RESEARCH PROPOSAL ON

MAKING USE OF COOLER VENT GAS FOR COAL MILL APPLICATION

BY

NIVEDIT S. MATHURSenior Lead Engineer,

Plant Layout – Mumbai,F.L.Smidth Private Limited.

MAKING USE OF COOLER VENT GAS FOR COAL MILL APPLICATION

- - - Waste Heat Recovery from Cooler Excess Air - - -

This Presentation consists of:-

# Introduction.# Objective of the Research. # Review of Related Literature.# Significance of the Research.# Viewpoints of industrial personals.# Research Methodology.# Schedule of Activities & Its Network Analysis.# Conclusion.# Acknowledgements.# References.# Questions.

Introduction:-# Most Energy Intensive System – 4 GJ/ton of cement. # Pyro Section – Preheater, Rotary Kiln & Cooler.# Inert & Non-inert Gas System.

Raw Mill Stack

Cooler

Raw Mil

Rotary KilnCoal Mill

Preheater Fan

Calciner

Preheater

Cooler Stack Electrostatic Precipitator

Reverse Air Bag House

Introduction:- Typical Cooler Layout

Objective of the Research:-

“Analyzing and developing a system for safely reuse of cooler vent gas for the coal mill”.

Review of Related Literature:-

# None of the journals covers the study of cooler vent gas in any form.

# Most of the journals covers about co-generation from cooler mid-air followed by waste heat recovery from rotary kiln.

# Past project executed by FLSmidth from the year 2000 onwards were studied along with current ongoing Jaypee Cement project of 4500 TPD, located at Sidhi, Madhya Pradesh.

# A dialogue with various industry personals was executed.

Significance of the Research:-

# Effective use of waste heat leading to energy saving.

# Providing flexibility to the cement manufacture while upgrading existing plant capacity and raw material selection.

# Eliminates continues use of Hot Air Generator (HAG) in the plant.

# Eliminates the need of wear resistance liners for the ID fans.

# Give rise to simplified layout and process circuit.

# Coal piping length from pneumatic screw pump to the kiln burner can be easily maintain within the requirement of 150 meters.

Significance of the Research:-

# It either eliminates or reduces the overall size of few equipments.

Change in design parameters of Coal Mill Booster Fan when Cooler Vent Gas is reusedSr No.

Design Specifications When Not Used

When Reused

1. Gas Flow (m³/sec) 43.7 42

2. Temperature (° C) 242 318

3. Density (Kg/m³) 0.701 0.553

4. Dust Concentration ( g dust/m³)

29 0

5. Relative Inlet Pressure (Pa) -3410 -2500

6. Required Motor Shaft Power (KW)

265 180

Viewpoints of industrial personals:-

# Normally preheater gas consist of 4% of oxygen while cooler vent gas consists of 21% of oxygen.

# Coal being volatile in nature leads to hazardous situations when comes in contact with high oxygen prone gases.

# Hot gases (either from preheater or cooler) consisting maximum of 6% of oxygen are permitted for coal mill application.

# Volatility is measured by, “Coal Volatile Matter” at ambient temperature. E.g Lignite & petcoke consists of 45% & 11% of Coal Volatile Matter at ambient temperature.

Research Methodology:-

1). Comparative study between preheater and cooler hot gases.

2). Formation of mathematical model.

3). Correlation and testing of the mathematical model with running operations at plant sites.

4). Developing a process circuit for safely reuse of cooler gas for coal mill.

5). Preparing a prototype and performing experimental test on it.

6). Formation of hypothesis on the basis of experimental test.

7). Formation of mathematical model on the newly proposed circuit.

Schedule of Activities & Its Network Analysis:-

A - Analyzing the behavior of preheater gas – 4 wks.

B – Analyzing the behavior of cooler gas when vented into the atmosphere without reusing at coal mill – 4 wks.

C – Analyzing the behavior of cooler gas when used at the coal mill.

D – Mathematical model – 1 formation when preheater gas are only used at coal mill & cooler gas are directly vented through ESP – 6 wks.

E – Mathematical model – 2 formation when both preheater & cooler gases are used at coal mill – 10 wks.

F – Correlating & testing the mathematical models with running operations of the plant at site – 8 wks.

