schenck - coal dust feeding 08-13

8/10/2019 SCHENCK - Coal Dust Feeding 08-13

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chenckProcessGmbH

2010

CoalDustFeedingSystems

SlideNo1

SchenckProcess

2013

Schenck Process Solutions for Sustainable Cement Production:

Coal Dust Feeding SystemsMULTICELL Rotary Feeder &

MULTICORK Coriolis Mass Flow Meter


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Coal Dust Feeding Systems


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1

The Schenck Process Group

At a Glance, Members of the Group, Global Partner, History, Awards, Test Centre,

Customers Success

2


Competence in Cement Manufacturing, Application Overview, Benefits, Key Elements

3

System Variants

Single Feeding, Multiple Feeding from one Silo into Several Kilns, Feeding of Different

Fuels into one Kiln, Tube Calibrator

4

Success in the Market

A Traditional Schenck Process Application, Number of Systems Sold, Customer Example


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1



Customers Success

2


Competence in Cement Manufacturing, Application Overview, Benefits, Key

Elements

3

System Variants

Single Feeding, Multiple Feeding from one Silo into Several Kilns, Feeding of

Different Fuels into one Kiln, Tube Calibrator

4


A Traditional Schenck Process Application, Number of Systems Sold, Customer

Example


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Cement, Gypsum,

Sand & Gravel,

Steel and NF Metals

industries

Chemicals, Food,

Pharmaceuticals and

Plastics industries

Mining industries Coal-Fired Plants and

associated industries

Transport automation

processes over

road, rail and port

Heavy Light Mining Power Transport Automation

Whether you are planning processing plants, feeding bulk solids, controlling material

flow, recording commodity flow, weighing goods or automating manufacturing and

transportation operationsSchenck Process is your reliable partner.

ABOUT US

AT A GLANCE.

Competence in

Chemicals, Food,

Pharmaceuticals and

Plastics industries

Competence in

Coal, Iron Ore,

Other Minerals and

Aggregates

Competence in

Coal-Fired Plants

and associated

industries

Competence in

Transport

Automation

Processes over

Road, Rail and Port

Competence in

Spare parts,

service and

components

Competence in

Building Materials,

Cement, Gypsum,

Sand & Gravel,

Steel and NF Metals

industries


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We are continually strengthening our international position by constantly expandingour global network of expertise and tapping into new markets in weighing and

process technology. This equips us perfectly for meeting the desires and needs of

our customers at a very high levelthe world over.

SCHENCK PROCESS GROUP

MEMBERS.


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Acting locally to support your needs the Schenck Process Group is working where you are.

Key Figures 2013:

~3,200 employees

Network of 33 Locations with

multiple offices

Over 130 territorial agencies

Over 30 worldwide service

bases offering customer-

focussed support

16 State-of-the-art assembly

facilities worldwide

Revenue ~EUR 600 m

With an unrivalled global network of operating companies we are

your competent global partner for weighing, feeding, screening and

automation solutions throughout the process industries.

NORTH AMERICA

SOUTH

AMERICA

EUROPE

AFRICA

AUSTRALIA

ASIA

A Global Partner:

Thinking Globally, Acting Locally


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Technological Pedigree:

Over 125 Years of Making Processes Work

1881

Carl Schenck opens

an iron foundry and

weighing machine

factory in Darmstadt,

Germany

Conversion into

Carl Schenck AG

1974 1984

IPO of

Carl Schenck AG

1993

1995

Start of

Schenck

Process as a

stand alone

entity

2000

Drr AG

acquires

a majority

stake in Carl

Schenck AG

2005

MBO of

Schenck Process

2006 2008 2009 2011

Strong international

growth and expansions

of production facilities

in Asia

Growth continues

even during the

Financial Crisis

I N O R G AN I C GROWTH

197019291972

1982 1993 1994 1996

O R G A N I C G R O W T H

20012003

2005

Southafrica Chile/Brazil Japan USA/China India Australia Ukraine/Colombia GB/Russia

2011

Singapore/Indonesia

2012


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Schenck Process Test Centre (1/2):

Germany

Which solution is best for which bulk solidmaterial?

Schenck Process now offers realistic tests in its

ultra modern Darmstadt Test Centre for anyonewho wants a precise answer to this question.

More test rigs and an improved level ofautomation mean that the Test Centre can now

run even more accurate tests, closely based on

clients actual processing conditions.

Trials in the four Test Labs can be run in

parallel without impacting negatively on oneanother. Three of the Test Labs contain

different equipment for filling and emptying with

big bags or pneumatic conveying.

We have already tested more than 26,000

bulk materials in more than 40,000 tests inthe Test Centre.

