2005 Yokota_ Aspen PlusFactSageChemApp interface.pdf

Aspen Plus/FactSage/ChemApp interface for Cement Production Process Simulation

Morihisa Yokota Ube Research Laboratory Corporate Research & Development UBE Industries, Ltd. 7th GTT WORKSHOP 2005 AACHEN GERMANY

Contents Why Cement Plant ? Problems in Cement Plant Operation Modeling Cement Plant with Aspen/ChemApp/Fact Cement Plant with Chloride Bypass System Conclusions Future Works

„Other High Temperature Process in UBE INDUSTRIES,LTD „Estimation of Miner Components Behavior in Cement Making (Henrian Solution Model)

7th GTT WORKSHOP 2005 AACHEN GERMANY

Clinker Burning Process ☆Counter Current Process

Solid Flow Gas Flow

☆12（or more)System Elements Fe-Ca-K-Cl-S-Si-Al-Mg-Na-O-N-C ☆Formation of clinker phases Alite 3CaO*SiO2 Belit Ca2SiO4,Fe2SiO4,Mg2SiO4 Aluminat 3CaO*Al2O3 Ferrite Ca2Al2O5 Ca2Fe2O5 Fuel(Coal)

Raw Meal

C4 C3 C2

Pre-Calciner C1 SP fan

Clinker Cooler 7th GTT WORKSHOP 2005 AACHEN GERMANY

Rotary Kiln

Waste and Byproduct Utilization in Cement Factories Inorganic Waste(Raw) Sewage Public refuse incineration ash Water supply sludge Coal ash Gypsum Slag Controlled soil Hydraulic cake

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Organic Waste(Alternative Fuel) Waste plastics Waste oil Waste tire Waste pachinko panels Waste tatami mats Bone meal

Cyclone clogging caused by Chloride and Sulfate accumulation

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Chloride Conc.

Raw Meal

Sulfate Conc.

60ppm

200ppm

C4

430ppm

2,000ppm

C3

840ppm

4,900ppm

C2

1,630ppm

11,100ppm

C1

11,880ppm

35,000ppm

70ppm

4,400ppm

Clinker

Chloride ；KCl, NaCl Sulfate ；K2SO4,CaSO4 etc

Accumulation of Chloride and Sulfate Formation of low melting point component Cyclone clogging Plant Operation Shutdown !

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Raw Meal

C4 C3 C2 Coating Build up C1

Cement Process Simulation with Aspen/ChemApp/FactSage Stand-Alone Data Base or Programs

Process Simulator

1990~  In-House Program     (Gibbs Energy Minimization)

1988~  Aspen Plus

1993~ “MALT”, “MALT2” 1997~ “HSC”, “TAPP” “MINEQEL for windows”

Cement Process Simulation 1997 ~

JANAF TABLE, NBS TABLE

“Barin” for in-organics Exhaust

Raw meal

Barin Database Pure Solids,Liquids and Gas

SOURCE

SYGASOUT

HEAT

MIX

FILTER

HEATOUT

HEATIN

C4GASOUT

SFLSHIN

C4BYPS2

C4GASMIX C4BYPVPR FLVPR

C4BYPASS C4MJFAN BYPSEPC4 FLASH C4FLSHIN

MJMNC4

C4CMIX

C4CYC

C4MNSEP SEP

C4MJC3

C3SLDIN C3GASOUT C3BYPS2

Pre-Calciner

C3GASMIX

C3BYPVPR C3BYPASS C3MJC4 BYPSEPC3 MJMNC3 C3GASIN

C3MJ C3RIN

C3CYC

SEP

2001~ “FactSage” 2002~ “ChemApp”