Schedule of Activities & Its Network Analysis:-

G – Progress report 1 submission & project review 1 – 4 wks.

H – Incorporating the changes based on the feedback given in the project review 1 – 5 wks.

I – Developing a process circuit for safely reuse of cooler gas at the coal mill – 12 wks.

J – Progress report 2 submission & project review 2 – 4 wks.

K – Incorporating the changes based on the feedback given in the project review 2 – 5 wks.

L – Initial planning, scheduling & cost analysis for developing a prototype – 8 wks.

Schedule of Activities & Its Network Analysis:-

M – Developing a prototype based on the newly proposed process circuit – 12 wks.

N – Performing experimental test on the prototype – 8 wks.

O – Generation of hypothesis based on the experimental test – 6 wks.

P – Progress report 3 submission & project review 3 – 4 wks.

Q – Incorporating the changes based on the feedback given in the project review 3 – 5 wks.

R – Formation of a mathematical model on the newly proposed process circuit – 10wks.

S – Final project report submission – 4 wks.

Schedule of Activities & Its Network Analysis:-# There are two critical paths in this network.

Conclusion:-

# Since the concept is already been put into practice by certain cement manufactures, it clearly calls for urgency and important of the research in order to fulfill the upcoming future demand.

# It also depicts the originality, feasibility and viability of the idea chosen.

# Unavailability of relevant journals also calls for need of this research which will successfully contribute to the technical communities & Industries.

Acknowledgements:-

Mr. Srinivasan – Deputy Manager – Process department – FLSmidth, Chennai.

Mr. Sanjeev Katayal – Head - Process department – ACC Limited, Mumbai.

Mr. Ajay Karmore – Senior Manager – Project Engineering – Holtec Consulting Private Limited, Gurgaon.

Mr. Amit Runthla – Area Manager – W.R.Grace & Co (India) Private Limited, Bangalore.

References:-

•Tahsin Engin, Vedat Ari. “Energy Audting and Recovery for dry type cement rotary kiln systems”. Energy Conversion and Management 2005; 46:551-562.

•Kaustubh S. Mujumdar, K.V. Ganesh, Sarita B. Kulkarni, Vivek V. Ranade. “Rotary Cement Kiln Simulator (RoCKS): Integrated modelling of pre-heater, calciner, kiln and clinker cooler”. Chemical Engineering Science 2007; 62:2590-2607.

•Shaleen Khurana, Rangan Banerjee, Uday Gaitonde. “Energy balance and co-generation for a cement plant”. Applied Thermal Engineering 2002; 22:485-494.

•Richard Bolwerk. “Co-processing of waste and energy efficiency by cement plants”. Council Government Munster.

•M. A. Doheim & S. A. Sayed. “Analysis of waste heat & its recovery in a cement factory”Heat Recovery Systems & CHP vol 7, No 5, pp. 441-444, 1987 printed in Great Britain.

•Ziya Sogut, Zuhal Oktay, Hikmet Karakoc. “Mathematical modelling of heat recovery from a rotary Kiln”. Applied Thermal Engineering 2010; 30:817-825.

References:-

•R. A. Sharma. “Co-generation and success story in Indian cement industry”. Master Consultancy & Productivity Private Limited, Secunderabad. rasmcppl@rediffmail.com.

•Ismail Teke, Ozden Agra, S. Ozgur Atayilmaz, Hakan Demir. “ Determining the best type of heat exchanger for heat recovery”. Applied Thermal Engineering 2010; 30:577 -583.

•Song Lin, John Broadbent, Ryan McGlen. “Numerical study of heat application in heat recovery systems”. Applied Thermal Engineeing 2005; 25:127-133.

•V. Kovalenko, V. Khirpunov, A. Antipenkov, A. Ulianov. “Heat Pipes based first wall”. Fusion Engineering and design 1995; 27:544-549.

•L. Shao, S.B. Riffat. “Flow loss caused by heat pipes in natural ventilation stacks”. Applied Thermal Engineering Vol 17, No 4, pp. 393-399, 1997 printed in Great Britian.

•Greg Palmer, Tony Howes. “Heat transfer in rotary kilns”. Cement Industry Federation Technical Conference 1998.

Questions?