2016-09-01 ficem icc (2016-09-06)...kiln riser duct • limited fuel source limited fuel source for...

PM-TECHNOLOGIES

NOVELTY NEW BURNING CHAMBER FOR

MEDIUM COARSE SSW

Gleisdorf, AustriaGleisdorf, AustriaGleisdorf, AustriaGleisdorf, Austria

PM-TECHNOLOGIES

about the companyabout the companyabout the companyabout the company

PM-TECHNOLOGIES

ABOUT THE COMPANY

- R&D for more more than 25 years

- HURRITEC double cyclone technology

(formerly: Hurriclon) since 1990

- innovative products (HURRITEC guide vane, etc)

- new office building incl. pilot-plant since 2003

- located in Austria (Gleisdorf, near to Graz)

Team PM-Technologies

FINEST SOLUTIONS

Several unique, patented technologies plus tailor-made

system solutions for the cement and mineral industry:

YOUR ENGINEERING PARTNER AND SYSTEM SUPPLIER

Josef Keuschnigg, DI

President

EFFECTS AND MEASURES WHEN INCREASING AFR

PM-Technologies - The innovators

ICC, AN UPDRAFT COMBUSTION CHAMBER, DOING IT THEY OTHER WAY

INCREASED GAS FLOW RATES

- Pressure drop reduction of cyclone stages to increase the level of clinker output

- Improved cyclone efficiency and low pressure drop

- Potential for increase in gas throughput of 30% to 40% by keeping the ∆p level

CLINKER QUALITY AND OUTPUT

- Kiln burner and cooler assessment, etc.

(in collaboration with external partners)

OPTIMISED OPERATING CONDITIONS IN LOWER PH AREA

- Reduction of dust re-circulation rate and build-ups

- Efficient chloride extraction via gas bypass system

EFFICIENT HEAT GENERATION AND HEAT TRANSFER

- Good burnout with moderate of needed calciner residence time

- Sufficient calcination at favourable calciner exit oxygen and temperature


ACTUAL STATUS OF CALCINER INSTALLATIONS

• huge residence time huge residence time huge residence time huge residence time in order to reach a good burnout of several different fuel types and to assure acceptable emissions.

• Straight long ducts Straight long ducts Straight long ducts Straight long ducts with one tertiary air intake with high stratification effect O2 and fuel particles are not mixed together

• Sometime meal staging, meal staging, meal staging, meal staging, which must be designed for good ignition of fuels

• Quite rare fuel /tertiary fuel /tertiary fuel /tertiary fuel /tertiary air air air air staging staging staging staging installation which are quite useful to reduce emissions

• huge volumes for high investment costs for high investment costs for high investment costs for high investment costs …

• All are done not for the initial process not for the initial process not for the initial process not for the initial process of calcination which can take place within less than 2sec.



ACTUAL STATUS OF BURNING CHAMBER INSTALLATIONS


• Dimension designs with short residence timeshort residence timeshort residence timeshort residence time and no increased

residence time for fuel particles

• Big mixing issue mixing issue mixing issue mixing issue when connecting the burning chamber with the

kiln riser duct

• Limited fuel source Limited fuel source Limited fuel source Limited fuel source for this design (gas, coal) due to need of short

flame, only small particle only small particle only small particle only small particle size distribution is working well

• meal staging difficultmeal staging difficultmeal staging difficultmeal staging difficult, due to meal is necessary in the camber to

protect the walls

• Add. CO issuesCO issuesCO issuesCO issues observed when particles have bottom duct

impingements

DEVELOPMENT OF A UNIQUE CALCINER TECHNOLGY

REQUEST FOR A CALCINER IN CEMENT INDUSTRY

• Alternative fuel rate: up to 100%

• Having high fuel flexibility in terms of particle size distribution and heat value

• Operation at a low calciner exit oxygen level

• Meeting emission levels (500mg/Nm³ NOx and 500mg/Nm³ CO)

• Maintaining of high calcination rate for a maximum production

• Low investment cost as needed and feasible



CAN WE REACH THIS WITH OUR NEW CONCEPT

We believe YESWe believe YESWe believe YESWe believe YES

>>>>>>>> ensure a high TSR at a low gas residence time only,ensure a high TSR at a low gas residence time only,ensure a high TSR at a low gas residence time only,ensure a high TSR at a low gas residence time only,

>> to enable the firing of coarser AFR fractions so that fuel treatment costs are reduced.>> to enable the firing of coarser AFR fractions so that fuel treatment costs are reduced.>> to enable the firing of coarser AFR fractions so that fuel treatment costs are reduced.>> to enable the firing of coarser AFR fractions so that fuel treatment costs are reduced.

