Technical Seminar Jakarta 2015
Jakarta, Indonesia, 21 - 23 April, 2015
Proceedings Convening Networking Sharing knowledge
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Final programme 21 April 2015 19:00 - 22:00
Informal get-together at Hotel Le Méridien Jakarta
22 April 2015
Technical Seminar at Hotel Le Méridien
08:30 - 09:00
Registration open: Coffee and networking
09:00 - 09.15
Welcome address Hendra Tjhai, Detlef Bluemke, PT Loesche Indonesia
09:15 - 09:30
Meet the delegates - Introduce yourself to the audience
09:30 - 10:30
Loesche vertical roller mills: State-of-the-art comminution Detlef Bluemke, PT Loesche Indonesia
10:30 - 10:45
Coffee and networking
10:45 - 12:00
Process, operation & evaluation of Loesche grinding systems Christian-Martin Ruthenberg, Loesche GmbH, Germany
12:00 - 13:00
Lunch and networking
13:00 - 14:00
Preventive maintenance - wear and repair Stefan Wölfel, Loesche GmbH, Germany
14:00 - 15:00
Machine monitoring Sebastian Muschaweck, Dr. Franz Muschaweck, DALOG Diagnosesysteme GmbH
15:00 - 15:30
Coffee and networking
15:30 - 17:00
World Café - interactive workshop
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Dr. Regina Krammer, Loesche GmbH, Germany
18:00
Departure from the Le Meridien Hotel to Segara Anchol for dinner
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Final programme 23 April 2015
Technical Seminar at Hotel Le Méridien
09:00 - 09:15
Welcome and summary of day 1 Hendra Tjhai, PT Loesche Indonesia
09:15 - 10:15
Process parameters and plant optimisation: False air - often underestimated Christian-Martin Ruthenberg, Loesche GmbH, Germany
10:15 - 10:30
Coffee and networking
10:30 - 12:00
Grinding aid: Advantages and operation optimisation Dr. Pietro Recchi, Mapei
11:45 - 13:00
Lunch and networking
13:00 - 14.00
Lubricants - Functions and the importance of maintenance Moch Mustofa, PT. Mitra Asmoco Utama
14:00 - 15:00
Pyroprocess evaluation - waste treatment with the new Rocket Mill Dr. Stefan Kern, A TEC Production & Services GmbH
15:00 - 15:15
Coffee & networking
15:15- 16:30
World Café - interactive workshop Dr. Regina Krammer, Loesche GmbH
Resumee of the two days and farewell
19:00
Dinner at the Hotel Le Méridien
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16:30 - 17:00
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Organisers Detlef Bluemke
Hendra Tjhai
Main activities: • Longterm experience as commissioning engineer E,C&I and process worldwide for Loesche • Head of Commissioning department and later deputy director of Technical Field Service at Loesche • Since 2013 Managing Director of PT Loesche Indonesia
Main activities: • Client relation • Spare part and after sales business • Link in between clients in the Asian region and the Loesche Group • Engineering consultancy
Managing Director, PT Loesche Indonesia
email:
[email protected]
Sales Engineer, PT Loesche Indonesia
email:
[email protected]
Jeane Haro
Office Manager, PT Loesche Indonesia Main activities: • Client relations • Marketing • Taking care about financial, administrative and tax matters
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email:
[email protected]
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In cooperation with LOESCHE Training Center, Germany: Theodora Bruns
Dr Regina Krammer
Main activities: • Development of blended learning concepts for internal and external use • Business development • Customer service
Main activities: • Development of blended learning concepts for internal and external use • Design of eLearning courses and computer supported cooperative learning (CSCL) • Knowledge management and communication
Head of Training Center, LOESCHE GmbH
email:
[email protected]
Deputy Head Training Center, LOESCHE GmbH, Germany
email:
[email protected]
Christian-Martin Ruthenberg
Technical trainer, LOESCHE GmbH, Germany Main activities: • Development of training concepts for customers • Process auditing • Training on process and operation of LOESCHE grinding plants
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email:
[email protected]
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Lecturers Detlef Bluemke
Christian-Martin Ruthenberg
Main activities: • Longterm experience as commissioning engineer E,C&I and process worldwide for Loesche • Head of Commissioning department and later deputy director of Technical Field Service at Loesche • Since 2013 Managing Director of PT Loesche Indonesia
Main activities: • Development of training concepts for customers • Training on process and operation of LOESCHE grinding plants
Managing Director, PtT Loesche Indonesia
Technical trainer, LOESCHE GmbH, Germany
email:
[email protected]
email:
[email protected]
Stefan Wölfel
Sebastian Muschaweck
Head of service, DALOG Diagnosesysteme GmbH
Main activities: • Worldwide execution of installation activities • Management of the installation department of Loesche GmbH, Germany • Strategic development and resource planning of installation supervisors
Main activities: • Expert in rotating equipment reliability, vibration analysis, inspection, and maintenance engineering • Certified Vibration Analyst Category III • Areas of expertise: cement machinery, large gearboxes and extruder machinery
email:
[email protected]
email:
[email protected]
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Head of Installation, LOESCHE GmbH
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Lecturers Dr. Franz Muschaweck
Dr. Pietro Recchi
Main activities: • Founder of DALOG Company • Expert in rotating equipment vibration diagnostics, reliability, trouble shooting, inspection, and maintenance engineering • Ph.D. in vibration diagnostics on gearboxes
Main activities: • 7 years experience in cement additives for Mapei • Master’s degree in organic chemistry • Main focus on providing technical support to our sales force in the region • Directly responsible for cement additives sales in Malaysia
email:
[email protected]
email:
[email protected]
Moch Mustafa
Dr. Stefan Kern
Main activities: • Leader of the engineering division • Training for customers on lubrication practices • Degree in mechanical engineering, active participant of MASPI (Masyarakat Pelumas Indonesia) • DELTA, WSML, BAT certification from ExxonMobil
Main activities: • Area Sales Manager • Doctoral studies: Chemical Engineering • PhD thesis: Co-Gasification of coal and biomass/wastes in a dual fluidized bed gasification system.
