025_tsp qjp400generalzwd_hzf_wxw 0807 preca study

8/18/2019 025_tsp Qjp400generalzwd_hzf_wxw 0807 Preca Study

1/18

ATC REPORT

Activity: STUDY

CHINA / QUJIANG Plant

Precalciner st!y

"y #HANG $EIDONG//HAN #HEN%ENG//

$ANG &IANG$EI

ATC' ()t*+,(st Jly ,--.

Distribution:

Region

BU

Plant Zhou Wei//Zhang JingHong

ATC Sinan Urhan//Renaud deBelmont

ther

Codi!i"ation TSP #JP$%%&'('RA)/ZWD*HZ+*W,W %-%. Pre"astud


2/18

TA0E O% CONTENTS

A1 E2ective S33ary11111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111114

1 5ain Re67rt11111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111 .

0 1ntrodu"tion2222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222223

4 Wor5 Done22222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222223

6 Analsis / Argument / Con"lusions22222222222222222222222222222222222222222222222222222222222222222222222222222222223

620 Ba"5ground 1n!ormation22222222222222222222222222222222222222222222222222222222222222222222222222222222222222222223

624 Sa!et2222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222-626 Pre"al"iner Sur7e2222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222228

62$ +alse Air Audit2222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222209

629 +an '!!i"ien"2222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222203

$ Re"ommendations222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222220.

9 A"5noledgements22222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222220-

3 A;;endi"es222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222220-


3/18

A1 E&ECUTI8E SU55ARY

O"9ectives:

The ob some #W relati7e missions ill be "om;leted:

+an e!!i"ien" Audit !or ?6 @iln 1D +an> 'SP +an ?0 'SP +an2

rganie a session to !ollo u; #W re"ommendations tra"5ing2

Reslts / %in!ins

Sa;ety:

The a""esses are 7er ;oor> no ;ro;er ste; or ladder to arri7e the measuring ;oints2

an Preheater "on"rete beams o7erhead the a""esses are too lo to ;ass through>

and no ne"essar alarm mar5s2

QJP Precalciner Evalati7n:

Although the 5iln !eeding 7ariabilit made hardl ;ossible an reliable in7estigation> it "an besaid that the C ;roblem does not "ome !rom ;reE"al"iner dimension Fbig enoughG2 4 le7el atC4 e=it is in a7erage too lo and ma be a root "ause on to; o! the huge "ir"uit 7ariation

be"ause o! 5iln !eed 7ariabilit2 Burner design should be !urther in7estigated2

1tems Target/(ormal '=isting status '7aluation

Residen"e time 42%s（ＮｏｒｍａｌＣｏａｌ）

623s @

PC tem;erature;ro!ile

Uni!orm andreasonable2

PC u;;er is higher than middle and bottomhuge 7ariationsEEE a= 8-℃ beteen to

;oints at same le7el2Bad

PC e=it gastem;erature

Stable I9℃ a=2 4$℃ Bad

C 5iln e=it 0%%;;m (ot measured2 )ater 4%%3 indi"ates %;;m (otmeasured

4 5iln e=it 6E9K

C PC e=it gas ＜9%%;;m (ormal 4%0$349%;;m Seldom＜9%%;;m Bad

4 PC e=it gas 46K %2-624K Poor

Tem;erature 1nmain se"tion

Stable Unstable a=2 7ariations $9℃ Bad

Burn "ondition b7isual ins;e"tion

(o s;ar5le atoutlet

an s;ar5les as !ound in di!!erent se"tion Bad

Stable !uels;litting PC

@iln/PCL$%:3% Around 3%K @

T*ere;7re' t*e


4/18

Misual ins;e"tion

We tried to e7aluate Pre"al"iner "ombustion "ondition b 7isual ins;e"tion during the

mission im;lementation2 We !ound that the brightness o! !lames beteen to ins;e"tion holesat same le7el Fmeasurement ;oint CG are 7er di!!erent at the same time man s;ar5les ere!ound inside the Pre"al"iner2 This "on!irms that the Pre"al"iner "ombustion "ondition is ;oor2

Fan Efficiency:

Under the s"o;e o! !an e!!i"ien" audit e ha7e "o7ered ?6 @iln 1D +an> 'SP +an ?0'SP +an2 Be"ause o! the la"5 o! ;oer !a"tor o! ?6 5iln "ooler 1D +an> e "anNt"om;lete +an e!!i"ien" Audit !or it2 The +ansN e!!i"ien" o! ?6 @iln 1D +an> 'SP +an and?0 'SP +an is ?' (? an! B(?2 +ansN '!!i"ien" is less than 39K and the +ansha7e ob7ious s"o;e !or the im;ro7ement2

T*e I36act @7l! "e + $/tc2 The analsis o! the +an '!!i"ien" and e"hani"al"he"5 on the +ans should be gi7en in order to !ormulate an a"tion ;lan to im;ro7e the;er!orman"e to redu"e the o7erall ;oer "onsum;tion o! the ;lant2

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5/18

Ta"le 7; acti7ns

(o2 A"tion Priorit

0Pro;er ste; or ladder !or the measurement ;oints should be installed somehandrails must be installed also2

Sa!et

4 Alarm mar5s should be !i=ed on the Preheater "on"rete beams o7erhead thea""esses

Sa!et

6&angas on the s"a!!olding o;tionall must be "arried aa to 5ee; !rom!alling don2

Sa!et

T*e a!ter stabilisation o! @ilnCombustion FATCG 1s Coal Trans;ortation Melo"it @

1s the !lu"tuation be"ause o! Cal"iner Tem;erature or "ooler TA

Burner design

0

001n"rease ?6 1D +an> 'P +ans Q ?0 1D +an !rom $9K to 39K in "onsultationith the +an e=;erts to redu"e -E8 @h/t 55

0

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6/18

1 5AIN REPORT

( Intr7!cti7n

This mission is mainl !o"us on Pre"al"iner stud and gi7es re"ommendations !or !urthero;timiation2 n the other hand> +an e!!i"ien" Audit o! ?6 @iln 1D +an> 'SP +an> and ?0 'SP+an and #W re"ommendations tra"5ing ha7e been "om;leted2

, $7r D7ne

Pre"al"iner tem;erature measurement has been done !or three times2

&as analsis o! ProEsstem has been done !or three times2

+an e!!i"ien" audit2#W re"ommendations !ollo u;2

4 Analysis / Ar3ent / C7nclsi7ns

Poor Pre"al"iner o;eration "ondition as mentioned in #W mission2 This mission is "arried outin order to get tem;erature ;ro!ile and gi7e re"ommendations !or !urther o;timiation2

41( acr7n! In;7r3ati7n

#JP ?6 5iln is semiEet ;ro"ess ;rodu"t line ith 0%%%t/d design "a;a"it2 Pro"ess !losheetsho belo:

%ire (: Pyr76r7cessin syste3 in QJian 6lant

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7/18

The hole ;rodu"t line is running at unstable status> the 5iln !eed still !lu"tuate F!rom 9%t/h to-%t/h ith 5iln !eed set -%t/hG ra meal "om;osition is not "onsistent2 These issues are allim;a"t on Pre"al"iner ;er!orman"e negati7el2 @iln onl rea"h ..%t/d89%t/d out;ut and

tri;;ed !our times during $ das F0.th 4%th JulG2

P*7t7 (: QJian 6yr76r7cessin syste3 3ain 6ara3eter c7n!iti7n ,--.-)

There are no thermo"ou;les at 5iln inlet> Pre"al"iner bottom> middle> u;;er and outlet> nomanometer and gas analer at the outlet o! Pre"al"iner2 u"h im;ortant in!ormation isnNtshoed in CCR s"reens2

The 5iln !eed Ouantit and material moisture "ontent as !lu"tuated seriousl due to the7a"uum !ilter "ondition2 This resulted in all ;ro;ro"essing sstem running at unstable"ondition2 1m;ro7ing 7a"uum !ilter running "ondition be"ame the !irst thing !or o;timiing all;ro;ro"essing sstem

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8/18

P*7t7 ,:


9/18

414 Precalciner Srvey

4141( Precalciner an! 6re*eater 3easre3ent

Precalciner te36eratre 3easre3ent:

A""ording to the re"ommendation o! #W re;ort> #JP has alread ;re;ared the measurementholes on the Pre"al"iner bod and du"ts> then e measured ;ri"al"iner tem;erature at di!!erentle7el> and "he"5 the 4> C "ontent o! gas at ;reheater di!!erent ;art through gas analer2Hoe7er> the 5iln running status as unstable and tri;;ed !our times during !our das F!romonda 0.th to Thursda 4%thG> 1t is di!!i"ult to e7aluate ;re"al"iner and all ;ro;ro"essingsstem e=a"tl e7en though e got three sets measurement data2

