aberthaw - report mission july 2007 - v 25 07 07
TRANSCRIPT
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From :Caroline JennyHenri Veyrenche
To : Alan RuxtonDai MorganChris Simms
Kenny HarrisonNorman CreightonFranc !ruggemanTom Freeman
ABERTHAWJuly 2007
CONTENTS
Summary .........................................................................................................................................................................2
1. Safety..............................................................................................................................................................................3
2. Operating cn!itin".................................................................................................................................................4
"#$ Ra% material &uality...............................................................................................................................................4
"#" Main !urner ..............................................................................................................................................................5
"#' Com(ustion..............................................................................................................................................................5
#. Ne$ analy"er c%%i""ining..................................................................................................................................6&. '( )an.............................................................................................................................................................................7
*. By+,a""..........................................................................................................................................................................8
)#$ *as (y+,ass.............................................................................................................................................................8
)#" Material (y+,ass to, o- C......................................................................................................................................9
-. Air 'nlea"....................................................................................................................................................................10
Anne/................................................................................................................................................................................12
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Summary
Air Inleak!
That i the main problem o" the kiln# E""ort mut be "o$ue% on the re%u$tion o" theeinleak& epe$ially at the rier %u$t#
'iln (a$k)en% analyer!
The new analyer are properly runnin* an% *i+e reliable in"ormation#,ow internal trainin* i nee%e% "or operator to how them the interet o" u$h ameaurement an% to train them to operate the kiln with thi new tool#
Air $on%itione% houl% be intalle% in the analyer $abinet#
(etter tan%ar% *a houl% be ue% to $alibrate thi analyer#
Sin$e we $ame& the %ata tranmiion problem ha been ol+e%#
Combution!
The burner *eometry houl% be $he$ke% at ea$h no--le reno+ation# .e u**et animpro+ement o" the $amera intallation in or%er to ha+e a better +iew o" the "lame
I an!
The I an %oent operate on it $ur+e# It $on%ition houl% be $he$ke% at net toppa*e#
(y)pa!
There i no notable *a or material by)pa# .e a%+ie a re*ular $he$kin* at ea$h plah
bo#
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1. Safety
//0 are %ell use1#/roce1ure o- locout o- air (laster is %ell a,,lie1#
02en i- huge ,rogress ha2e (een o(ser2e13 there is a remaining ga, o- ,rogress as -ar asti1iness o- the ,lant is concerne1: many e&ui,ments %ere lea2ing a-ter the %ors -rom theiln sto,,age#
Se2eral 1oors o- the riser 1uct are not ,ro,erly close14 some o- them o,en %ith air (laster -lo%# Riss o- (urning %ith hot gases -lo% must (e consi1ere1#
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ate" ene!
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2. Operating cn!itin"
2.1 Ra$ %aterial uality
There is not a s,eci-ic ,re+homogenisation: 5imestone -rom South 6uarry3 slag an1 7ronare roughly ,remixe1 in the &uarry#/antsone3 /FA an1 /a,er Ash are a11e1 at the ra% mill#
5SF8$9'#. SR8 "#; AF8$#;)
The ra% meal is 2ery -ine#
The iln -ee1 (urna(ility is 2ery goo1 < excellent as sho%n on the -ollo%ing chart3summari=ing tests con1ucte1 recently :2007.174.2AberthawKiln feed
Refus à200µm
Refus à100µm
Refus à90µm
CaOlcuit
elta!C
"#$ A%$ 'ndiceK14(0
A)titude
*chantill+n
% % %
11/11/2006 0.2 2.6 3.8 1.61 2.5 98.8 2.4 3.3 107 Très Bon
02/12/2006 0.2 2.6 3 0.85 4.1 96.5 2.1 3.1 127 Très Bon
11/01/2007 0.2 2.2 3.4 3.24 -0.5 102.7 2.0 3.3 91 Bon
24/01/2007 0.2 3.4 4.8 0.75 7.6 92.0 2.2 3.2 86 Bon
11/02/2007 0.2 2.8 4 1.41 1.7 99.8 2.1 3.0 135 Très Bon
23/02/2007 0.2 2.4 3.2 0.91 2.3 98.8 1.9 3.0 162 Excellent
03/03/2007 0.4 3 4.6 0.76 3.0 98.0 2.1 2.9 157 Excellent
14/03/2007 0.69 1.8 99.5 1.7 2.7 217 Excellent
20/03/2007 0.2 2.5 3.7 1.05 2.7 98.7 2.4 3.0 140 Excellent