C3MN

C3CMIX

Fuel

EXHSTP

PINDRY

DECOMP2

DRYFLSH2

SEP

PBS

PBURN PBURNIN

C2SLDIN

PMIX

PB11

C2GASOUT

C2BYPS2 RSTOIC

FLASH2

RYIELD

C2GASMIX C2BYPVPR

RGIBBS

C2BYPASS PDRYCOAL

Air

C2MJC3 C2MNC3

PASPIN P-PAS

PBYPASS

PBC1

PGPAS

C2LEAK C2RIN BYPSEPC2

PBC2

C2R

MJMNC2 C2ROUT

RGIBBS

SEP

PREFR

PCS PROUT

PSLDIN C1GASOUT C2CMIX C2MNSEP C2MNC1

RGIBBS

PGASOUT

KGASOUT

C2CYC

C2 Cyclone

SEP

Fuel

C2MJC1

EXHAUST C1GASMIX

1ST-AIR

WET-COAL DRYREAC NITROGEN

C1MNC2 C1SLDIN

DRYFLSH

RSTOIC

DRY-COAL

C1BYPS2 C1BYPASS

Q-DECOMP

FLASH2

DECOMP KBURN1 KB1M KB1S INBURNER KB11 KB12 RYIELD

KBURN2

RGIBBS

KB2S KB2M

RGIBBS

KBURN3

KB3S KB3M

RGIBBS

KBURN4

KB4SKB4M

KB5M

KB5S KBURN5

RGIBBS

KBURN6

RGIBBS

KB6S KB61

BYPSEPC1

C1R

C1MJC2 C1BYPVPR

MJMNC1

KB62 KB6M

RGIBBS

RGIBBS

SEP

C1MN KGBC5

KGBC4

KGBC2

C1MNSEP

KGBC1

SEP

KB3G

KB4G C1MNK KGBC3

KB5G

C1CMIX C1MJK

KB6G G-PAS KSBC5

KSBC6

AIR-SEP

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C3 Cyclone

C3ROUT

QDECOMPP

C3MJC2

DRYREAC2

PN2

KB1G

2003~ “Kiln-Simu” for rotary kiln

C3MNC4

RGIBBS

C3MNSEP

PB12 PCOAL

KGBC6

Aspen+ChemApp+FactSage

C3R

P1STAIR

KB2G

2002~ Cement Process Simulation with

C4 Cyclone

C4MNFAN SEP

KSBC3

KSBC4

KSBC1

KSBC2

KSLDIN

GASOUT

Clinker

Air

2ND-GAS COOL3

COOLSLD2

CLINCA

COOL2

COOL1 COOLSLD1

KC6S KC61 SEP

COOLG3

COOLG2

SLDR6

SLDR5 KC51

RGIBBS

KC5S

SLDR4

SLDR3

KC41 RGIBBS

KC4S

SLDR2

KC3S

RGIBBS

SLDR1

KC12

KC2S

KC1S

RGIBBS

Q

KC11

KC21

KC22 RGIBBS

RGIBBS

COOLG1 SINTERQ2

COOLAIR

SINTERQ3

COOLG12 CASPLIT1

SINTERQ1

CASPLIT2 SINTERQ5

SINTERQ4

SINTERQ6

Q FSPLIT

QSEP1

Rotary kiln(6 blocks)

SINTER-Q

C1CYC

C1 Cyclone

Chloride and Sulfate at High Temperature (FactSage)

Sulfate 0.08

Chloride

S compounds in Solid+Slag mol

0.07

5.0vol% O2 Liq. or Solid K2SO4

0.06 0.05

3×K2Ca2(SO4)3

Slag-MgSO4

0.04 0.03 0.02

Slag-CaSO4

CaSO4 0.01 0 800

900

1000

1100

1200

Temperature C

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Slag-Na2SO4

Slag-K2SO4 1300

1400

1500

Oxygen Partial Pressure on Sulfate Decomposition

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Process Simulation Tools

OS CPU RAM

+

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PC Windows 2000 pro XEON 2.4GHz 2GB

Components considered in Cement Process Simulation Pure Liquids;3 components

Pure Solids;155 components

Solid Solution Belit phase Ferrite phase

Gas;116components

Slag;28components

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Save *.cst file from FactSage

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Databanks and Definition of Fact Components in ASPEN Selection of Databank

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Definition of Components in case of “SiO2”

Single Stage Equilibrium Calculation

ASPEN PLUS GUI

ChemApp Block

Any number

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Specification of ChemApp Block 1; P,T 2; P,dH(W), incase of dH=0 adiabatic 3,4; Target calc. Pressure;Pa Temperature(K) in type1, dH(W) in type2 Number of Phase

in this case only “Slag-liquid” was considered

Name of Phase

Number of Components in this case 273 compounds were considered

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definition of cst file name

Aspen Plus Model for Cement Process ChemApp Equilibrium Block Off-Gas

Burner

Pre-heater+Pre-Calciner

Coal Rotary Kiln and Cooler Raw

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Coal Product

Calculation Sequence in Process Simulation

ChemApp Block

ASPEN PLUS creates Calculation Sequence Automatically Iteration vs. Residue(Loop)