Owner and CEO, DALOG Diagnosesysteme GmbH
Chief Lube Engineeer, PT. Mitra Asmoco Utama
Proposal Engineer & Product Manager, A TEC Production & Services GmbH
email:
[email protected]
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email:
[email protected]
Regional Technical Manager Asia Pacific, MAPEI
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About LOESCHE Since 1906, LOESCHE GmbH has been constructing vertical roller grinding mills. Patented in 1928, our roller grinding mill technology has been continually advanced and in the meantime is synonymous with LOESCHE GmbH. The key competence of the company is the design and development of individual concepts for grinding and drying plants for the cement, steel and iron, power, ores and minerals industry. The service portfolio ranges from first concept to commissioning augmented by maintenance, repair, training as well as modernization of grinding plants and spare parts activities. In April 2012, LOESCHE GmbH, Germany, has entered into a close cooperation agreement with pyroprocess specialist A TEC Holding GmbH, Austria. LOESCHE and A TEC will be partners for the realisation of plant improvement projects, environmental projects and will be in the position to offer complete process solutions. Having taken over the specialised department “Combustion Technology” of UCON AG Containersysteme KG, Gelsenkirchen, in April 2012, LOESCHE offers thermal process technological solutions, thus covering another field of activities with related products e.g. industrial burners and hot gas generators.
When communicating learning content about all matters pertaining to LOESCHE technology the Training Center uses the principle of ‚integrated learning‘ (Blended Learning Concept) with the aid of the latest learning methods and media. It combines online courses which are not tied to a specific time and place with traditional attending teaching and seminars in order to consolidate the knowledge so imparted in the best manner possible and with lasting effect.
For more information please refer to: www.loesche.com LOESCHE GmbH Hansaallee 243 D-40549 Duesseldorf Tel.: +49-211-5353-0 Fax: +49-211-5353-500
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LOESCHE is a privately owned company with its headquarter located in Dusseldorf, Germany and is represented worldwide with more than 850 employees, subsidiaries in the USA, Brazil, Spain, Great Britain, South Africa, India, United Arab Emirates, Indonesia, Russia and P.R. China as well as agents in more than 20 countries. The LOESCHE Training Center was founded in 2008. A young, innovative team of editors, eLearning authors and technical trainers drafts and creates trainings and eLearning courses, documents and manuals in accordance with the latest media-didactic principles, tailored to the needs and requirements of the customers.
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Loesche vertical roller mills: State-of-the-art comminution by Detlef Bluemke, PT Loesche Indonesia
LOESCHE vertical roller mills State-of-the-art comminution
© by LOESCHE
Detlef Blümke, Managing Director PT LOESCHE Indonesia Technical Seminar Jakarta 2015
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Table of contents
Introduction
Introduction
LOESCHE in brief
Loesche vertical roller mill for cement grinding Some comments on grindability State-of-the-art cement grinding plant Summary/Conclusions LOESCHE GmbH is a privately owned company founded 1906 in Berlin, Germany Certified according to DIN EN ISO 9001 Main shareholder: Dr. Thomas Loesche Management: Dr. Thomas Loesche, Dr. Joachim Kirchmann Rüdiger Zerbe
Employees in Düsseldorf: 370 Employees worldwide: 958 Turnover 2014: Euro 500 millions worldwide 2
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Introduction
Introduction
~ 800 employees at 15 Loesche subsidiaries worldwide
31 representative offices worldwide
America
Europe
LOESCHE America, Inc. Pembroke Pines, Florida, USA
LOESCHE GmbH (Head Office)
LOESCHE Equipamentos Ltda. Rio de Janeiro, Brazil
LOESCHE Automatisierungstechnik GmbH Lünen, Germany
Düsseldorf, Germany
Africa LOESCHE South Africa (Pty.) Ltd. Johannesburg South Africa LOESCHE Nigeria Ltd. Ibese, (Lagos) Nigeria
LOESCHE ThermoProzess GmbH Gelsenkirchen, Germany LOESCHE Energy Systems Horsham, UK LOESCHE Latinoamericana S. A. Madrid, Spain LOESCHE OOO Moscow, Russia
LOESCHE India (Pvt.) Ltd. New Delhi, India LOESCHE Mills Ltd. Shanghai & Beijing, PRC LOESCHE Middle East FZE Dubai, UAE LOESCHE Middle East Tehran Branch Office Tehran, Iran LOESCHE Vietnam Ho Chi Minh City, Viet Nam PT Loesche Indonesia Jakarta, Indonesia
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Asia
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Introduction
Introduction
~ 100 employees at 11 Loesche stakes worldwide
Material flow, feed materials, products
A TEC Group, Austria
America
Europe
Aixprocess GmbH, Germany
Asia A TEC Asia Sdn. Bhd. Kuala Lumpur, Malaysia
Austria TEC S.A. de C.V. Puebla, Mexico
A TEC Production & Services GmbH Gödersdorf/Krems, Austria
A TEC Greco Projetos e Equipamentos Ltda Sao Paulo, Brazil
A TEC Plant Construction GmbH Eberstein, Austria
A TEC Technology Services (Beijing), Co., Ltd. Beijing, China
A TEC Sales Office Branch Poland Chelm, Poland
Sales & Consulting A TEC Iraq Office Erbil, Iraq
