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1Gas Analysis Technology- optimization & upgrade
Agenda:Gas Analysis for Optimization & Upgrade
Introduction to gas analysis
Kiln inlet analyzer for optimization
Upgrade of existing kiln inlet analyzer system
Optimization benefits
Upgrades of gasanalysis
At filter
In coal mill department
For emission monitoring
Maintenance and support
By Christian Markussen
Area Sales Manager / Product Specialist
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2Gas Analysis where and why?
Where ?
Kiln inlet
Calciner exit
Preheater exit
Coal mill department
Stacks
WHY ?
Process optimization
Safety control
Emission control
Specialised in sample handling
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3GASloq system layout
Gas conditioning
Analyzers
System controller
Cabinet or site shelter
4. Coal mill dept.
Optimization and upgrades- requires gas analysis
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4Optimization with ECS/ProcessExpert Fundamental data
Temperature
Pressure
Feed rate
Fuel rate
Raw material analysis
Clinker material analysis
Combustible analysis
Gas analysis
Gas analysis for kiln optimization Kiln Inlet or Calciner Exit
Simple - Strong - Reliable
Main focus is easy maintenance
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5Kiln inlet reality
The most difficult place to measure
The equipment has been known as Complicated tubing, valves etc.
Weak probes are bending
Time consuming probe are blocking
The measurement is known as Top 3 of Most Wanted signals
Kiln inlet is the best spot for:
Optimized fuel consumption
Optimize quality
Stable and safe kiln operation
Kiln stop prevention
Emission reduction
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6 O2 /CO Targets:
Optimized fuel consumption
Optimize quality
Stable and safe kiln operation
Kiln stop prevention
Emission reduction
Safety
The operators are depending on the kiln inlet analyser system in order to fully reach the kiln design capacity at optimum operating conditions
Oxygen analysis is on TOP 3 of any operators Most Wanted signal list
NO Targets: Clinker quality improvement
Burning zone temperature trend
Lower emission
SO2 Targets: Volatile control
Prevent kiln stops
Reduction of material build-ups
Reduction of ring formation in kiln
Reduction of manual kiln clean-out
Reduction of kiln system corrosion
CO analysis combined with O2 is very powerful in evaluating kiln performance
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7Selection of correct sample point
The sampling point has to be taken in respect to:
Representative gas
No influence from any false air
Mechanical impact from material fall through
Risk of material build-up
Dust impact
Condensation from volatiles
Practical installation with regard to available platform location and minimized obstacles outside
KilnLoq solution
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8 Simple: An Air cannon is one large air receiver, one valve and one pipe
Strong: An Air cannon is very strong and powerful in construction and operation
Reliable: An Air cannon is installed, connected and then forgotten
Air cannon gas analysis
Air cannon
Air receiver Valve Pipe/Nozzle
Air blaster One pipe design
Patented - One Pipe design
The normal filter construction compared to the coaxial One Pipe filter design:
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9The Shock Blaster Effect
Process dust Filter
surface cleaning
ONE PIPE cleaning.Works as
efficient as a shock blaster Amplification
chamber
Effectiv probe tip cleaning
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Easy Maintenance
Full admission all the way to probe end by removing
access port
Inspection of probe and maintenance can
be made without dismantling
Access only possible due to the ONE PIPE probe design
KilnLoq probe and extraction device
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Avoid bending of the KilnLoq Probe
Built to last
KilnLoq has many features that prevent the probe from bending
Heavy multi layer steel construction more than 8 times stronger
Automatic periodical extraction of probe to minimize material build-ups
Automatic shock blaster control integrated
Remote or local extraction of probe during kiln clean out
Measurement of heat input to probe from process
Probe position feature minimises insertion length
Using water as cooling
Easy Maintenance
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Upgrade of existing kiln inlet analyzer system
We can assist you
Determine the best measuring point
Evaluating reuse of existing equipment
Integrate existing analyzer units and even fix these
Find the most competitive deal
Performance Status on KilnLoq
In operation since spring 2003
More than 200 KilnLoq systems commissioned
More than 240 systems sold
Highest run factor on the marked in most cases higher than 95%
An average of 60 min weekly preventive maintenance
8 KilnLoq systems in Pakistan
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An reduction of 1% O2 in the kiln = 2% higher clinker production
An reduction of 1% O2 in the kiln = 1% lower fuel consumption
A shortage in oxygen level of 1% in the kiln inlet will cause kiln stops, wear, excessive manual clean-outs
Oxygen analysis is on TOP 3 of any operators Most Wanted signal list