Iteration Loop

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Calculated Example of Cl, SO3 Circulation in Process Chloride and Sulfate accumulation in bottom Cyclone

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Calculated Clinker Phase

Alit 3CaO*SiO2

Belit Ca2SiO4 Fe2SiO4 Mg2SiO4

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Aluminat 3CaO*Al2O3

Ferrite Ca2Al2O5 Ca2Fe2O5

Chloride Bypass System

Dust Collector

Raw Meal Pre-Heater

Bypass Fuel

Chloride Circulation Kiln

Clinker Cooler 7th GTT WORKSHOP 2005 AACHEN GERMANY

Cement Process with Chloride Bypass System Quench at Mixing Chamber KCl(Gas) →KCl(liq) → KCl(Solis) fan

Bug filter

Bypass Dust Mixing Chamber

Clinker Cooler 7th GTT WORKSHOP 2005 AACHEN GERMANY

Cooling fan

Aspen Plus model with Chloride Bypass System ChemApp Equilibrium Block

Chloride Bypass

Bypass Gas Recycle Line

Off-Gas

Burner

Pre-heater +Pre-Calciner

Coal Rotary Kiln and Cooler Raw

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Product

Effect of Chloride Bypass System Dust Collector

Raw Meal Pre-Heater

Bypass Fuel

Chloride Circulation Kiln

Clinker Cooler

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Conclusion Aspen/ChemApp/Fact interface was applied to Cement Process

Counter Current and Complex System 12 System Elements Formation of clinker phases Sintering in liquid phase

Cement Process was modeled as a series of Equilibrium Reactors(ChemApp) by Aspen Plus Accumulation of Chloride and Sulfate in Cement Process were successfully estimated in this Model

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Future Works

9Application of Aspen/ChemApp/Fact interface to Coal Gasification Plants Organic Waste Gasification Plants Coal fired Power Plants

9Linking ChemApp/Fact with CFD Calculation rotary kiln

Coal Fired Power Plant

9Behavior of Trace Elements in Cement Plants 7th GTT WORKSHOP 2005 AACHEN GERMANY

25/25

Some Processes with High Temperature in UBE

Ube Ammonia

Coal Gasification

EUP

Coal

Waste Plastics Gasification Coal Fired Power Plant

Behavior of Ash in Gasifier Gasification Modeling CFD+Fact? 7th GTT WORKSHOP 2005 AACHEN GERMANY

Behavior of Ash in Boiler Coal Combustion Modeling CFD+Fact?

Application of “Advanced feature” of FactSage Major Elements in “Cement Process”

Al-Ca-Fe-Si-Mg-Na-K - Cl-S-O Miner or Trace Elements in “Cement Process”

Pb-Zn-Se-Cd-Hg-Tl

We’d like to know (estimate) the behavior of Miner or Trace Elements in the Process !! In FACT-SLAG, “Zn” and “Pb” are included. Se,Cd,Hg,Tl are created as dilute Henrian solution, and then merge it into the FACT-SLAG solution phase.

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Handling of dilute solutions in the Aspen Plus/FactSage/Chemapp interface FactSage version 5.3.1 Aspen Plus version 12.1.12 &

Technical Tip ID 115127(19-Jan-2005)

ChemApp version 5.3.2

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Al-Ca-Fe-Si-Mg-Na-K-Cl-S-O-F-Pb-Zn System with Dilute Components(Se-Cd-Hg-Tl) Ftoxide System (FACT-SLAG)

Dilute Components added to FACT-SLAG

These compounds are added to a “User Databank”

In Fact53, some compounds have “＊” in its chemical formula, then, these compounds must be re-defined in “ASPEN-PLUS” MG*S*O4, zn*cl2, etc 7th GTT WORKSHOP 2005 AACHEN GERMANY

7th GTT WORKSHOP 2005 AACHEN GERMANY