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More than 50 years of expertise. Reducing emissions by monitoring the gas composition at the kiln inlet = Saving Money.

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Presentation on theme: "More than 50 years of expertise. Reducing emissions by monitoring the gas composition at the kiln inlet = Saving Money."— Presentation transcript:

1 More than 50 years of expertise

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

3 INTERNATIONAL NETWORK ITECA SOCADEI SAS 445 Rue Denis Papin Europôle de lArbois CS Aix en Provence Cedex 3 FRANCE + 33 (0) (0) Europe - North, Central & South America - Asia - Middle East - Africa Aix en Provence Paris

4 ITECA SOCADEI - TODAY 3 DIVISIONS

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

6 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. Kiln Inlet Gas Sampling & Analysis: WHY?

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

8 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

9 Traditional technology : basic principle Gas Sampling and Analysis 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 Filter

10 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

11 Case study 1– Reliability Continuous operation for 20 consecutive days 4300 TPD Line with 63% alternative fuels

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

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

14 ITECAs system: principle Wet sampling Closed circuit double cooling system Analysis Cell CO, O 2, NO x, CH 4 Gas conditioning Dryer Gas analysis Gas Sampling and Analysis

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

16 Efficient probe cleaning system 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) Cooled jacket Cooled probe Cooled jacket Gas Sampling and Analysis

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

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

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

20 Sampling Probe Automatic Extraction Gas Sampling and Analysis

21 ITECAs Sampling Probe Automatic Extraction Safe and Reliable Gas Sampling and Analysis

22 ITECAs Sampling Probe Automatic Extraction Safe and Reliable

23 Close loop cooling circuit Gas Sampling and Analysis

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

25 Water / gas separation circuit Water / gas separator : most of the water is removed here Cyclone separator : any remaining water as liquid is removed here Water + Gas Water Gas The gas is then dried in the gas dryer by reducing its temperature to 3°C

26 Dust filter Gas flow regulators - One for each analyser (70 l/h /analyser) + evacuation Command and display Paramagnetic oxygen analyser Infrared analyser : CO, NO, CO 2 Gas dryer Gas Analysis Gas Sampling and Analysis

27 Working temperature : max 1400 °C Working dust concentration : up to 2 kg/m 3 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 Performances - Advantages Gas Sampling and Analysis

28 Case study 2 – cement plant Gas Sampling and Analysis 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 Case study – cement plant Gas Sampling and Analysis Traditional OXYGEN READING ITECA Air purges

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

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

32 Case study – cement plant Gas Sampling and Analysis CONCLUSION

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