Optimization benefits
Conclusion Kiln inlet
Reduce fuel cost or get higher production
Reduce production stops
Proven technology more than 200 references
Correct and continuous analyser signals
Highest run factor on the marked
Easiest maintenance on the marked
Getting a simple, strong and reliable gas analyser
system
Very short payback time typical less than 200 days
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Upgrades of filter or use of alternative fuels may require new gasanalysis
Filter protection systemSafety & Interlocking
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Low installation costs
plug and play modular design
Easy operation through large HMI colour touch screen
High resistance to contamination and corrosion from the process gas
Focus on design for easy maintenance
GASloq 1200 Low installation costs through simple standard FLS Airloq modular design
High powered probe cleaning by air gives better run factor for the equipment
No moving parts in probe ensures trouble free service and maintenance
Build-in air receiver ensures the highest possible pressure at any time
Probe Cleaning Panel
Filter protection systemCO/CH4 and O2:
True continuous sampling by double probe gives maximum safety
High run factor due to simple layout
DDOP probe
Double Dry nOn cooled Probe (DDOP)
Made of stainless steel Maximum temperature 600C Maximum dust: 200 g/m3 Weather protection
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Equipment for Measuring at Coal Mill Area
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Coal Mill Area
Supervision of coal mill department in silos and dust collectors
Detects impending spontaneous combustion of coal
Operation data for inert coal mill process
Single or Multi Scanning capabilities
Coal Mill Area Analyser Systems
GASloq 1200 multiscan system
Up to 6 silo measuring points
Continuous O2 at filter
ABB, Siemens or Emerson analysers
GASloq 600 single probe system
Used for silo or filter
ABB, Siemens or Emerson analysers
Power
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Upgrade of gas analysis to fulfil emission requirements
Different solutions for measuring gas depending on requirements
CO, CO2, NOx, SO2, TOC, O2 CO, CO2, NO, NO2, SO2, H2O, HCl, HF, NH3
NEO LaserGas Monitor
GASloq system
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Different solutions for measuring dust depending on requirements
Durag D-R 800
Durag D-R 290
Durag D-R 300
Durag D-R 800 Optical Dust Monitor
Forward scattered light reflection
principle
Designed for small and medium dust
concentrations
Easy one-side installation
Easy configuration without need for PC
Integrated purge air unit in the
electronics unit
Automatic function test with soiling
correction
TV 17. BImSchV approved
M-Certs approval pending
BeamSplitter
Shutter
Transmitter Diode
ReceiverDiode
Pane
Purging Air
CleaningFlange
Measuring Light Beam
Reference Light Beam
Fibre Optic
MeasuringVolume
Light Trap Objective
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ReportLoqController
Analyser
Dust
TOC
HF HCL
SO2
NOx
CO
ECS or none-ECS
Measurement PLCReal-time
Monitoring
Control
System
History, Analysis
& Reporting
Emission Monitoring and Reporting
Environmental reporting systems type ReportLoq
Meets local legislation for environmental reporting
Integrated solution with emission monitoring equipment
We cheated a little
you dont really need the wrench
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Easy maintenance
Human Machine Interface (HMI) display
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Human Machine Interface (HMI) display
Used for setup of the system
Used for information on status, failure and warnings
Human Machine Interface (HMI) displaySystem start/stop and manuel probe cleaning
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Human Machine Interface (HMI) displayCalibration
Human Machine Interface (HMI) displayAlarm list
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Human Machine Interface (HMI) displayTrend facilities
Spare [email protected]@flsmidth.com
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Service Contract
Remote service & trouble shooting by internetNo open ports in Firewall!!
References in Pakistan
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FLSmidth Gas Analysis Technologya Unique Supplier
More than 40 Years of experience in combining process knowledge from the cement and minerals industry with practical solutions of gas analysis
Patented technology offering unique selling proposition to our customers
Focus on simplicity high run factor through ease of maintenance
Specialized gas analysis organization with a huge accumulated experience base
Trouble shooting by experts supported by fast spare part deliveries
The credibility from belong to the FLSmidth One Source Brand
Full Gas Analysis Product Range
EQUIPMENT FOR ALL CEMENT APPLICATIONS:
Kiln Inlet competitive kiln operation
Calciner maximised throughput
Preheater filter protection system
Coal Mill secure supply of combustibles
Stack emission monitoring and reporting
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Thank you for your attention
Friendships are like standing in wet cement -
The longer you stay, the harder it is toleave, and you can never go.withoutleaving your footprints behind !
Any questions ?