The Cement Experience More than 50 years of expertise

Reducing emissions by monitoring the gas composition at the kiln inlet = Saving Money

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ITECA SOCADEI - TODAY 3 DIVISIONS CEMENT - Analysers for on line process control - Centralised laboratories - Production equipments (kiln seals…) Colour On line analysis INSTRUMENTATION Dedicated to the solid bulk industry (food, calcium carbonate, sugar, cement…)

CEMENT DIVISION Process optimization ON LINE CONTROLS PRODUCTS RANGE Quality Sustainability Process optimization Process optimization ON LINE CONTROLS Quality control  CENTRALIZED LABORATORIES SUSTAINABILITY ENERGY SAVING  PRODUCTION EQUIPMENTS

Kiln Inlet Gas Sampling & Analysis: WHY? O2 CO The most important gases to be monitored for kiln control are: Oxygen : too low fuel may not be burning correctly  wasting energy. too high  possible to increase fuel input and raw material input and therefore possible to increase production CO : This gas is created in the flame, when the flame is not burning correctly Dangerous, toxic loss of energy (incomplete combustion) NOx : This gas is also created in the flame. Flame Surface T°  NOx creation . NOx = indicator of the temperature of the clinkering zone in the kiln = indicator of the end quality of the clinker that is manufactured.   All these gases can be measured using our sampling system, and the measurement of these gases already provides a great deal of valuable information on the operation of the kiln. NOx

Gas Sampling and Analysis Different sampling locations Precalciner Gas sampling Kiln Cooler Output Analyser Our experience: all cement plants are facing the same trouble  Clogging of the sampling probe in the Fume Box

Gas Sampling and Analysis an efficient kiln back end gas sampling Requirements for an efficient kiln back end gas sampling Low Maintenance - High availability Withstand high dust concentration without blockage Withstand high temperatures Quick response time : high gas flow rate Sturdy construction to withstand build-up fall

Gas Sampling and Analysis Traditional technology : basic principle Filter Gas is sampled and then filtered through a ceramic/metal/glass filter The gas sampling is stopped and the filter and the probe are cleaned using compressed air

Gas Sampling and Analysis Traditional technology : limitations Clogging problems (probe and filter): high maintenance Sample contamination due to purge air : low availability High maintenance on the membrane pump Low gas flow rate (max 120 l/h) : slow response time Bending due to blocks falling from the tower

Gas Sampling and Analysis 4300 TPD Line with 63% alternative fuels Case study 1– Reliability Continuous operation for 20 consecutive days 4300 TPD Line with 63% alternative fuels   

Gas Sampling and Analysis Tower O2 no change Iteca O2 Drop CO Rise

Gas Sampling and Analysis Tower O2 no change Iteca O2 Drop CO Rise

Gas Sampling and Analysis Closed circuit double cooling system ITECA’s system: principle Wet sampling Analysis Cell CO, O2, NOx, CH4 Closed circuit double cooling system Dryer Gas analysis Gas conditioning

Gas Sampling and Analysis No ceramic filter to clean or to replace ITECA’s Wet sampling probe Cooled jacket Cooled probe GAS Water spray 3 bars-30 l/h The sampled gas passes through the water spray, dust is trapped outside the probe before entering the line No ceramic filter to clean or to replace

Gas Sampling and Analysis Efficient probe cleaning system Cooled jacket Cooled probe Every 10-20 min (adjustable), high pressure water (8 bars) is sent through the sampling line to clean the probe High pressure water pulses (4 to 5 l) Efficient cleaning + No sample contamination from air purge

Gas Sampling and Analysis Sturdy sampling probe Resistance to accidental fall of blocks Connections to suction gas pump and water Sampling end Jacket Ø 168 mm Sampling line Ø 34 mm Weight (without water): 150 to 200 kg (depends on probe’s length) Double cooling system: jacket + sampling line

Gas Sampling and Analysis Sampling Probe installation Avoid inlet seal false air influence The probe is installed so that its tip is at least 500 mm beyond the inlet seal

Gas Sampling and Analysis Sampling Probe 3D design to check the feasibility and find optimum probe location

Gas Sampling and Analysis High torque extraction Sampling Probe Automatic Extraction High torque extraction Secured system for the extraction of the probe in case of any problem on the power supply or the cooling circuit Prevention system on a regular basis used to remove the coating around the probe

Gas Sampling and Analysis ITECA’s Sampling Probe Automatic Extraction Safe and Reliable HIGH TORQUE EXTRACTION Secured system for the extraction of the probe in case of any problem on the power supply or the cooling circuit Prevention system on a regular basis used to remove the coating around the probe

Gas Sampling and Analysis ITECA’s Sampling Probe Automatic Extraction Safe and Reliable

Gas Sampling and Analysis Close loop cooling circuit Oversized capacity closed cooling circuit (water T° < 65°C) + High cooling water flow rate : 2 500 l/h  Sampling probe really protected No hot fluid No high pressure  Persons really protected

Gas Sampling and Analysis Gas Conditioning and Analysis Electrical control Gas Analysis Gas Conditioning

Gas Sampling and Analysis Cyclone separator : any remaining water as liquid is removed here The gas is then dried in the gas dryer by reducing its temperature to 3°C Water / gas separation circuit Water + Gas Water / gas separator : most of the water is removed here Water Gas Liquid ring pump Gas suction : 1800 litres/hour

Gas Sampling and Analysis Gas Analysis Command and display Gas flow regulators - One for each analyser (70 l/h /analyser) + evacuation Infrared analyser : CO, NO, CO2 Paramagnetic oxygen analyser Gas dryer Dust filter

Gas Sampling and Analysis Performances - Advantages Working temperature : max 1400 °C Working dust concentration : up to 2 kg/m3 Gas sampling flow rate : 1800 litres/hour Response time (sampling and conditioning): 5 to 10 s No sample contamination from air purge No wear parts on the liquid ring pump Heavy duty probe able to withstand build-up fall

Gas Sampling and Analysis Case study 2 – cement plant Pre-calciner kiln Kiln capacity 4200 tpd Partial fuel substitution with pet coke The Iteca system was installed in parallel with an existing traditional probe Tests were conducted over an 8 month period

Gas Sampling and Analysis Case study – cement plant Air purges OXYGEN READING Traditional ITECA

Gas Sampling and Analysis Case study – cement plant ITECA GAS READING NOx O2 CO

Gas Sampling and Analysis Case study – cement plant CO READING ITECA TRADITIONAL

Gas Sampling and Analysis Case study – cement plant CONCLUSION The reliability factor achieved was greater than 95% over an 8 month period The gas sampling provided accurate and reliable data for O2, CO and NOx The plant decided to purchase 2 more gas sampling systems from ITECA Reduction of emissions, reducing consumption while increasing production: BENEFITS ON BOTH SUSTAINABILITY and PROFITS

More info? Some question? www.iteca.fr bernard.seemann@iteca.fr