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INTERNATIONAL NETWORK
ITECA SOCADEI SASBâtiment B3Rue Denis PapinLotissement du TourillonCS 3047813592 Aix en Provence Cedex 3FRANCE( + 33 (0)4 42 97 77 002 + 33 (0)4 42 97 77 33, [email protected], www.iteca.fr
Europe - North, Central & South America - Asia -Middle East - Africa
Aix en Provence
Paris
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THREE DIVISIONS 1. On line colour analysis 2. Instrumentation (level detection, loading
trolleys, operating control…) dedicated to the solid bulk industry
(food, calcium carbonate, sugar, cement…)
3. Cement division:• - Analysers for on line process control• - Centralised laboratories• - Production equipments (kiln seals…)
ITECA SOCADEI - TODAY
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PRODUCT RANGE
On line Process Control
Centralised Laboratory
Production Equipment
CEMENT DIVISION
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On line Process Control
Free Lime Particle SizeComposition
Ignition LossAl - Fe - Ca - Si - S - P - K
CO2 - SO3
5/h2/h7/h 4/h Continuous
RAW MIX HOT MEAL CLINKER CEMENT
Crusher
Preblending
Additives
Raw Mill
Blending Silos
Precalciner
Kiln Cooler
Additives
CementMill
ClinkerSilo
Cement Silo
Quarry
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Grinding media sorting machine
Inlet Seal Outlet SealGas sampling &analysis
Production Equipment
RAW MIX HOT MEAL CLINKER CEMENT
Crusher
Preblending
Additives
Raw Mill
Blending Silos
Precalciner
Kiln Cooler
Additives
CementMill
ClinkerSilo
Cement Silo
Quarry
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"NEAR ZERO LEAK" KILN SEALS USING GRAPHITE BLOCK TECHNOLOGY
Kiln Seals
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Inlet Seal
Inefficient Seals=
Energy & production capacity losses
Cold outside air
Hot gases are replaced by
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Outlet Seal
Hot secondary air is replaced by
Cold outside air
Inefficient Seals=
Energy & production capacity losses
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LAMELLAR SEALThe metal plates are either burnt, worn out or loose their elasticity
Inefficient Seals=
Energy & production capacity losses
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Inefficient Seals=
Energy & production capacity losses
DOUBLE LAMELLAR SEAL – INLET AND OUTLETEXAMPLE : 6 MONTHS AFTER INSTALLATION
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Inefficient Seals=
Energy & production capacity losses
DOUBLE LAMELLAR OUTLET SEAL
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Inefficient Seals=
Energy & production capacity losses
DOUBLE LAMELLAR OUTLET SEAL
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REVERSE LAMELLAR SEALThe metal plates are either bent out of shape, burnt or loose their
elasticity
Inefficient Seals=
Energy & production capacity losses
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FLOATING RING +PNEUMATIC PISTON TYPE SEAL
The piston rings wear out quickly
The floating ring is not maintained in contact with the kiln.
The floating ring is deformed and no longer touches on all points of
the circumference of the kiln
Inefficient Seals=
Energy & production capacity losses
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Inefficient Seals=
Energy & production capacity losses
PISTON OUTLET SEAL - THE FLOATING RING DOES NOT FOLLOW THE MOVEMENT OF THE KILN
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Inefficient Seals=
Energy & production capacity losses
PISTON INLET SEAL - THE FLOATING RING IS BENT
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Inefficient Seals=
Energy & production capacity losses
PISTON INLET SEAL - SEVERE LEAKAGE
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Inefficient Seals=
Energy & production capacity losses
SPRING LOADED PLATE TYPE SEAL
The springs loose their elasticity due to the high temperature
The plates are not maintained in contact with the kiln.
It is not possible to retighten the springs when the kiln is in
operation
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Inefficient Seals=
Energy & production capacity losses
SPRING LOADED PLATE SEAL - THE PLATES ARE NO LONGER ALL IN CONTACT
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Inlet seal : 4 meters diameter Kiln back end temperature: 1000°C Cost of energy : 0.01 US$/1000 KCal
Inefficient Seals=
Energy & production capacity losses
0
50 000
100 000
150 000
200 000
250 000
300 000
20 25 30 35 40 45
Savi
ngs
in U
S$ /
year
Kiln back end pressure in mmH2O
10 mm gap8 mm gap6 mm gap4 mm gap
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Outlet seal : 4 meters diameter Secondary air temperature: 900°C Cost of energy : 0.01 US$/1000 KCal
Inefficient Seals=
Energy & production capacity losses
0
50 000
100 000
150 000
200 000
250 000
2 4 6 8 10 12
Savi
ngs
in U
S$ /
year
Hood pressure in mmH2O
20 mm gap15 mm gap10 mm gap5 mm gap
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Inefficient Seals=
Energy & production capacity losses
How to calculate the energy losses
Air flow = leak surface x air speed m³/s m² m/s Calculate the false air entries :
| ∆P| . 2 . g Air speed = v = —————— 2,5 . 1,3
1/2
Where air speed is a function of the pressure :
Energy savings = 1,3 x air flow x (1000 - 30) x 0,32 Kcal/s air density Kg/m³ m³/s °C Air specific heat Kcal/Kg.°C
Then calculate the energy savings according to the following formula (replace 1000°C and 30°C with the plant specific appropriate values) :
Cost of coal = 1 370 000 Dong/TonCalorific value = 6500 Kcal/KGCalorific cost : 1000 Kcal = 211 DongOr: 1 000 Kcal = 0,0087 €
And then calculate the monetary value of the energy savings using the cost of fuel including preparation cost (handling and grinding) :
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• Provide effective leak tightness around the inlet chamber (or kiln discharge hood) to prevent cold air entry or release of hot gas.
