cement Process

9th TCMA Technical Workshop

Optimized Integrated Solution

Reasons of Gas Analysis in Cement Process

Reduced emission / Environmental protection

9th TCMA Technical Workshop

Optimized Integrated Solution

Gas Analysis at Preheater / Precalcinator

9th TCMA Technical Workshop

Optimized Integrated Solution

Gas Analysis at Preheater / Precalcinator

9th TCMA Technical Workshop

Optimized Integrated Solution

Gas Analysis at Preheater / Precalcinator

9th TCMA Technical Workshop

Optimized Integrated Solution

Gas Analysis at Preheater / Precalcinator

9th TCMA Technical Workshop

Sampling Conditioning System

Optimized Integrated Solution

Gas Analysis at Kiln Inlet

9th TCMA Technical Workshop

Optimized Integrated Solution

Gas Analysis at Kiln Inlet

9th TCMA Technical Workshop

Optimized Integrated Solution

Gas Analysis at Kiln Inlet

Gas Sampling Probe KIP 1000R

9th TCMA Technical Workshop

Optimized Integrated Solution

Gas Analysis at Kiln Inlet

Gas Sampling Probe System

Cooling System & Heat Exchanger System

Gas Conditioning and Analyzer System

Integrated Hybrid Control System

9th TCMA Technical Workshop

Optimized Integrated Solution

Gas Analysis at Kiln Inlet

9th TCMA Technical Workshop

Optimized Integrated Solution

Gas Analysis at Coal Mill / Silo

9th TCMA Technical Workshop

Optimized Integrated Solution

Gas Analysis at Coal Mill / Silo

Mill Filter Outlet

Mill Filter Outlet

Configuration of Sample Switching System

9th TCMA Technical Workshop

Optimized Integrated Solution

Gas Analysis at Coal Mill / Silo

Photos showing an Analyzer Panel with Sample Switching System

Optimized Integrated Solution

Gas Analysis at Coal Mill / Silo

Sampling on top of the coal silo