Europe Aixprocess GmbH Aachen, Germany Aixergee GmbH Aachen, Germany Aixenviro Gbr Aachen, Germany
Greco Combustion Systems Europe GmbH Krems, Austria
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Table of contents
Loesche vertical roller mill for cement grinding
Introduction
Cement grinding as part of the process
Loesche vertical roller mill for cement grinding Some comments on grindability State-of-the-art cement grinding plant
Quarry
Summary/Conclusions
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Cement
Kiln
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Cement grinding
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Raw meal/Coal grinding
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Loesche vertical roller mill for cement grinding
Loesche vertical roller mill for cement grinding
Working principle
Material and gas flow of a clinker/slag grinding plant
1) Rotary feeder 2) Mill table with grinding track
Raw material Fly ash External material recirculation system Metal Product Gas flow
3) Master roller 4) Support roller 5) Rocker arm 6) Hydro-pneumatic spring system 7) Bevel-planetary-gear box 8) Electric motor 9) Gas inlet 10) Ring duct 11) Louvre ring 12) Classifier 13) Grit cone 14) Outlet duct to dedusting system
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Table of contents
Some comments on grindability
Introduction
Definition and common tests
Loesche vertical roller mill for cement grinding Some comments on grindability
Grindability is the resistance of a material against the forces acting upon it during the grinding process – usually given as specific energy consumptions (kWh/t)
State-of-the-art cement grinding plant Summary/Conclusions
Common grindability tests Zeisel Bond Grinding tests of machinery suppliers and cement manufacturers
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Some comments on grindability
Some comments on grindability
Loesche grindability test (1)
Loesche grindability test (2) LOESCHE grindability factors (MF, LF) spec. energy consumption wear factor (vp) The factors are used to determine the right mill and gear box size as well as a suitable material for the wear parts.
Laboratory mill LM 3,6
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Flow sheet LM 3,6
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Some comments on grindability
Some comments on grindability
Comminution process (1)
Comminution process (2) roller alite
alite
grinding table
belite
multiple material „layers“ 100 um
compressive and shear forces acting upon the particles crack initiation at weakest point of structure crack propagation perpendicular to lowest level of compressive forces
Source: http://booksite.elsevier.com/samplechapters/9780750651035/9780750651035.PDF (2015-03-23)
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Comminution process (2)
Comminution process (2)
alite
alite
belite 100 um
alite
alite C4AF C3A belite belite microcracks
100 um
100 um
photomicrograph of clinker; nital etch (Campbell 1999)
Some comments on grindability
photomicrograph of clinker; nital on KHO etch (Campbell 1999)
Some comments on grindability
Source: http://booksite.elsevier.com/samplechapters/9780750651035/9780750651035.PDF (2015-03-23) 18
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Some comments on grindability
Some comments on grindability
Comminution process (3)
Influencing parameters Classification of microcracks
alite euhedral
belite C4AF
alite in void
intra-
20 um
20 um
from Siegesmund et al. (2010)
* SEM photographs clinker fracture surface (Campbell 1999)
fracture surface, hard to grind clinker
mineralogical composition (Vol. %)
40 um
trans-
pore space
„mechanical“ strength of minerals
geometry, spatial distribution
spatial distribution
open microcracks, grain boundaries
grain size, grain shape
porosity
flaws in crystal lattice
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intergranular
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Some comments on grindability
Some comments on grindability
Clinker microstructure
Clinker microstructure alite
Lime Saturation Factor (LSF) The Lime Saturation Factor is a ratio of CaO to the other three main oxides. Applied to clinker, it is calculated as:
alite
belite
belite
LSF=CaO/(2.8SiO2 + 1.2Al2O3 + 0.65Fe2O3)
200 um
100 um
Often, this is referred to as a percentage and therefore multiplied by 100.
Clinker exhibits a wide range of compositions, microstructures and physical properties
The LSF controls the ratio of alite to belite in the clinker. A clinker with a higher LSF will have a higher proportion of alite to belite than will a clinker with a low LSF.
C3S, C2S, C4AF, C3A contents mechanical properties of individual clinker minerals
alite
spatial distribution of minerals grain size, grain shape porosity microcracks
belite
200 um
Typical LSF values in modern clinkers are 0.92-0.98, or 92%-98%.
belite
200 um alite 22
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Some comments on grindability
Some comments on grindability
Clinker microstructure
Range of clinker grindabilities
Silica Ratio (SR) The Silica Ratio (also known as the Silica Modulus) is defined as: SR = SiO2/(Al2O3 + Fe2O3) A high silica ratio means that more calcium silicates are present in the clinker and less aluminate and ferrite. SR is typically between 2.0 and 3.0.