• Improve pressure stability in the kiln
• Allow installations on existing kilns without modifying the kiln shell and the inlet chamber (or discharge hood)
• Limit maintenance to a minimum
• Improve cooling of the Nose Ring refractory plates.
KILN SEALDESIGN OBJECTIVES
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OUTLET SEALDESIGN FEATURES
Kiln
GraphiteBlocks
Graphite Blocks are installed to form a static barrier between the discharge hood and a circular sliding track
rotating with the kiln
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The blocks are maintained in placeusing cables and counterweights
OUTLET SEALDESIGN FEATURES
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OUTLET SEAL
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Expected lifetime for the graphite blocks: from 4 to 7 years
Yearly wear: around 3 to 5 mmMaximum allowed wear: 150mm
Graphite = auto lubricating material maintenance reduced to a
minimum
OUTLET SEALDESIGN FEATURES
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When required a counter pressure is createdto prevent hot kiln gases from damaging the
graphite blocks
Fan and valve assembly
OUTLET SEALDESIGN FEATURES
Graphite plateCable
T° probe
Graphite cooling system (fan + butterfly valve)
Nose ring plates cooling system
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Clinker dust is collected in a hopperand returned to the drag chain
OUTLET SEALDESIGN FEATURES
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As an option it is possible to install
a new nose ring segment cooling
system with multiple nozzles
OUTLET SEALDESIGN FEATURES
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GRAPHITE BLOCKS
• Graphite plates arranged symmetrically & interlocked leak tightness enhanced
• Grooved metal insert at the top of each plate friction wear from the cables prevented
• Natural friction wear of the graphite constant efficiency of the leak tightness
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Kiln
Graphite Block
Kiln inlet
Cooling ductSliding track
Shell
Graphite Blocks are installed to form a static barrier between the inlet chamber and a circular sliding track
rotating with the kiln
INLET SEALDESIGN FEATURES
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Graphite blocks are air cooled Excess dust is evacuated through a hopper
INLET SEALDESIGN FEATURES
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INLET SEAL AT NIGHT
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INSTALLATION SCHEDULE
1 2 3 4 5 6 7 8 9 10
Check ovality shape and eccentricityFit bearing race supportFit bearing raceAdjustments, weld and checkFit bearing race links, weldFit leak tight casingConnection to the fume boxFit casing, adjustments, weldFit graphite plates cooling systemFit graphite plates, cables and counterweights,
TrialsKiln required to turn using the "inching motor"
TOTAL INSTALLATION TIME : 10 DAYS
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KILN SEAL
REFERENCES&
TESTIMONIALS
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38
Performance factor :Comparison of some key running parameters before
and after replacement of discharge sealBEFORE AFTER
COOLERTertiary Air Temp 800-850 DegC 900-950 DegC
Exhaust Air Temp 215-280 DegC 185-240 DegC
PREHEATERKiln Feedrate 175-195 tph 190-205 tph
Preheater Fan speed 800-820 rpm 750-810 rpm
Downcomer Temp 380-400 DegC 400-420 DegC
ATOX(Inleaks)
ATOX Feedrate 210 tph 235 tph
Recirculation Damper* 0 to 20% open 30 to 45% open
ESP Fan* 955-970 rpm 950-960 rpm
LAFARGE CAULDON UK
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References
KILN SEALS
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REFERENCE HOLCIM INDIA
KILN SEALS
ITECA HAS NOW INSTALLED 15 SEALS WITH HOLCIM INDIA
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REFERENCES
• ITECA’s seal = Near Zero Leak Performance over the years (installed 2001)• Dust in the casing enters a double flap valve system into the cooler very clean atmosphere. The plant won an award for cleanliness
• Non-emission of clinker dust protection of mechanical components such as bearings, tires etc.
• Auto lubricating graphite blocks no maintenance work on the seal. Only the wire rope is changed during every shut down
• Ability to operate the hood (in case of outlet seal) under low negative pressures without any false air entries
OPERATIONAL EXPERIENCE
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REFERENCE
KILN SEALS
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CONCLUSION
Effective leak tightness = cold air entry prevented significant fuel savings
Effective leak tightness = pressure stability improved production increased
Benefits include:
• Adaptation on all existing types of kilns and easy installation
• Rotational, radial and axial movement absorption
• Absorption of kiln rotating defect
• Absorption of kiln expansion
• Efficient leak tightness resulting in increased lifetime of tyres, bearings… close to the kiln
• Very limited maintenance