The tem;erature ;ro!ile a"ross the Pre"al"iner as not uni!orm2 The tem;erature 7ariationsas rea"h to 8-℃ F !rom -6-℃ to 863℃G at same le7el F4%EJul measurement ;oint D0 andD4 ith .9-%t/h 5iln !eedG> and $9℃ 7ariation at the same ;ointF!rom -%0℃ to -99℃ during

7er short time >0.EJul measurement ;oint C6 ith 3%t/h 5iln !eedG2

Gas analysis

We measured 4> C "ontent o! gas at the PC e=it> C4 outlet> the DrE"rusher e=it and 1D !aninlet in order to e7aluate Pre"al"iner "ombustion "ondition and "al"ulate !alse air o! PH and PC2The details sho in main re;ort2 4 K at PC e=it is still loer F%42%KG and CK is higher than)a!arge standard F9%%;;mG in a ma


10/18

@iln +eed: 3%t/h FR/CL02-.G De"arbonation Degree: 80E89K 0.EJulE4%%3 0$:9% E 03:09

( , 4 O, ? CO 663

AFPC 1nletG .8-E-9% -09E-4-PC e=it

(o indi"ation 0%%%%

BFPC ConeG .3%E-%% ..8E-99 .84E-46 02$E42% 69%%E349%

CFPC iddleG -.4E--9 -4%E-4- -%0E-99 C4 C"lone e=it 02.E424 643$E6-03

DFPC U;sideG -$8E-94 -0-E-40 -9$E-3- The DrE"rusher e=it .28E-20 4-4$E6%%$

PC e=it --0E8%9 The 1D !an inlet 829E823 09-.E4-6%

C4 C"lone e=it

@iln +eed: 39E.%t/h FR/CL02-.G 0-EJulE4%%3 0%:$% E 04:%%

( , 4 O, ? CO 663

AFPC 1nletG -3.E-.% 80-E86%PC e=it

(o indi"ation 0%%%%

BFPC ConeG .8%E-%3 -%-E-0- -06E-0. %2-E024 4.9E04.%

CFPC iddleG -69E-$3 -0.E-4% -.-E--0 C4 C"lone e=it %29E%28 449.E90.0

DFPC U;sideG -69 -.9E--3 -8$ The DrE"rusher e=it .20E.24 $%04E$304

PC e=it -39E-.4 The 1D !an inlet -2$E-29 $--4E9..0

C4 C"lone e=it -30E8%$

@iln +eed: .9E-%t/h FR/CL02-.G 4%EJulE4%%3 8:6% E 0%:$%

( , 4 O, ? CO 663

AFPC 1nletG 8$8 8%$ @iln inlet %26E%2$ 94%%E.-%%

BFPC ConeG -80 -66 .8. PC e=it 029E624 44%6E4%0$

CFPC iddleG -64 -$6 -$8 C4 C"lone e=it 42-E$24 4346E0-84

DFPC U;sideG -6- 863 --3 The DrE"rusher e=it -2.E824 4--E484

PC e=it 86- The 1D !an inlet 820E826 4969E46.-

C4 C"lone e=it -68

Ta"le (: Precalciner an! 6re*eater 3easre3ent !ata in QJian 6lant ,--.-)

4141, S73e interrelate! calclati7ns an! analysis

Precalciner 87l3e 34:

#uJiang ;re"al"iner 7olume is 4-3m6> and larger Pre"al"iner Molume "an ;ro7ide a su!!i"ient

"a;a"it !or 5iln> #JP ?6 5iln sie is 6299$m> 5iln 7olumeF$%.m6G is big enough !or 0%%%t/d

out;ut "a;a"it2

Gas vel7city in Precalciner 3/s:

The gas 7elo"it in;re"al"iner is 9m/s> and lo 7elo"it in main se"tion F $ m/sG "an in"rease

!uel residen"e time in the Pre"al"iner2

PC t;e @SM (S+ +C +)S SC C DED @HD

W Fm/sG 9- $293 $9 929329 0% -04 .0% 0-4%

Ta"le ,: T*e !i;;erent !esin 7; calciner as vel7city

Resi!ence ti3es:

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11/18

The gas residen"e time in "al"iner is 623 s2 And ea"h o! the ;re"al"iner t;e sho a 7er iderang o! residen"e times> but the longer residen"e times is better !or burnout and heate="hange> and a7oid "arring e="essi7e heat to the u;;er stages o! the PH> normall> an

additional one se"ond residen"e time ill redu"e heat "onsum;tion b 095"al/5g2(ormal gas residen"e time 42% se" Fneeds to be $29 se" to allo !or (= redu"tionG V alloburnout o! C2

0a;are Precalciners Resi!ence ti3es:

%ire 4: Gas resi!ence ti3e in 6recalciner in 0a;are area

rom the Precalciner Study Technical Aenda!

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12/18

Precalciner *eat l7a!in cal/341*:

#uJiang ;re"al"iner heat loading is -65"al/m6h2

(ormall> the higher the "lin5er ;rodu"tion the higher the Ouantit o! !uel> and the higherPre"al"iner heat loading2 Presentl the trend is toards heat loading o! 9%.%"al/m6h2

0a;are 6lant Precalciner *eat l7a!in:

%ire : Precalciner *eat l7a!in !ata in 0a;are area

Precalciner 07a!in t/34!:

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13/18

#uJiang ;re"al"iner material loading is 6t/m6d2 There is still room in #JP ;re"al"iner to

in"rease ;rodu"tion b around 6%K Fto bring to $t/m6dG :

Su;;lier PC t;e PC )oadingFt/m6dG

Comments

Polsius Pre;ol $ V 3

+)S1nline $ V $29

Se;arate )ine . V .26 PC "ombustion in TA onl

+uller $29 V 3

1H1 (S+ 32% V .29

@HDPro"lon 629 V $

ProTo; 429 Able to o;erate 3%% mg/(m6 (=

A)) @ilns 929

Ta"le 4: Di;;erent ty6e 6recalciner l7a!in

0a;are 6lant Precalciner l7a!in t/34!:

%ire B: Di;;erent 6recalciner l7a!in in 0a;are area

And e got #uJiang ;re"al"iner measurement and "al"ulation li5e this:

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14/18

Table $: #uJiang PC measurement and "al"ulation 4%%3%.

41414 8isal ins6ecti7n 7; 6recalciner:

We ins;e"ted the interior o! Pre"al"iner on the same le7el Fmeasurement ;oint CG throughins;e"tion holes> ;oint C0 as 7er dar5 at the same time ;oint C4 !lame as 7er bright2 ans;ar5les ere !ound inside the Pre"al"iner e7en though at the outlet ;oint D> This im;lies thePre"al"iner "ombustion "ondition is ;oor> burnout rate is lo2

P*7t7 : Precalciner internal c73"sti7n c7n!iti7n in QJian ,--.-)

4141 Precalciner Evalati7n A""ording to the Pre"al"iner measurement and gas analsis> e "an get some "on"lusion li5e

this:

1tems Target/(ormal '=isting status '7aluation

&as 7elo"it in PC $290%m/s 9m/s @

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15/18

929329m/s +)S

Residen"e time 629s 623s @

PC heat loading 9%.%"al/m6

h -6 "al/m6

h A bit highPC loading 429.29t/m6d 6t/m6d @

De"arbonation degree 8489K 8089K @

PC tem;erature ;ro!ileUni!orm andreasonable2

PC u;;er is higher thanmiddle and bottoma=27ariations 8-℃ beteento ;oints at same le7el2

Bad

PC e=it gas tem;erature Stable I9℃ 4$℃ a=2 Bad

C PC e=it gas＜9%%;;m

(ormal 4%0$349%;;mSeldom＜9%%;;m

Mer bad

4 PC e=it gas 46Kithout C %2-624K BadTem;erature 1n main se"tion

StableUnstable a=2 7ariations

$9℃Bad

Burn out rate b 7isualins;e"tion

(o s;ar5le atoutlet

an s;ar5les as !oundin di!!erent se"tion

Bad

Stable !uel s;litting PC 9%K Around 3%K @

Unburned "arbon hot meal ＜%24K (o testing

Ta"le B: T*e c736aris7n "et@een QJian 6recalciner an! taret ,--.-)

