1Gas Analysis Technology- optimization & upgrade

Agenda:Gas Analysis for Optimization & Upgrade

Introduction to gas analysis

Kiln inlet analyzer for optimization

Upgrade of existing kiln inlet analyzer system

Optimization benefits

Upgrades of gasanalysis

At filter

In coal mill department

For emission monitoring

Maintenance and support

By Christian Markussen

Area Sales Manager / Product Specialist

2Gas Analysis where and why?

Where ?

Kiln inlet

Calciner exit

Preheater exit

Coal mill department

Stacks

WHY ?

Process optimization

Safety control

Emission control

Specialised in sample handling

3GASloq system layout

Gas conditioning

Analyzers

System controller

Cabinet or site shelter

4. Coal mill dept.

Optimization and upgrades- requires gas analysis

4Optimization with ECS/ProcessExpert Fundamental data

Temperature

Pressure

Feed rate

Fuel rate

Raw material analysis

Clinker material analysis

Combustible analysis

Gas analysis

Gas analysis for kiln optimization Kiln Inlet or Calciner Exit

Simple - Strong - Reliable

Main focus is easy maintenance

5Kiln inlet reality

The most difficult place to measure

The equipment has been known as Complicated tubing, valves etc.

Weak probes are bending

Time consuming probe are blocking

The measurement is known as Top 3 of Most Wanted signals

Kiln inlet is the best spot for:

Optimized fuel consumption

Optimize quality

Stable and safe kiln operation

Kiln stop prevention

Emission reduction

6 O2 /CO Targets:

Optimized fuel consumption

Optimize quality

Stable and safe kiln operation

Kiln stop prevention

Emission reduction

Safety

The operators are depending on the kiln inlet analyser system in order to fully reach the kiln design capacity at optimum operating conditions

Oxygen analysis is on TOP 3 of any operators Most Wanted signal list

NO Targets: Clinker quality improvement

Burning zone temperature trend

Lower emission

SO2 Targets: Volatile control

Prevent kiln stops

Reduction of material build-ups

Reduction of ring formation in kiln

Reduction of manual kiln clean-out

Reduction of kiln system corrosion

CO analysis combined with O2 is very powerful in evaluating kiln performance

7Selection of correct sample point

The sampling point has to be taken in respect to:

Representative gas

No influence from any false air

Mechanical impact from material fall through

Risk of material build-up

Dust impact

Condensation from volatiles

Practical installation with regard to available platform location and minimized obstacles outside

KilnLoq solution

8 Simple: An Air cannon is one large air receiver, one valve and one pipe

Strong: An Air cannon is very strong and powerful in construction and operation

Reliable: An Air cannon is installed, connected and then forgotten

Air cannon gas analysis

Air cannon

Air receiver Valve Pipe/Nozzle

Air blaster One pipe design

Patented - One Pipe design

The normal filter construction compared to the coaxial One Pipe filter design:

9The Shock Blaster Effect

Process dust Filter

surface cleaning

ONE PIPE cleaning.Works as

efficient as a shock blaster Amplification

chamber

Effectiv probe tip cleaning

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Easy Maintenance

Full admission all the way to probe end by removing

access port

Inspection of probe and maintenance can

be made without dismantling

Access only possible due to the ONE PIPE probe design

KilnLoq probe and extraction device

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Avoid bending of the KilnLoq Probe

Built to last

KilnLoq has many features that prevent the probe from bending

Heavy multi layer steel construction more than 8 times stronger

Automatic periodical extraction of probe to minimize material build-ups

Automatic shock blaster control integrated

Remote or local extraction of probe during kiln clean out

Measurement of heat input to probe from process

Probe position feature minimises insertion length

Using water as cooling

Easy Maintenance

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Upgrade of existing kiln inlet analyzer system

We can assist you

Determine the best measuring point

Evaluating reuse of existing equipment

Integrate existing analyzer units and even fix these

Find the most competitive deal

Performance Status on KilnLoq

In operation since spring 2003

More than 200 KilnLoq systems commissioned

More than 240 systems sold

Highest run factor on the marked in most cases higher than 95%

An average of 60 min weekly preventive maintenance

8 KilnLoq systems in Pakistan

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An reduction of 1% O2 in the kiln = 2% higher clinker production

An reduction of 1% O2 in the kiln = 1% lower fuel consumption

A shortage in oxygen level of 1% in the kiln inlet will cause kiln stops, wear, excessive manual clean-outs