5
15
25
35
45
power consumption - mill [kWh/t] 24
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Some comments on grindability
Table of contents
Quantification of clinker grindability
Introduction
Basically clinker grindability can be assessed by analysing the mineralogical composition and the clinker microstructure, however quantification bears many difficulties
Loesche vertical roller mill for cement grinding Some comments on grindability State-of-the-art cement grinding plant
The following general relationships can be used to qualitatively determine the clinker grindability C3S content high
good grindability
C2S content high
poor grindability
grain size of C3S, C2S high
poor grindability
C2S clusters abundant
poor grindability
abundance of intragranular microcracks
good grindability
Summary/Conclusions
Source: Hills, Linda M., Clinker Microstructure and Grindability: Updated Literature Review, SN2967, Portland Cement Association, Skokie, Illinois, USA, 2007, 15 pages. 26
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State-of-the-art cement grinding plant
State-of-the-art cement grinding plant
Main aims
General concept Compact design
Environmental impact
LDC classifier with „Vortex Rectifier“
consumption of resources (e.g. energy, water) emissions (e.g. CO2, NOx, dust)
Operational costs
LM (2+2/3+3) with modified s-rollers
consumption of water, grinding aid fuel consumption (HGG) specific electrical energy consumption
Investment costs (CAPEX) Flexibility of the grinding system wide range of feed materials desired (blended cements) wide range of product finenesses – high Blaine products
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Waste heat recovery system for slag grinding
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State-of-the-art cement grinding plant
State-of-the-art cement grinding plant
Loesche’s “green” cement grinding plant Compact plant design comparison view 1
Loesche’s “green” cement grinding plant Compact plant design comparison view 2
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State-of-the-art cement grinding plant
State-of-the-art cement grinding plant
Flexibility
Cement types produced in Loesche VRM´s products according to EN 197-1 (2)
the cements are produced at various fineness's actual number of products much higher (products ground without Loesche having operational data) Source: A. Wolter (2010); TU Clausthal 32
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State-of-the-art cement grinding plant
State-of-the-art cement grinding plant
LM 56.3+3 grinding efficiency
S-roller position (1) Standard position of S-roller
Particle trajectories onto mill table are influenced by: centrifugal force friction between particle and mill table friction between particle and particle size and shape of particles 34
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State-of-the-art cement grinding plant
State-of-the-art cement grinding plant
S-roller position (2)
Low specific energy consumption due to S-roller position
Changed position of S-roller
Standard position of S-roller
Production values of LM 56.3+3 CS after installation of new S-rollers Increase of through-put
Reduction in energy consumption AV-Produkt Clinker 82% Gypsum Type I(natural) 4% Limestone 7% Fly ash 7%
CEM II/ A-L
Advantages better guidance of de-aerated material to M-rollers reduced level of mill vibration reduced amount of water for grinding bed formation increased through-put reduced specific power consumption
5,84%
CEM II/ B-L
Increase of through-put
8,21%
-7,17% -11,12%
-25,00%
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-20,00%
-15,00%
Energy savings - total
-10,00%
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0,00%
5,00%
10,00%
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BLL-Produkt Clinker 65% Gypsum Type I(natural) 5% Limestone 25% Fly ash 5%
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State-of-the-art cement grinding plant
State-of-the-art cement grinding plant
Smooth operation and better material guideance
LM 56.3+3 with LDC classifier
Production values of LM 56.3+3 CS after installation of new S-rollers “Vortex Rectifier” Rotor
Grit cone
low dp leading to a reduced specific energy consumption 44
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State-of-the-art cement grinding plant
State-of-the-art cement grinding plant
LDC classifier “Vortex Rectifier” (1)
LDC classifier “Vortex Rectifier” (2)
worldwide patented “Vortex Rectifier” vortex kinetic energy recuperation restores a linear flow in the ductwork
Conventional design high velocity differences
Pathlines colored by velocity magniture (m/s)
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Pathlines colored by velocity magniture (m/s)
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LDC (new design) homogeneous velocity distribution
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State-of-the-art cement grinding plant
State-of-the-art cement grinding plant
Low specific energy consumption due to “Vortex Rectifier”
Features and achievements
Central Europe
LM 46.2+2
Product
GGBS
CEM I
CEM II/B-M
Mill through-put (t/h)
~ 120
~ 125
~ 155
Fineness (Blaine)
4100
4000
3400
fan (kWh/t)
4.0 - 4.8
4.5 - 5.5
3.8 - 4.3
total (kWh/t) (mill, fan, classifier)
26 – 27
25 - 26
20 - 21
LDC classifier with „Vortex Rectifier“
reduced CAPEX
~ 4-8% lower Espec LM (2+2/3+3) with modified s-rollers ~ 5-7% lower Espec
spec. energy consumption
reduced thermal energy consumption
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Compact design
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State-of-the-art cement grinding plant
Table of contents
as “green” as cement grinding can be
Introduction
Environmental impact
consumption of resources (e.g. energy, water) emissions (e.g. CO2, NOx)
Operational costs
consumption of water, grinding aid fuel consumption (HGG) specific electrical energy consumption
Investment costs (CAPEX)
Loesche vertical roller mill for cement grinding
Yes
Some comments on grindability State-of-the-art cement grinding plant
Yes
Cement types produced in Loesche VRM´s Summary/Conclusions
Yes
Flexibility of the grinding system
wide range of feed materials desired (blended cements) wide range of product finenesses – high Blaine products
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Yes
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State-of-the-art cement grinding plant Water and energy – precious resources
Water and energy are the basis for life and the world as we know it today
State-of-the-art cement grinding plant
water as well as energy are not available unlimited both resources will become scarce and more expensive
Consequently saving energy and water is essential for ecologically and economically viable production - also or in particular in the cement industry
Presented by Detlef Blümke PT Loesche Indonesia
[email protected] www.loesche.com
Preventive Maintenance and observation of operation behaviour is a must to keep grinding systems performing most efficient with the minimum waste of energy and resources