A;ter t*e 3easre3ents' it @as ;7n! t*at t*e c73"sti7n is n7t 6r76er in t*e t7tal 6yr7

syste31T*e real Calciner 6er;7r3ance c7l! n7t "e evalate! 3ainly "ecase 7; t*e


16/18

%ire .: T*e ;alse air 6r7;ile in 6yr76r7cessin syste3

41B %an E;;iciency

This mission !an e!!i"ien" audit has "o7ered ?6 @iln 1D +an> 'SP +an ?0 'SP +an2 We didnNt"om;lete the ?6 5iln "ooler 1D +an audit be"ause o! the la"5 o! ;oer !a"tor2 The details o! the+ansN e!!i"ien" audit are ;la"ed in a;;endi"es2

The total Poer sa7ings are "al"ulated to be - V 8 @h/t o! "lin5er2 FAssumed that @iln 1D +an'!!i"ien" is ta5en as $%K and not 0.KGPlant to "onta"t ith !an e=;erts to in"rease !an e!!i"ien"2

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17/18

Rec733en!ati7ns

Acti7n (: Pr76er ste6 7r la!!er ;7r t*e 3easre3ent 67ints s*7l! "e installe! s73e

*an!rails 3st "e installe! als71

,: Alar3 3ars s*7l! "e ;i2e! 7n t*e Pre*eater c7ncrete "ea3s 7ver*ea! t*e

accesses1

4: Gan@ays 7n t*e sca;;7l!in 76ti7nally 3st "e carrie! a@ay t7 ee6 ;r73

;allin !7@n1

O"9ective: Sa!et

$ay t7 i36le3ent: 1nstall handrails> ste; and ladder2 Carr aa gangas and s"a!!olding2Re;erence !7c3ents: Sa!et guideline2

Plant 7r U res67nsi"le: Plant2

E26ecte! reslt: De"rease )T12

Acti7n : Install t*er37c76les at Precalciner "7tt73' 3i!!le' 66er an! iln inlet1

Cr7ss+c*ec Pre*eater 3an73eters an! t*er37c76les relar t7 ac*ieve

37re ni;7r3 c73"sti7n an! !ecar"7natati7n1

O"9ective: ;timie ;reheater and ;re"al"iner "ombustion

$ay t7 i36le3ent: To bu and install thermo"ou;les at ;ro;er ;osition2 ATC "an ad7i"e2

Re;erence !7c3ents: Combustion o;timiation2


E26ecte! reslt: 1n"rease out;ut and de"rease heat "onsum;tion2

Acti7n B: I36r7ve vac3 ;ilter 6er;7r3ance t7 re!ce t*e ;ee! 3aterial =antity an!

=ality !eviati7n1

O"9ective: Stabilie all ;ro;ro"essing sstem2

$ay t7 i36le3ent: Tr to !ind high Oualit !ilter "loth and im;ro7e 7a"uum eOui;ment2


Plant 7r U res67nsi"le: Plant> BU and ATC2

E26ecte! reslt: 1m;ro7e ;ro;ro"essing sstem stabilit and in"rease "a;a"it2

Acti7n .: 57!i;y c7al trans67rt 6i6e t7 !ecrease t*e 67ssi"ility 7; c7al ;ee! ;lctati7n

O"9ective: De"rease the !lu"tuation o! "oal !eed to "al"iner

$ay t7 i36le3ent: odi! in"line "oal trans;ort ;i;e to horiontal or 7erti"al ;i;e22

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18/18



E26ecte! reslt: 1m;ro7e ;ro;ro"essing sstem stabilit2

Acti7n : I36r7ve !ryin crs*er air sealin an! @el! 7r c*ane !ct t7 re!ce ;alse

air

O"9ective: De"rease !alse air

$ay t7 i36le3ent: Weld and "hange orn out du"t2 1m;ro7e air sealing at dring "rusher2

Re;erence !7c3ents: #W2


E26ecte! reslt: De"rease ;oer "onsum;tion 4@Wh/5g"li2

Acti7n : Try t7 c7ntr7l r2 Zhang e;ing> the ;ro"ess engineer> r2+ang =iongi> the ele"tri"al engineer> rs2> Zhou =iaorong> the Oualit anager !or their e!!ortsto ma5e this mission a Su""ess!ul2

. A66en!ices

Pitot data o"

#u$ian %&&'&(

Fan e""iciency

caiculation #u$ia

#u$ian P)

calculation

025_tsp qjp400generalzwd_hzf_wxw 0807 preca study

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