Oxygen analysis is on TOP 3 of any operators Most Wanted signal list

Optimization benefits

Conclusion Kiln inlet

Reduce fuel cost or get higher production

Reduce production stops

Proven technology more than 200 references

Correct and continuous analyser signals

Highest run factor on the marked

Easiest maintenance on the marked

Getting a simple, strong and reliable gas analyser

system

Very short payback time typical less than 200 days

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Upgrades of filter or use of alternative fuels may require new gasanalysis

Filter protection systemSafety & Interlocking

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Low installation costs

plug and play modular design

Easy operation through large HMI colour touch screen

High resistance to contamination and corrosion from the process gas

Focus on design for easy maintenance

GASloq 1200 Low installation costs through simple standard FLS Airloq modular design

High powered probe cleaning by air gives better run factor for the equipment

No moving parts in probe ensures trouble free service and maintenance

Build-in air receiver ensures the highest possible pressure at any time

Probe Cleaning Panel

Filter protection systemCO/CH4 and O2:

True continuous sampling by double probe gives maximum safety

High run factor due to simple layout

DDOP probe

Double Dry nOn cooled Probe (DDOP)

Made of stainless steel Maximum temperature 600C Maximum dust: 200 g/m3 Weather protection

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Equipment for Measuring at Coal Mill Area

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Coal Mill Area

Supervision of coal mill department in silos and dust collectors

Detects impending spontaneous combustion of coal

Operation data for inert coal mill process

Single or Multi Scanning capabilities

Coal Mill Area Analyser Systems

GASloq 1200 multiscan system

Up to 6 silo measuring points

Continuous O2 at filter

ABB, Siemens or Emerson analysers

GASloq 600 single probe system

Used for silo or filter

ABB, Siemens or Emerson analysers

Power

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Upgrade of gas analysis to fulfil emission requirements

Different solutions for measuring gas depending on requirements

CO, CO2, NOx, SO2, TOC, O2 CO, CO2, NO, NO2, SO2, H2O, HCl, HF, NH3

NEO LaserGas Monitor

GASloq system

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Different solutions for measuring dust depending on requirements

Durag D-R 800

Durag D-R 290

Durag D-R 300

Durag D-R 800 Optical Dust Monitor

Forward scattered light reflection

principle

Designed for small and medium dust

concentrations

Easy one-side installation

Easy configuration without need for PC

Integrated purge air unit in the

electronics unit

Automatic function test with soiling

correction

TV 17. BImSchV approved

M-Certs approval pending

BeamSplitter

Shutter

Transmitter Diode

ReceiverDiode

Pane

Purging Air

CleaningFlange

Measuring Light Beam

Reference Light Beam

Fibre Optic

MeasuringVolume

Light Trap Objective

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ReportLoqController

Analyser

Dust

TOC

HF HCL

SO2

NOx

CO

ECS or none-ECS

Measurement PLCReal-time

Monitoring

Control

System

History, Analysis

& Reporting

Emission Monitoring and Reporting

Environmental reporting systems type ReportLoq

Meets local legislation for environmental reporting

Integrated solution with emission monitoring equipment

We cheated a little

you dont really need the wrench

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Easy maintenance

Human Machine Interface (HMI) display

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Human Machine Interface (HMI) display

Used for setup of the system

Used for information on status, failure and warnings

Human Machine Interface (HMI) displaySystem start/stop and manuel probe cleaning

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Human Machine Interface (HMI) displayCalibration

Human Machine Interface (HMI) displayAlarm list

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Human Machine Interface (HMI) displayTrend facilities

Spare partsgas-service@flsmidth.comgas-service@flsmidth.com

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Service Contract

Remote service & trouble shooting by internetNo open ports in Firewall!!

References in Pakistan

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FLSmidth Gas Analysis Technologya Unique Supplier

More than 40 Years of experience in combining process knowledge from the cement and minerals industry with practical solutions of gas analysis

Patented technology offering unique selling proposition to our customers

Focus on simplicity high run factor through ease of maintenance

Specialized gas analysis organization with a huge accumulated experience base

Trouble shooting by experts supported by fast spare part deliveries

The credibility from belong to the FLSmidth One Source Brand

Full Gas Analysis Product Range

EQUIPMENT FOR ALL CEMENT APPLICATIONS:

Kiln Inlet competitive kiln operation

Calciner maximised throughput

Preheater filter protection system

Coal Mill secure supply of combustibles

Stack emission monitoring and reporting

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Thank you for your attention

Friendships are like standing in wet cement -

The longer you stay, the harder it is toleave, and you can never go.withoutleaving your footprints behind !

Any questions ?