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Process, operation & evaluation of Loesche grinding systems by Christian-Martin Ruthenberg, Loesche GmbH, Germany
Process, operation & evaluation of LOESCHE grinding systems
© by LOESCHE
Ch.-M. Ruthenberg, Technical Trainer Corporate Service/Training Center Dept., LOESCHE GmbH Technical Seminar Jakarta 2015
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Agenda
Different LOESCHE mill types Range of application
Different LOESCHE mill types
LOESCHE VRMs are mainly used in: Cement industry Coal fired power plants Iron making plants with blast furnace injection/ PCI (pulverised coal injection) Minerals and ore industry
Processes inside a mill Different process circuits Control values
Raw material mill
Evaluation of performance
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Coal/petcoke mill
Mineral mill
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Clinker & slag mill
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Different LOESCHE mill types
Different LOESCHE mill types
Mill structure: LM 56.4 RM with LSKS 88
Differences
56
Feed material Moisture content Grain size distribution Flow characteristics Grindability
.4
88
Illustration extract out of DWG 935021-00-3 LM 69.6 RM 4
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Different LOESCHE mill types
Agenda
Differences
Different LOESCHE mill types Processes inside a mill
Machine Grinding force (according to grindability) Table speed (centrifugal force) Dam ring (grinding bed) S-rollers (deaeration) Louvre and armour ring (drying)
Different process circuits Control values Evaluation of performance
Illustration extract out of DWG 935021-00-3 LM 69.6 RM 6
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Processes inside a mill
Agenda
The LOESCHE VRM combines
Different LOESCHE mill types Processes inside a mill
Grinding
Different process circuits
mill drive, gearbox, table and rollers Hot gas source: HGG, cooler, gas pre-heater
Classifying
Evaluation of performance
Transportation
Transportation Gas flow introduced by fan
Control values
Classifying
Drying
Drying Grinding
LDC / LSKS
in one machine. Clinker/slag mill 8
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Process circuits
Process circuits
Raw meal grinding plant
Coal grinding plant with external inert gas source
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Process circuits
Agenda
Clinker/slag grinding plant
Different LOESCHE mill types
Damper S (Stack)
Processes inside a mill Different process circuits
Damper R (Recirculation)
Control values Evaluation of performance
Damper Z1 (Fresh air)
Hot gas generator
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Mill inlet pressure
Mill differential pressure
Clinker/slag grinding plant
Clinker/slag grinding plant
Damper S (Stack)
Damper S (Stack)
Damper R (Recirculation)
Damper R (Recirculation)
Damper Z1 (Fresh air)
Damper Z1 (Fresh air)
Hot gas generator
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Hot gas generator
Page 41
Mill outlet temperature
Process gas flow
Clinker/slag grinding plant
Clinker/slag grinding plant
Damper S (Stack)
Damper S (Stack)
Damper R (Recirculation)
Damper R (Recirculation)
Damper Z1 (Fresh air)
Damper Z1 (Fresh air)
Hot gas generator
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Hot gas generator
Page 42
Control Values
Agenda Raw material
Coal
Clinker
Differential pressure
-
Outlet temperature
Gas flow
Inlet pressure
Processes inside a mill Different process circuits Control values Evaluation of performance
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Different LOESCHE mill types
Page 43
Evaluation of performance
Process evaluation Clinker/slag grinding plant
Damper S (Stack)
Improvements (according to requirements)
Damper R (Recirculation)
Audit Assessment Operation
Damper Z1 (Fresh air)
Construction
Commissioning
Optimisation
Performance Run Hot gas generator
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Summary Different LOESCHE mill types
Raw material, coal and clinker/slag mill
Processes inside a mill
Grinding, drying, transport and classifying
Different process circuits
Thank you for your attention
Raw material, coal and clinker/slag mill
Control values
Inlet pressure, differential pressure, outlet temperature and gas volume
Evaluation of performance
Operation, audits and required improvements
Essential knowledge of system, process and relations
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Preventive Maintenance - Wear and repair by Stefan Wölfel, Loesche GmbH, Germany
Preventive maintenance – Wear & repair
© by LOESCHE
Stefan Wölfel, Head of Installation Department Loesche GmbH Technical Seminar Jakarta 2015
Page 46
Agenda Main assembly groups This presentation
Overview Mill stand Table M-Rocker arm/M-Rocker arm bearing M-Roller/M-Roller bearing S-Roller Lever sealing Spring assembly Cabinets N2 accumulators Swinging out rollers Grinding parts Recording wear of grinding parts Hard facing of grinding parts Mill drive Classifier/Classifier drive Auxiliarie parts
helps you in order to plan your maintenance and conduct preventive maintenance. Therefore all companies have to find a way in coping with downtimes and scheduled maintenance intervalls.
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Wear and repair – Technical Seminar 2013 – Rev.1
gives you a guidance for problems encountered.
Page 47
Overview
Mill stand
Example of a LOESCHE Mill LM 3+3
Visual check: condition of bolts of bearing caps condition of weldings
Mill body incl. lining
oil accumulations on concrete foundation
M-Roller M-Rocker arm
condition of anchor bolts
Sealing air S-Spring assembly S-Rocker arm S-Roller Mill gearbox Mill drive
condition of gearbox attachment bolts Interval: weekly
Table
Variant 1 Superbolt system
M-Spring assembly Mill stand
Illustration
Illustration 4
Q………….. en Maintenance Rev.A
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Variant 2 Hydraulic tension system
Page 48
Table
M-Rocker arm Visual check: axial bearing screws grease pipeline connections
Visual check condition of: dam ring louvre- and armour ring clamping ring scrapers
Maintenance: change wear rings of sealing air assembly check bearing clearance change bearings
Maintenance: repair by fill-up welding and hard-facing replace worn parts
Interval: visual check weekly Maintenance: check bearings yearly check sealing air gap in 6 month shift interval according to the specific „wear behavior“ of the mill
Interval: check wear monthly shift interval according to the specific „wear behaviour“ of the mill
Illustration
Illustration 6
Q………….. en Maintenance Rev.A
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M-Rocker arm bearing
M-Roller
Maintenance: change bearings
Visual check: attachment bolts of roller axle and tire wear of guard oil leakages
Interval: change bearing after 30000 h shift interval according to the specific ‚wear behavior‘ of the mill.