Additional test facilities can be found across our

worldwide Group Locations in Austria, Brazil,

Czech Republic, UK and USA.


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Competence in process technology

Experience and know-how

Global presence

Award winning product line

Certification / quality assurance

R&D and Technological leadership

Strong aftermarket capabilities

Excellence in project management

Schenck Process Group:

Our Experience for our Customers Success

Global partner offering local support

(Sales, Engineering and Service)

Product and solutions provider

Leading pre and after sales care

Leading technical products with the

highest quality and reliability

Diversified customer base withoverlapping application know-how

Global manufacturing close to customer

reducing delivery times

Our Experience Customers Success


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1



Customers Success

2


Competence in Cement Manufacturing, Application Overview, Benefits, KeyElements

3

System Variants



4



Example


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Process step covered by the Schenck Process Group

Legend:

Cement Plant Schematic:

Process Steps Covered by Schenck Process

Raw Material Preparation & Handling Calciner and Kiln Feeding Cement Storage, Blending and Despatch


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Process step covered by the Schenck Process Group

Legend:

Cement Plant Schematic:


Calciner and Kiln Feeding


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Application

Throughput

Rate

Accuracy

User Benefit

Feeding and measuring of pulverised

materials e.g. coal dust

Up to 50 t/hr

0.5%

Enhanced production through stablekiln operation

Systems Sold ~ 1,100

Core Products MULTICELL & MULTICORK Mass

Flow Feed System

Coal Dust Feeding:

Typical Application Overview


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Short-term feed constancy

Schenck Process:


Reduced fuel consumption

through less excess air to be heated in kiln

Reduced power consumption

through reduced power of exhaust fan

Low installation height requirements

through compact design

Reliable, trouble-free operation

Cost effectiveness

Exact material flow measurementimmune to

external forces

Ease of maintenance and service

Low number of moving parts

High resistance to wear

Fast and stable control performance

Pulsation free material discharge

Stable kiln operation

Longer lifetime of kiln refractories

Improved clinker quality

Minimised downtimes

Customers BenefitsSystem Characteristics


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MULTICELL and MULTICORK Mass Flow Feeding System (Standard Configuration)

Schenck Process:


MULTICELL (Pre-Feeder)

Function: Shock-pressure-proof horizontal rotary feeder

Range: 6 standard sizes based on volumetric feed rates

MULTICOR(Measuring System)

Function: Shock-pressure-proof measuring system based on

the coriolis principle

Range: 4 standard sizes based on volumetric feed rates

Pneumatic Conveying

Function: Pneumatic transfer to the kiln

Range: Variable lengths up to 200m


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Schenck Process:


Optimal coal dust feeding in three steps:

Pulverised coal dust feeding requires economic efficiency, quality and maximum

reliability. The parameters are based on the interplay of overall system engineering,

material discharge, feeding and pneumatic conveying.

1. Pulsation-free silo extraction

2. Exact measurementexcellent feeding performance

3. Pulsation-free transport

Perfectly matched system components are a basic requirement for optimal coal dust

feeding. This is realised in a pressure-proof, mass-flow feed system using the coriolis

principle with a horizontal star feeder.


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Schenck Process:


The large silo outlet and agitation system which is integrated into the

MULTICELL horizontal rotary feeder ensures the homogenisation of the

material and its pulsation-free discharge from the silo.

1. Pulsation-free silo extraction: MULTICELL

The material flow is measured quickly and precisely using the MULTICOR K

coriolis principle which is unaffected by external influences. In combination

with the horizontal rotary feeders speed control direct mass flow

measurement is achieved. This ensures that the actual feed rate exactly

corresponds to the specified nominal value.

2. Exact measurementexcellent feeding performance: MULTICOR K

We ensure the ideal layout of the pneumatic conveying system. The design

pressure, intake volume to the blower and and the conveyors cross-section

are calculated to ensure optimal transport of the fuel from the feeder to the

burner.

3. Pulsation-free transport: Pneumatic Conveying


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Schenck Process:


Horizontal rotary feeder

Designed for feeding pulverised materials such as coal dust

Large open area inlet ( 700mm1,400mm)

6 different standard sizes available based on volumetric feed rates

Shock-pressure-proof to 10 bar

Flameproof to 10 bar

Long service life (high-quality laggings)

Excellent homogenisation of different material zones

Constant fill level of the rotary wheel

Low pulsation

MULTICELL Rotary Feeder

Agitator

MULTICELLView from topInside the MULTICELL

Agitator drive

Wheel drive Rotary wheel

Wide inletsectionAgitator

Rotary wheel


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Schenck Process:




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The silo contains different zones of material with a different degree

of aeration and bulk density as there is no real mass flow inside.

