1. The Cement Experience
More than 50 years of expertise

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

3. Many references Worldwide
INTERNATIONAL NETWORK
ITECA SOCADEI SAS 445 Rue Denis Papin
Europôle de l’Arbois
CS 30478
13592 Aix en Provence Cedex 3
FRANCE
   (0)     + 33 (0)
Europe - North, Central & South America - Asia - Middle East - Africa
Aix en Provence
Paris
Many references Worldwide

4. 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…)

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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
  

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

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

14. 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

15. 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

16. Gas Sampling and Analysis
Efficient probe cleaning system
Cooled jacket
Cooled probe
Every 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

17. 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

18. 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

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

20. 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

21. 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

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

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

24. Gas Sampling and Analysis
Gas Conditioning and Analysis
Electrical control
Gas Analysis
Gas
Conditioning

25. 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

26. 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

27. 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

28. 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

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

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

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

32. 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

33. More info?
Some question?