Maintenance: change wear rings of sealing air assembly change slip ring seal change worn wear parts clean air filter take oil samples for analysis
Rebuilding of bearing seats is possible but not required, if bearings are replaced in good time
Interval: visual check weekly Maintenance: oil analysis every 3500 h change slip ring seal after 15000 h shift interval according to the specific „wear behavior“ of the mill Illustration 8
Q………….. en Maintenance Rev.A
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M-Roller bearing
S-Roller
Maintenance: change bearings
Visual check: attachment bolts of roller axle and tire wear of guard oil leakages
Interval: change bearings after 30000 h Shift interval according to the specific „wear behavior“ of the mill
Maintenance: change wear rings of sealing air assembly change slip ring seal change worn wear parts clean air filter take oil samples for analysis Interval: visual check weekly Maintenance: oil analysis every 3500 h change slip ring seal after 15000 h shift interval according to the specific „wear behavior“ of the mill Illustration 10
Q………….. en Maintenance Rev.A
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Lever sealing
Spring assembly
Visual check: attachment bolts of lever sealing parts wear of lever sealing parts proper adjustment of gaskets and bellows
Visual check: attachment of clamping nuts grease connections condition of buffers condition of hyd. connections oil leakages condition of bellows condition of hyd. cylinders
M-Lever sealing
Maintenance: change worn parts Interval: visual check weekly Maintenance: change worn parts according actual wear shift interval according to the specific „wear behavior“ of the mill
Spring assembly S-Roller
Maintenance: change stop-plates of buffers change bellows check bearing clearance change gaskets of hyd. cylinders
Components of M-Lever sealing S-Lever sealing
Interval: visual check weekly Maintenance: shift interval according to the specific „wear behavior“ of the mill
Illustration
Illustration 12
Q………….. en Maintenance Rev.A
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Q………….. en Maintenance Rev.A
Spring assembly M-Roller
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Cabinets Visual check: oil levels oil flow (HSMS) oil leakages on cabinets and pipelines discoloration of oil
N2 accumulators HSMS
HSLM
Visual check: corrosion, damages on accumulators proper fixation of accumulators proper attachment of valve protection caps oil leakages Maintenance: check nitrogen-pressure of all accumulators check proper attachment of valves change bladders, gaskets pressure tests acc. pressure-vessel regulations
Maintenance: change oil filters, air filters change oil clean tank take oil samples for analysis Interval: visual check daily Maintenance: oil analysis every 3500 h refer to lubrication instructions
HSSW
Filling valve
Piston accumulator
Interval: visual check weekly
Typical pipe-connector
Maintenance: check nitrogen pressure once a week, if no pressure loss, check every 4 months, if no pressure drop check yearly
N2 Oil Illustration
Illustration 14
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Q………….. en Maintenance Rev.A
Bladder accumulator
Page 53
Swinging out rollers Visual check: check completeness and function of all auxilliary parts Swing-out cylinder to be stored vertically
Grinding parts Taper pin connection
Maintenance: (prior to use of auxiliary parts): change oil bleed off air of swing-out cylinder clean tank
Visual check: check wear of tires with tire profile ruler check wear of grinding plate
Flanged sleeve
Swinging-out device
Maintenance: change grinding parts welding of worn out sections of tires, grinding plant and wear rings of dam ring Interval: check wear monthly shift interval according to the specific „wear behavior“ of the mill
Important: Proper dismounting and mounting of taper pinand flanged sleeve connection of rocker arm-fork connection
Level
Interval: Visual check: Prior to using auxilliary parts
Support
Typical wear pattern
Tire profile ruler
approx. 10mm
Roller
Grinding plate
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Wear on grit cone
Wear on grit cone supports
Every time you have the chance of looking into the mill internals, you should check all parts in regards to wear (especially for the classifier, louvre and amour ring, tires, and table liners).
Example to the right: The grit cone supporting tubes show wear in the top part. There are 8 supporting tubes. Only the four ones above the rollers show wear.
Example to the right: Grit cone shows wear on two levels in front of each roller. Wear positions and shapes are similar. The top level wear is in the axis of each roller. The bottom level wear is about 50 cm ahead. End user didn't allow SINOMA to patch the holes, as LOESCHE recommended.
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Wear on rotor, guide vanes, and static guide vanes
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Wear on guide vanes
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Wear on guide vanes
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Wear on fixation pipes
Page 57
Wear on mill body armour plates
Wear on lever sealing
Examples to the right: The vertical lever sealing plates show some wear. Vertical plates in front of the rollers are worn on the upper part. Vertical plates behind the rollers are worn in the lower part. The horizontal plates above roller shaft show wear on the side in front of the roller.
Example to the right: The mill body armour plates show wear on the welding openings, especially above 2m between the rollers.
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Wear on louvre ring
Wear on roller
Example to the right: Abnormal wear is observed at one position on roller 1. During commissioning, the roller n°1 faced some problems to turn freely, then rotation was better after the first maintenance. Leading the roller to slip on the grinding bed always in the same angular position: the most likely cause of local wear. Other rollers and other parts of roller 1 show normal shaped wear.