>e can clearly see that the K is getting (etter %ith a lo%er silica ratio#
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These results can ex,lain ,rocess 1i--iculty 1uring the ,erio1 the MS %as high#
2.2 ain Burner
Visual -lame ins,ection is 1i--icult an1 the camera is ,artly (loce1 (y cliner 1e,osit# A (etter 2isi(ility %ill lea1 to a (etter checing o- the -lame as con-irmation o- themeasurement o- the settings#
The last measurements con1ucte1 (y the ,lant gi2e the -ollo%ing results
7s 8 #"? S% 8 9#9;;@%ith a11ition o- $99C -or axial air tem,erature to tae into account the real tem,eratureat the no==leBThe last calculation o- the (urner 1esign gi2es a (ias coe--icient o- $39? -or the Ra1ial Air#/re2iously @calculation o- ")
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#. Ne$ analy"er c%%i""ining
The ,ro(e seems to ha2e3 u, to no%3 no ,ro(lem o- (uil1+u,#"3 C an1 S" signals are ali2e#During our 2isit3 the analysers 1ata trans-er nee1e1 a mo1i-ication to -ree=e the 2alue1uring the se&uential ,urge to gi2e a (etter rea1a(ility to the o,erators# Since that time3the ,ro(lem has (een -ixe1#N Value is %ell measure1 (ut the transmission to Control Room: the signal %as constant(et%een " ,urges# @,ro(lem has (een sol2e1 since %e control itBThe ne% analyser is %ell ,ositione1 an1 gi2es results that are coherent %ith our analysers#
The gas analyser ca(inet is not air con1itione1: (y a tem,erature o- $)C outsi1e3 it %as
alrea1y 2ery hot @')CB insi1e# That coul1 (e 1amaging -or the electronic com,onent o- the analyser -or higher external tem,eratures# At least 2entilation or (etter3 air con1itione1 shoul1 (e installe1#
The set o- stan1ar1 gases3 ase1 (y A!! -or their -irst cali(ration is not %ell a1a,te1 -or the current le2els o(ser2e1 at the iln (ac en1#
*enerally %e use to cali(rate %ith stan1ar1 gas at "
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&. '( )an
>e measure1 the 7D Fan -lo%#
(ate Hur 4 O2 Te%p 5C)l$
N%#6 )l$ %#6 )l$ %#6"
9'
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Then %e 1ra%3 on the same chart3 the same cur2es in the current o,erating con1itions@s,ee1 o- the -an3 tem,eratureB# These ne% cur2es are calculate1 (y the xls chart#
7t gi2es the -an cur2e in the current con1itions3 (lue#7- the -an runs correctly the ,oint measure1 shoul1 (e at the cross ,oint o- the (lue cur2es#
For the ,lant 7D Fan it is not the case: the o,erating ,oint is (elo% an1 seems to (e on acur2e -or ")r,m s,ee1 o- the -an (ut the control room 2alues gi2e 9r,m#- course3 this -irst measurement must (e cross+chece13 as the measuring ,oints %erenot ,er-ectly locate1 @the measuring ,oints shoul1 (e as close as ,ossi(le -rom the 7D -anan1 %e use1 existing holes locate1 a (it -ar -rom the -anB# Ho%e2er the result got issigni-icantly -ar -rom its theoretical ,osition#
That ,ro(a(ly means either that a -raction o- the -umes is internally recycle1 (y the -an%hich lea1s to a 1ra-t ca,acity re1uction or that the -an is e--ecti2ely running slo%ly#
At the next sto,,age air tightness o- the -an shoul1 (e checout an1 ne% ,oint o- measurement create1 Gust (e-ore an1 Gust a-ter the -an in or1er to 2ali1ate easily thee--iciency o- the -an#
*. By+,a""
*.1 a" 3y+pa""
0*60762007 0&60762007
:&* :&* 10H1* 102* 10&* 1000 101*
at. Enter. C2fr% C1 Ea"t
at. Enter. C2fr% C1 We"t
at. Enter. C#fr% C2
at. Enter. C&fr% C#
aterial ut f C& t te iln
aterial .?I .". ?.'#) III ". 9C $)C
a" .) .$ ?.9#) II? $'# I;'C I;'C
0ach time the material %as hotter than the gas: no hot gases go trough the material 1uct#>e conclu1e that there is no signi-icant gas (y+,ass#
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*.2 aterial 3y+pa"" tp f C&
Sam,ling ,ointsLs ,osition
)'cm ,1 .)cm ,2 .$cm ,# ))cm ,& .cm
Ma,,ing starts .9 cm -rom the e1ge then e2ery "9cm#
9#' 9;#" $9#) I'#$
$'#. 9I#; $9#I I;9#$
$I 9#' 9I#$ 9)#I
$#I 9?#I 9; 9I#.
;iln $)#" 9?#; 9?#I 9I#$)#) $"#' 9.#? 9)#)
$I#I $I#. 9? 9;#$
$I#? $I#' $.#) $9#
$#' $# $.#$ $"#)
,* $$#) $. $9#; 9)#. I; I;?#" I'#? I;)#' 99#.
$"#. $' $$# 9;
,1 ,2 ,# ,&
This ma,,ing re2eals no C" material (y+,ass 1irectly toC.4
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,* @?9cm to the e1geB
Spla" 3/$$cm a(o2e the,oints /$ to /.
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-. Air 'nlea"
>e ha2e 1one a ma,,ing o- oxygen through the to%er to 1etermine the entry o- -alse air#
For each le2el %e calculate1 the ,ercentage o- air in leas com,are1 %ith the total to%erexit gas -lo%# >e use1 the a2erage o- the !e-ore 7D Fan -lo% %e measure1#
For the Kiln !ac+0n13 %e use1 the 1ata gi2en the ne% analyser#
0*607607
10#* 10#*
a" ut f C& ;iln Bac+En!
Te%p
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0#607607 0*607607
1*#0 11 :#*
Befre '()an Befre '()an a" ut f C2
Te%p e coul1nLtmeasure the " le2el at the C$ cyclones#
0#607607 0*607607
17#0 1*#0 11
After '()anBefre'()an
;ilnBacEn!
After '()anBefre'()an
;ilnBacEn!
Te%p
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Anne/
!y+,ass ma,,ing sheet7D Fan ,itot sheet7D Fan cur2es
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