The Schenck Process MULTICELL Rotary Feeder ensures an

excellent homogenisation of the different material zones throughthe integrated agitator. The separation of the wheel and agitator

drives ensures an optimised speed of the agitator.

Schenck Process:



Excellent Homogenisation

The wide inlet section of the MULTICELL with a diameter of

minimum 700mm together with the integrated agitator ensure a

constant fill level in the chambers of the rotary feeder.

Constant Fill Level

All these characteristics lead to a pulsation free infeed of the

material into the pneumatic conveying line.

Pulsation Free Discharge

Geometry and Focussed Agitation to Promote Constant Flow


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Schenck Process:




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The Coriolis measurement principle of the MULTICORK is ideally suited for the feeding

of pulverised fuels such as coal dust and meets all requirements regarding short-term

feed constancy and long-term accuracy.

Working Principle:

Bulk material enters the centre of themeasuring wheel and is accelerated in

tangential direction

This action creates a torque, which

corresponds directly to the feed rate

The torque is measured with ameasuring module (Schenck Process

load cell)

The data is communicated from the

measuring module to Schenck Process

DISOCONTcontrol system

Schenck Process:


Material flow through the MULTICOR K

MULTICORK - The Coriolis Measurement Principle


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Schenck Process:


MULTICORK Coriolis Mass Flow Meter

Measuring wheel

The Coriolis PrincipleInside the MULTICOR K

Material infeed into

pneumatic

conveying line

Mass Flow Meter based on the Coriolis Principle

Continuous fixed-speed rotating measuring wheel in dust-tight body

Ideally suited for the feeding of pulverised fuels such as coal dust

Prerequisite for stable kiln operation

Quick and accurate measurementno influence of external factors

4 different standard sizes available based on volumetric feed rates

Compact design

Throughput rate up to 50 t/hr (depending on system configuration)

High short-term feed constancy

High long-term accuracy

Shock-pressure-proof up to 10 bar

Material infeed

FR

FC

FZ

Legend: FC= Coriolis Force

FZ= Centrifugal Force

FR= Friction Force


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Schenck Process:


MULTICORK - The Coriolis Measurement Principle

FR

FC

FZ P = feed rate [t/h]

MP =

R 2

M = torque = FC R = angular velocity [1/s]

R = radius of measuring wheel [m]

As the particles move along the vertical guide vanes, they are accelerated in the

circumferential direction. The rotation of the measuring wheel causes three forces to act

on the particles as they move along the guide vanes:

FZ= centrifugal force:acts in the radial direction

FR = frictional force:acts in the opposite direction to FZ

FC = coriolis force:acts in the tangential direction and produces a measurablereaction torque in the measuring wheels rotation that is directly proportional to themass flow rate


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Schenck Process:


Pneumatic Conveying

Pneumatic conveying of fuels to the kiln

Conveying distance: up to 200m

Conveying rate: up to 50 t/hr

Direct infeed into the pneumatic conveying

line - no additional machinery for air lock

required

Roots blower for pulsation free conveying

The roots blower and the pipe diameterare configured based on the feed rate of

the system


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1



Customers Success

2



3

System Variants



4



Example


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Single feeding

(Standard Configuration)

Variant 1:

Multiple feeding from one silo

into several kilns

Variant 3:

Feeding of different fuels into

a single kiln using one

conveying tube

Variant 2:

Schenck Process:


Depending on the plant concept various system variations are possible:


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Single Feeding (Standard Configuration)

Feeding from one silo directly into a single

conveying line to feed one kiln

Low installation height through compact

design (3,5m only)

High feed constancy

Pulsation-free discharge

Exact material flow measurement - immune

to external forces

Variant 1: Single feeding (Standard Configuration)


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Designed for a stable kiln operation through high feed constancy




Large inlet section

(700 - 1,400mm)

Integrated Agitator

Separate drive for agitator

for optimised

agitation speed

+

+

Excellent homogenisation

Pulsation-free infeed into

pneumatic conveying line

High speed control

0.2 sec.

MULTICOR

Coriolis Mass Flow Meter

No influence by external forces

Highly accurate measuring


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Single Feeding of one Kiln


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Reduced operation cost: reduced primary air volume

only one blower required only one conveying tube required

Flexible adjustment of fuel composition higher clinker quality maximum utilisation of alternative fuels

Reduced grinding cost Materials can be grinded individually to the

required size No common grinding of all materials to the

highest fines


Feeding of different fuels into a single kiln

Variant 2: Feeding of Multiple Fuels


using one common conveying tube

Serial connection of two or more standard

configurations (Variant 1)


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Feeding of different fuels into a single kiln using one conveying tube


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Multiple Feeding from one Silo into Separate Kilns