Examples to the right: Louvres in the area just behind the rollers show significant wear. The wear is more distinct on the external side. The wear in the remaining part of the louvre ring is low.
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Recording wear of grinding parts Zero measurement / wear measurement
Hard-facing of grinding parts Hard-facing of tires in situ (On site)
Example of recording measurements (zero measurement or wear measurement) of tire:
Example of recording measurements (zero measurement or wear measurement) of grinding plate:
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Hard-facing of grinding parts
Hard-facing of grinding parts
Hard-facing of tires in situ (On site)
Hard-facing of tires in situ (On site)
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Mill drive Visual check: abnormal noise during operation oil levels oil leakages Maintenance: change, clean oil filters, air filters change oil take oil samples for analysis check coupling alignment check (change) compression parts of coupling
Classifier Typical gearbox
LSKS
Typical lubrication unit
Classifier housing
Maintenance: replace worn parts repair worn parts by fill-up welding
Typical arrangement
Typical coupling
Static flaps Classifier rotor
Interval: Visual check weekly
Classifier grid cone
Maintenance: Shift interval according to the specific „wear behaviour“ of the mill
Interval: Visual check daily Maintenance: oil analysis every 1000 h refer to lubrication instructions
Rotor blades Separation gap Top view
Condition of gearbox attachment bolts
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Flaps / guide vanes Illustration
Illustration Q………….. en Maintenance Rev.A
Classifier drive
Visual check: check for proper attachment of bolts check for wear
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Auxiliary parts
Classifier drive LSKS Visual check: check for proper fixation of gearbox and motor check oil level check for oil leakages check grease pipeline connections Maintenance: change oil take oil samples for analysis check coupling alignment check (change) compression parts of couplings
Main auxiliary parts:
Classifier drive
(see also Swinging out device)
Auxiliary parts for S-roller Eye bolt
Auxiliary parts for M-roller
Lifter
Bearing cartridge
Classifier Auxiliary parts for table
Hydraulic jack
Oil analysis every 3500 h Refer to lubrication instructions Cylinder Table support
Illustration 34
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Illustration 35
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Q………….. en Maintenance Rev.A
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Thank you for your attention
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Page 64
More than just conventional Condition Monitoring by Dr. Franz Muschaweck& Sebastian Muschaweck, DALOG Diagnosesysteme GmbH
Technical Seminar Jakarta 2015 Jakarta, Indonesia, 21 – 23 April 2015
More than
just conventional Condition Monitoring
Dr. Franz Muschaweck Sebastian Muschaweck Certified ISO 9001: 2000 With product development
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Page 65
DALOG® Diagnosesysteme GmbH
DALOG® Products and Services
Development of systems for Preventive Maintenance Unexpected machine failures should be reduced.
Founded: 1998 Since 2006 Representative Office Beijing, China Since 2012 Sales Office Coimbatore, India
Precision Maintenance Avoiding machine failures by knowing the machine dynamic and therefore working towards a smoother operation.
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Predictive Maintenance “Condition Based Monitoring” Knowing the health of your Machine at any time.
Page 66
DALOG® Products and Services
DALOG® Applications – World Wide
“Vibrations and high Dynamic is a symptom” the aim is to find the root cause for having a longer life cycle of the machines
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Page 67
DALOG® D-MPC® is applicable for:
DALOG® VRM Gearbox Facts!
FACTS!
High Dynamic Production
• Every 3rd VRM Gearbox > 2000 kW fails Stable Operation with • 60% of the gearboxes fail more than once • 90% of the machine owners are not aware of DALOG Machine Protection Concept the dynamic of the machine – nor that it can be improved (it‘s not healthy)
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Page 68
DALOG® VRM Chart
DALOG® Mill Protection Concept D-MPC®
High Dynamic Production
Failure prevention!
Stable Operation with
DALOG® Mill Protection Concept
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
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© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Failure prediction!
Page 69
DALOG® Condition Monitoring… „Dalog has saved another gearbox in one sold-out market“ Feedback from our Client
DALOG® Planetary bearing fault
Acceleration Sensor
What exactly is condition monitoring?
Planetary bearing fault detected Nov. 2011
Bearing fault detected in November Fault progressing monitored, spare parts and repair planed Repair was done during annual shut down in march
No loss time and expensive secondary damage
Planetary bearing fault repaired March 2012
Online Alarm sent to Operator Alarm level
Early Gearbox failure detection of gears and bearings Planned Maintenance or repair works Know the status of your machine at any time Avoid expensive secondary damages
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Page 70
DALOG® Single tooth crack
Single crack on tooth detected Severe secondary damage avoided Temporary repair and further operation Gears will be replaced in upcoming annual shutdown
DALOG® Torque Monitoring… „Do you know how your VRM is performing?“ Single developing tooth crack
Strain Gage
What exactly is torque monitoring?
Antenna Ring
Early Gearbox failure detection – direct measurement
Antenna Head
High Sensitivity of disturbed/ unstable Process operations – instant alarming Detecting of Motor driving faults
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Detecting of wear and grinding rollers / table faults
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Page 71
DALOG® Torque Monitoring… Torque Alarms... „High frequency torque measurment captures the dynamic proportion of the system unlike the motor power signal“
...online torque alarms – informing the operator in real time about critical machine operation
DALOG® Case Study VRM - DALOG Torque Sensor – High Dynamic Indicating Table Liner Fault Severe overload of gearbox!
