PowerPointPrsentation

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Dedusting of Exhaust Gases to Optimize Fuel Use
By A TEC AMERICA Ing. Jonathan Forinton At
FICEM/APCAC XV Technical Conference 2008 in
Panama
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Content

• Situation - what plants have today?
• Aim of the Project A TECs investigation
• Issues Testing overview and results
• Solutions A TECs proposed configuration
• Results from some reference plants
• Next steps

SITUATION
AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS
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Situation Requirement in plants

• Requirement for hot gas to dry coal best served
  by kiln exhaust gas
• Exhaust gas contains dust due to imperfect
  separation in top stage cyclones
• Raw meal dust in exhaust causes higher operating
  costs

SITUATION
AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS
How much dust? 3000 t/d CF 1.6 Cyclone ?
93 ? Feed 200 t/h Dust 14 t/h (60
g/Nm3)
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Situation Extra operating costs

• Transporting the dust to the mill
• Pressure loss is directly proportional to dust
  load
• ? Kiln ID fan energy increase approx 35
• Long distances between pre-heater and mill, Dust
  in duct needs manual cleaning out.
• ? Extended shut-down activities time

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AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS
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Situation Extra operating costs

• Milling the dust
• Since raw meal is generally finer than coal,
  costs in milling appear negligible, however
• ? Separator energy increase approx 10
• Coal Transport air
• Transport air
• Coal 0.2 m3/kg Anthracite 0.5 m3/kg
• ? Transport energy increase by approx10
• ? Heat up extra cold air (small effect only)

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AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS
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Situation Effect on operation

• Operating
• Raw meal in burner fuel supply does not mix with
  coal (pulsing of meal coal)
• ? Upsets fuel control, emissions
• Silica in raw meal can affect clinker quality
• ? Upsets customers
• Maintenance problems on burner tip
• ? Lower availability of kiln

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AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS
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Aim of the project

• Investigate how to reduce dust content as far as
  possible
• Investigate which cyclone type is best?
• Refine plant GA configurations

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AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS
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A TEC Technical Centre Austria
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Issues - Testing

• Any option has to consider balance between
  pressure drop and separating efficiency
• ? A TEC investigated 4 cyclone types

SITUATION
AIM OF THE PROJECT
ISSUES

• HURRICLON 3 ST
• HURRICLON, special design to get the best
  possible separation, even a pressure drop up to
  2000 Pa is acceptable.
• C1 Normal cyclone elongated cylinder
• C2 Normal cyclone

SOLUTIONS
RESULTS
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Issues Summary of Test
HU HURRICLON Cyclone
C Normal Cyclone
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AIM OF THE PROJECT
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SOLUTIONS
RESULTS

• Results of Test

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Cyclone HU HU Special C1 C2 Efficiency
64 71 49 59 Pressure loss
Pa 950 1800 950 1900
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A TEC PROCESS CENTER FLOW SHEET
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Solutions Testing Final Result

• CONCLUSIONS OF TESTING
• For coal mill application relatively low dust
  load and fine grain size separation efficiency
  of centrifugal separators is 30 to 70
• A separation efficiency of more than 60 was
  clearly reached with HURRICLON 3 dedusting.
• The best separation efficiency can be achieved
  with a special cyclone but at too high pressure
  loss!
• A Cyclone with the same pressure loss as a
  HURRICLON3 has a lower separation efficiency.

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AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS
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Solutions Keeping good results

• Separation efficiency varies with inlet gas
  quantity
• In case of varying coal humidity (eg. seasons)
• Hot gas shared with other mills (eg. 2 mills)

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AIM OF THE PROJECT
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With return cycle there is clearly a positive
influence on the separation efficiency.
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Solutions Final Proposal
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AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS

• Flowsheet OPTICOAL
• Installation

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Results Cemex-Saraburi 1
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AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS
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• This project was then copied to Line2

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Results Lafarge FR Cement
SITUATION
AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS
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Results Lafarge Fortune Cement
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AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS
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Next Steps for A TEC

• The OPTICOAL idea has been applied successfully
  to some other applications,
• eg.
• For cleaning hot gases before Slag Grinding,
  St. Lawrence Cement Mississauga plant 2008.
• A TEC are looking for further applications in
  cement, mining or waste industries.

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AIM OF THE PROJECT
ISSUES
SOLUTIONS
RESULTS
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Thank you for your attention!
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