COMBUSTION CHAMBER


MEAL

TERTIARY AIR

FUELS BRAINCHILD

CFD

FLUIDICMODEL

It is our main target to develop the

SCC/ICC so that our customer will

get the best calciner technology!


READY FOR A DETAILED CFD CHECK TO

IMPLEMENT THE SCC/ICC AT A REFERENCE PLANT

Coal Particles

SRF Particles SRF Burnout

In-line Version

First resultsFirst resultsFirst resultsFirst results

Coal 0.7-1.5 s RT >99% burnout

SRF, 4 mm 2 s RT >98% burnout

SRF, 24 mm 12 s RT >97% burnout

IN-LINE COMBUSTION CHAMBER

MI-CFD STUDY @ 100% SRF

100% SRF @ IN-LINE COMBUSTION CHAMBER

UPDARFT COMBUSTION CHAMBER

CFD

FLUIDICMODEL


SRF SPECIFICATION

Staged meal inlets

70% of meal

30% of meal

100% SRF are injected

in the riser below the TA

via 2 SRF inlets

(7.5 m/s gravity feed, 50°)

Temp. Temp. Temp. Temp. °°°°CCCC

SRF

fractions

10x10, 20x20,

30x30, 60x60,

100x100

each fraction split into:

Thinner fractionThinner fractionThinner fractionThinner fraction

0.7mm thickness, 400 kg/m³

Thicker fractionThicker fractionThicker fractionThicker fraction

(2.5mm thickness, 1000 kg/m³

TEMPERATURE PROFILE (880°C exit temperature)

SRF 1

SRF 2

TA spiralTA spiral


CFD

FLUIDICMODEL


O2 PROFILE

Exit Exit Exit Exit OOOO2222: 2.53%: 2.53%: 2.53%: 2.53%

SRF particles are

shown in pink colour.

OOOO2222 %%%%

100% SRF @ IN-LINE COMBUSTION CHAMBER BurnoutBurnoutBurnoutBurnout %%%%

BURNOUT

Thinner SRF fraction burnout: 97%

Thicker SRF fraction burnout: 96%


CFD

FLUIDICMODEL


RESIDENCE TIME, THINNER /THICKER SRF PARTICLES (@ 400 kg/m³ & 1000 kg/dm³ density)


Residence Residence Residence Residence

ttttime (s)ime (s)ime (s)ime (s)

Size Size Size Size 1111

(10x10)


(10x10)


(20x20)


(20x20)


(30x30)


(30x30)

Size 4Size 4Size 4Size 4

(60x60)

Size 4Size 4Size 4Size 4

(60x60)


(100x100)


(100x100)

1.5 s 1.5 s 1.5 s 1.5 s

2.0 s2.0 s2.0 s2.0 s

Average RT Average RT Average RT Average RT

0,7mm 0,7mm 0,7mm 0,7mm

2,5mm2,5mm2,5mm2,5mm

2.5 s2.5 s2.5 s2.5 s

4.0 s4.0 s4.0 s4.0 s

6.0 s6.0 s6.0 s6.0 s

7.0 s7.0 s7.0 s7.0 s

7.5 s7.5 s7.5 s7.5 s

9.0 s9.0 s9.0 s9.0 s

9 .0 s9 .0 s9 .0 s9 .0 s

10.0 s10.0 s10.0 s10.0 s


CFD

FLUIDICMODEL


CALCINATION

Total calcination >95%Total calcination >95%Total calcination >95%Total calcination >95%

Calcination %Calcination %Calcination %Calcination %

Meal particle trajectories

are drawn in and are

coloured according to the

progress in calcination.