Multiple Feeding from one silo into several

kilns

Two or more standard configurations(Variant 1) connected to the silo through a

MULTIFLOW discharge system

Minimised investment costs - only one silo

required to feed several kilns

Perfect material discharge from the silo with

the MULTIFLOW

Possibility to temporarily close one outlet if

not required

Variant 3: Multiple Feeding


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Schenck Process MULTIFLOW Silo Discharge System



Large silo connection NW 1400/1900/2000/2500

Consistent wall declination

Large outlet dimensions NW 700/800

Excellent material flow, even if only one outlet

is in operation

No wear parts

No drive, no drive control

No energy consumption


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Multiple Feeding - Both Outlets in Use


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Multiple Feeding - Only One Outlet in Use


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On Stream Calibration with the Tube Calibrator

Shut-off gate,

closed for calibration

Bin weighing

system on

load cells

Flexible connection

DISOCONT

Control System

Reduced costs - improved performance

Conventional calibration systems,

consisting of a pre-hopper with a starfeeder, require a lot of maintenance and

are very cost intensive

The Schenck Process tube calibrator

offers a simpler solution at reduced costs:

On-stream calibrationat any time

during normal operation

No peripheral equipment required

The calibration tube is mounted onload cells

Low height requirements

(~ additional 2m compared to

standard configuration)


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On stream calibration using the Schenck Process Tube Calibrator


On Stream Calibration with the Tube Calibrator


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Single Feeding of one Line (Standard) with Tube Calibrator


Single Feeding System with Tube Calibrator


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1



Customers Success

2



3

System Variants



4



Example


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Schenck Process Coal Dust Feeding Systems have a long tradition in the market

In total, about 1,900 systems have been supplied

Solids Flow Meter

(~100 sold)

History

19941970 today

Coal Dust Feeding:

A Traditional Schenck Process Application

SIMPLEX Loss-in weight

Feeder(~700 sold)MULTICORCoriolis Mass

Flow Meter(~1,400 sold)


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Number of Systems Supplied

3

24 23 25

34

38 42

45

71 74

75

72

120

143

150 147

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

Number of coriolis coal dust feeding systems sold (Year-end of 2012): ~1,400


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Project Specifications:

Three silos for the blending of 3 different fuels:

shale, petcoke and sewage sludge

Two conveying lines for two kilns with 3 in-feed

points each

MULTIFLOW silo discharge for optimised

extraction/material flow

MULTICELL 1000/100 rotary feeder for feed

rates of up to 25t/h per system

MULTICORK coriolis mass flow meter

A Schenck Process turn-key project including:

3 Silos with 6 dosing systems, steel works,

infrastructure/supports and complete plant

control

Customer Example 1:

Feeding of 3 different fuels into 2 Conveying Lines


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Shale

Petcoke

Sewage

sludge

Customer Example 1:



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Customer Example 1:



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Customer Example 2:

Feeding of coal dust to two burner at Pre Calciner
http://localhost/var/www/01_KAM/01_HOLCIM/03_Werke_Referenzen%20und%20Projekte/Rum%C3%A4nien/Alesd/Kohlenstaubdosierung%20#108269/Doku_CD_GB/1.General%20documents/01_V072038B01%20Coal%20Dust.pdfhttp://localhost/var/www/01_KAM/01_HOLCIM/03_Werke_Referenzen%20und%20Projekte/Rum%C3%A4nien/Alesd/Kohlenstaubdosierung%20#108269/Doku_CD_GB/1.General%20documents/01_V072038B01%20Coal%20Dust.pdf


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Customer Example 2:


Scope of supply (in 2008):

Engineering for conveying coal dust from mill to silo

silo and explosion flap/protection

silo outlet (MULTIFLOW)

two tube calibrator, MULTICELL and MULTICOR

pneumatic transport to calciner (1...5 t/h)


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Customer Example 2:


A statement of a satisfied customer:

...... The system is for one year in

operation now and we are happy to

express our satisfaction with the

support of Schenck Process GmbH

within the project engineering and

realisation phase.

The system is reliable and accurate and

full fills completely the requested needs

for our application within the cement

process.....


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Short-term feed constancy

Schenck Process:

Summary - Coal Dust Feeding Systems

Reduced fuel consumption

through less excess air to be heated in kiln

Reduced power consumption

through reduced power of exhaust fan

Low installation height requirements

through compact design

Reliable, trouble-free operation

Cost effectiveness

Exact material flow measurementimmune to

external forces

Ease of maintenance and service

Low number of moving parts

High resistance to wear

Fast and stable control performance

Pulsation free material discharge

Stable kiln operation

Longer lifetime of kiln refractories

Improved clinker quality

Minimised downtimes

Customers BenefitsSystem Characteristics


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schenck - coal dust feeding 08-13

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