bereichskennung oder produktname process instrumentation and analytics januar, 2003 folie 1 a&d...
Post on 17-Dec-2015
221 Views
Preview:
TRANSCRIPT
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 1 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process Analytics
Solutions for the Cement IndustryApplications
FLK sampling system
Kiln inlet
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 2 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process Analytics
Applications of gas analysis systems in Cement PlantsApplications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 3 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process Analytics
Gas analyzer equipment in cement works must be able to withstand a very tough environment:
high gas temperature up to 1400 C
high dust concentration up to 2000 g/m3
high content of Alkalis, Sulfates and Chlorides
in addition, high level of mechanical stress and strain
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 4 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
Conventional gas sampling systems with water cooling have a number of serious weak points:
they block up easily because of the condensation thatforms due to the low operating temperature
lime deposits and corrosion with water as coolant
caking of material on the probe causes excessivemechanical stress
High cost for maintenance and low reliability
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 5 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process Analytics
The problems with the gas analysis in cement rotary kilns can be minimized or eliminated by using our patented gas sampling system
The Problem and our Solution
Formation of condensation
The operating temperature of 200 C at which our probe operates is above the dew point of the flue-gas and the acid.
Lime deposits and corrosion with water as coolant
Using a special synthetic liquid as coolant prevents lime deposits and corrosion
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 6 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process Analytics
Caking of material on the probe
Minor deposits are removed during regular automatic retraction and cleaning with compressed air.
High maintenance costs
Thanks to the high operating temperature and the effective method of cleaning our system can achieve periods of maintenance free operation up to three months
The Problem and our Solution
The problems with the gas analysis in cement rotary kilns can be minimized or eliminated by using our patented gas sampling systemApplications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 7 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process AnalyticsFLK Gas Sampling System
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 8 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process AnalyticsGas Sampling probe
for gas temperatures up to 1400 C
gas sample temperature up to 200 C lateral intake chamber to reduce entry of dust
self-cleaning of dust deposits during retraction and insertion
variable probe length to meet the customer requirements
high mechanical stability due to oval design
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 9 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process AnalyticsAutomatic Retraction unit
in case of faults the probe is retracted automatically from the kiln
redundant motorized retraction due to electrical and pneumatic motor
heavy duty and maintenance free mechanical design
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 10 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process AnalyticsDedusting Filter
electrically heated operation
operating temperature controlledby thermostat
maintenance free sinter metal filter
preheating of compressed air
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 11 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process AnalyticsPurge unit
automatical cleaning of gas paths
adjustable cleaning cycles
minimum pressure recognition
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 12 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process AnalyticsHeat exchanger
synthetic coolant high boiling point environmentally friendly
closed coolant circulation, pressure free operation
monitoring of temperature, flow and level
operating temperature adjustabel (130C – 220 C)
fast and easy installation and commissioning
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 13 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process AnalyticsHeat exchanger
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 14 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process AnalyticsControl- and monitoring unit
Compact cabinet with SIMATIC S7-300 or Allen Bradley SLC500 central power distribution
Function controlling of purge cycles
and gas sampling monitoring of temperature, flow and level automatical probe retraction in case of faults
easy to change parameter settings without programming expertise
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 15 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process AnalyticsGasflow and cooling circuit
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 16 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
Process AnalyticsGas treatment and Analysis
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 17 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
Up to 3 IR absorbable gas components plus oxygen
Easy-to-use menu driven operation
AUTOCAL with ambient air
Up to 8 gas components in one analyser cabinet with theMulti-Component gas analyser ULTRAMAT23
Gas treatment and Analysis Process Analytics
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 18 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 19 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 20 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 21 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 22 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 23 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 24 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 25 A&D PI2 SE1
Siemens Process Analytics in the Cement Industry
FLK Gas sampling system Process Analytics
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 26 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
FLK Gas sampling system
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 27 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
FLK Gas sampling system
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 28 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
FLK Gas sampling system
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 29 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
FLK Gas sampling system / Benefits
Synthetic heat transfer liquid instead of water
Gas sample temperature up to 200 C no condensation-build up in the sampling probe
no lime deposits and corrosion
no freeze over of the coolant
high availability and less maintenance compared with water cooled
systems Short commissioning time
the system comprise just 6 components
components ready to connect
typical commissiong time: 3 to 5 days
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 30 A&D PI2 SE1
Economic performance analysis of typical Customer benefits
Optimized burning process
1% excess of Oxygen means: 10 kcal of extra energy consumption per kilo of clinker
In the case of a kiln with a capacity of 3000 tons/dayoperating 300 days a year, this means:
9.000.000.000 kcal of extra energy consumption perannum
or
1.097.560 kg of extra coal consumption assuming an energy content of 8200 kcal per kilo of coal
Process Analytics
Siemens Process Analytics in the Cement Industry
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 31 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
Economic performance analysis of typical Customer benefits
Optimized burning process
With a coal price of $ 45 per ton this means:
1.097,560 tons of extra coal x $ 45 = $ 49.365 higher energy costs
This saving means that the payback period on the investment in FLK GAS is less than 2 years
And remember too that this does not even take into account the savings that can be made on maintenance compared with water-cooled systems
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
Bereichskennung
oder Produktname
Process Instrumentation and Analytics
Januar, 2003 Folie 32 A&D PI2 SE1
Process Analytics
Siemens Process Analytics in the Cement Industry
Economic performance analysis of typical Customer benefits
Optimized burning process
0102030405060708090
100
0 3 6 9 12 15 18 21 24
Months
USD
Investment Saving
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
top related