70% of meal

Staged

meal inlets

30% of meal


CFD

FLUIDICMODEL


NOx EMISSIONS @ ICC EXIT

648 mg/Nm³ NOx @10% O2

(553 ppm NOx @ 2.53% O2)

Note:

By including a longer sub stoichiometric

re-burn zone before the TA in-take, an

additional potential to reduce NOx should

be useable.


NO (ppm)NO (ppm)NO (ppm)NO (ppm)

1000 ppm1000 ppm1000 ppm1000 ppm

Kiln back end NOxKiln back end NOxKiln back end NOxKiln back end NOx

NOX REDUCTION IN A CALCINER



SuppressingSuppressingSuppressingSuppressing AirAirAirAir----Fuel Fuel Fuel Fuel mixingmixingmixingmixing

Low Nox burners, FGR, etc.

LowerLowerLowerLower potential potential potential potential forforforfor NOxNOxNOxNOx (10(10(10(10----40%)40%)40%)40%)

But potential risk for higher CO

Fuel Fuel Fuel Fuel ReburningReburningReburningReburning////StagingStagingStagingStaging

Creation of CHi and OH radicals with

reduce both NOx and CO

Higher potential Higher potential Higher potential Higher potential forforforfor reducingreducingreducingreducing bothbothbothboth

(10(10(10(10----80%)80%)80%)80%)

SNCR/SCRSNCR/SCRSNCR/SCRSNCR/SCR

Inject of NH3 or NH2CONH2

@ (900-1100°C)

Higher potential Higher potential Higher potential Higher potential forforforfor reducingreducingreducingreducing NOxNOxNOxNOx

(10-80%)

LowerLowerLowerLower potential potential potential potential –––– unoptimisedunoptimisedunoptimisedunoptimised

Higher potential Higher potential Higher potential Higher potential ---- optimisedoptimisedoptimisedoptimised

NOX REDUCTIONWITH SUB-STOCHIOMETRIC REBURN ZONE


Calciner ICC

λ > 1

Calciner sub-

stoch.

λ < 1

Kiln

λ > 1

Creation of a reducing atmosphere Creation of a reducing atmosphere Creation of a reducing atmosphere Creation of a reducing atmosphere means:

• IncreaseIncreaseIncreaseIncrease production of hydrocarbon radicals of hydrocarbon radicals of hydrocarbon radicals of hydrocarbon radicals CHi & OH

• Allow them to react with react with react with react with fuel nitrogenfuel nitrogenfuel nitrogenfuel nitrogen

• AvoidAvoidAvoidAvoid availability of binding partner Obinding partner Obinding partner Obinding partner O2 2 2 2 in a first stepin a first stepin a first stepin a first step

• Remaining fuel, TA and meal intake after reduction process

System depending on fuel compositionfuel compositionfuel compositionfuel composition and volatilesvolatilesvolatilesvolatiles

• high volatiles more availability of radical production

• high volatiles -> high temperatures and risk of add. NOx

• temperature control is needed -> staged meal feeding


High NOx level

Lower NOx level

ICC CALCINER SOLUTIONS

OUR INNOVATIVE APPROACH

Josef Keuschnigg jun.Josef Keuschnigg jun.Josef Keuschnigg jun.Josef Keuschnigg jun.

CALCINER OPTIMIZATION & SOLUTIONS

Our innovative approachOur innovative approachOur innovative approachOur innovative approach

INNOVATIVE CALCINER SOLUTIONS„Combining innovation with the customer’s needs create unique opportunities.”

CONVENTIONAL CALCINERwith customized calciner heart

INNOVATIVE CALCINERwith unique combustion chamber

LOW CAPEX OPTIMIZATIONMI-CFD based optimization




• Combustion zones design criteria Combustion zones design criteria Combustion zones design criteria Combustion zones design criteria as well as the fuel

inputs are dependent on the used fuels (PSD, chemical

composition) as well as on the emission targets and

legislations.

• Hot preHot preHot preHot pre----combustion zonecombustion zonecombustion zonecombustion zone, controlled by lower meal

feed.

• TA Staging at the calciner vesselTA Staging at the calciner vesselTA Staging at the calciner vesselTA Staging at the calciner vessel (1,0 s TA1 to TA2) in

order to take influence on the combustion at the calciner

heart.

• Remaining meal is fed via 2 boxes above the TA1 level.

• Efficient TAEfficient TAEfficient TAEfficient TA mixing is essential to reach high burnout

levels and to avoid stratification.

PM-TECHNOLOGIES’ PHILOSOPHY

“It is our philosophy to put the focus on a customized customized customized customized

calcinercalcinercalcinercalciner heart heart heart heart according to the requirements and targets

as you can not win/compensate that much at the top as

you can win in the lower you can win in the lower you can win in the lower you can win in the lower calcinercalcinercalcinercalciner area!”area!”area!”area!”Bypass take-off(as low as possible)

1St fuel input(AR at the top of orifice)

Sub-stoichiometric

combustion zone

TA Staging

Top Chamber(for mixing & turbulence)

ICC (highest retention time &

burnout)

2nd fuel and meal input

1st meal input

SNCR injection(for further NOx reduction)




Resicendtime

(1-2) Kiln inlet & venturi 0 sec.

(3-4) riser duct 0,5..0,8 sec.

(4-5) ICC burning chamber 0,7 sec.*

(5-8) riser duct after ICC incl. top mixing chamber

1,5 sec.*

(8-9) down comer ducts till bottom stage

1,3 sec.

SUMME of gas retention time 4,0 sec.*

Exp. Fuel residence time 4..>12sec.

* Volumetric calculation

Residence times acc. feasibility study:

2

3

4

5

6

8

9

1



COST COMPARISON„Combining innovation with the customer’s needs create unique opportunities.”

Innovative 4s Standard 7s

Add. Building, foundation and steel structure 300t .. 850k€ 400t .. 1.125.k€

Engineering and quipment delivery

(riser duct, Calciner till bottom stage

150t .. 800k€ 190t .. 1.000k€

Dismanteling & Installation costs 450t .. 1.350k€ 590t .. 1.770.k€

Refractory supply & installation 470t .. 1.175k€ 650t .. 1.465k€.-

Investment sum 4.175k€ 5.360.k€

-22% Investment

• Design criteria's: 100% alternative fuel use

• Fuel particles up to 70x70mm 2D + 20% 3D

• Moisture SSW of fuel up to 30%

• Lowest possible NOx and CO emission levels

• Calcination degree > 95% needed to reach the production of 2500/2700tpd

INNOVATIVE RETROFITTING OF CEMENT KILNS

INNOVATIVECALCINER SOLUTIONS

PROVENMULTI-POINT MEAL FEED

CYCLONE STAGE OPTIMIZATIONS

LOW CAPEX

HOT MEAL BYPASS SYSTEMS

UNIQUE

RE-INNOVATING

PREHEATERS & CALCINERS

““““Combining innovation with the customer’s needs creates unique retrofitting opportunities.” Combining innovation with the customer’s needs creates unique retrofitting opportunities.” Combining innovation with the customer’s needs creates unique retrofitting opportunities.” Combining innovation with the customer’s needs creates unique retrofitting opportunities.”



PM-TECHNOLOGIES

Neugasse 111, A-8200 Gleisdorf

phone: +43 / 3112 / 41990-00

fax: +43 / 3112 / 41990-99

[email protected]

www.pm-technologies.at

The innovators

cyclone stage calciner kiln inlet & chloride bypass staged meal feeds cooler dedusting

YOUR ENGINEERING PARTNER AND SYSTEM SUPPLIER

We are an acknowledged specialist in plant engineering due to our unique and patented technologies and customised solution concepts for

kiln plants, grinding and classifying plants in the cement industry.

dynamic classifier product separationimpact hammer mill

FINEST SOLUTIONS

“Low cost, more efficient plant operation enabled by modifications

optimally matched to demands and plant inventory!”

Thanks for your attention,

2016-09-01 ficem icc (2016-09-06)...kiln riser duct • limited fuel source limited fuel source for...

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