Warning and Alarming via Torque Sensor
Torque Torque Torque Torque Torque
1 2 3 4 5
Periodically shocks each of them introduced every time the rollers are passing the cracked table liner
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Alarm Alarm Alarm Alarm Alarm
Page 72
DALOG® Case Study VRM - DALOG Grinding Table Example - Benefits
DALOG® Process Monitoring… „Vibrations and High Dynamic are symptoms – find the root cause!“ Torque Signal
Early detection of the problem results in:
-
Reducing the load of the Gearbox due to early rectification of the problem.
-
Increasing the lifecycle of the Gearbox.
What exactly is process monitoring? Root Cause Analysis Correlation of high resolution data of torque and process signals during high dynamic situations.
Mill Operation Parameters
Longer lifecycle of machine Detecting of Process and operational irregularities
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Page 73
DALOG® Case Study VRM Basic data – Mill type – Mill size – Installed motor power – Nom. torque
DALOG® Case Study Process Monitoring Torque Signal before DALOG Monitoring
Raw mill 220 t/h 1600 kW 14 kNm
Problem description – During DALOG commissioning it got observed that the mill is showing repetitive vibration patterns during operation. – Therefore unsettled operation combined with many Tdyn (Torque dynamic) and Timpact (Torque impact) alarms
unstable operations
– Higher vibration and reduced production rate
stable operations
Torque Signal after Mill optimization 18
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Page 74
DALOG® Case Study VRM - DALOG
DALOG® Reporting... „Profit from our Experience and Knowledge!“
Analysis Torque vs. Mill Operation Parameters in High Resolution
Mill Feed
Reporting
Torque
Independent and Objective
Mill DP
Complete Report about the condition of the machine.
Hydraulic Press.
„Findings“ „Conclusions“ „Recommendations“
Motor Power
Trends, Analyse
Mill Vibration.
Statistics: Process stability Long term process trends
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Page 75
DALOG® Monitoring
DALOG Implementation into the CCR
DALOG Implementation into the CCR © Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
DALOG® Monitoring
Page 76
DALOG® What’s so special about us?
DALOG® in Cement Plants Our Customers:
We have more than 200 condition monitoring systems for Vertical Roller Mills installed worldwide…
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Page 77
DALOG® Quietly Running Machine
Thank You! DALOG® Diagnosesysteme GmbH Mühlbachstraße 21 86356 Neusäß / Germany Phone: +49 (0) 821 74 777 10 Fax: +49 (0) 821 74 777 19 E-Mail:
[email protected] www.dalog.net © Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
© by LOESCHE
© Confidential. DALOG reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on the third parties.
Page 78
Process parameters and plant optimization by Christian-Martin Ruthenberg, Loesche GmbH, Germany
Process parameters and plant optimization
© by LOESCHE
Ch.-M. Ruthenberg, Technical Trainer Corporate Service/Training Center, Loesche GmbH Technical Seminar Jakarta 2015
Page 79
Agenda
Processes inside a mill
Processes inside a mill Process Parameters Dependencies Examples
Transportation
Classifying
Drying
Grinding
Summary
Clinker/ slag mill 2
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Processes inside a mill
Processes inside a mill Flow
Transportation Flow
Drying Temperature
Classifying Speed
Pressure
Constantly controlled & stable
Grinding Pressure
Consistent product
Temperature
Speed
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Agenda
Process Parameters
Processes inside a mill
Pressure
Mill inlet vs. Outlet (dp mill) Filter inlet vs. Outlet (dp filter) Working and counter pressure (grinding force) Compressed air
Process Parameters Dependencies Examples Summary
Flow
Material Reject Gas Water (Fuel) Product
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Mill outlet gas Material Water Product
7
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Temperature
Page 82
Process Parameters
Agenda
Speed and position
Processes inside a mill
Roller Classifier Damper Hopper filling
Process Parameters Dependencies Examples Summary
Drives
Mill main Classifier Mill main fan
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Dependencies
Agenda Processes inside a mill Process Parameters
Temperature
Dependencies Examples Summary
Pressure
Speed
Flow
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Examples – Filter differential pressure
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Examples – Feed material change
Page 85
Examples – Hopper segregation
Examples – scrapper wear
Minimum value
Max value
Limestone hopper level
6.85 m
10.23 m
Raw mill body vibration
7.81 mm/s
14.24 mm/s
Raw mill motor power
4536 kW
5490 kW 14
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Examples – lovre ring covers
Examples – rotary valve
Finding: 3,38 m² -> 88 m/s Design: 4,79 m² -> 61,5 m/s
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Page 87
Clinker/slag grinding plant
Agenda Processes inside a mill
Damper S (Stack)
Process Parameters Dependencies
Damper R (Recirculation)
Examples Summary
Damper Z1 (Fresh air)
Hot gas generator
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Summary Processes inside a mill transport, grinding, drying and classifying
Process parameters flow, pressure, temperature and speed
Thank you for your attention
Dependencies
flow, pressure, temperature and speed
Examples
high complexity of possible measures
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Page 89
Grinding aid: Advantages and operation optimization by Dr. Pietro Recchi, MAPEI
Loesche Indonesia | VRM Seminar | 22-23 April, 2015
Cement Grinding Additives for Vertical Mills Product characteristics & Industrial case studies
© by LOESCHE
Dr. Pietro Recchi | Regional Technical Manager Asia-Pacific
Page 90
Vertical Roller Mills (VRMs) for cement production
VRM for cement production - advantages
“Thanks to the necessity of continuous improvements in the cement grinding process and related cost reduction, Vertical Mills have been introduced to the cement industry. Although at first this technology was mainly used for grinding solid combustibles and kiln-feeding raw materials, recent technical improvements allowed vertical mills to become a competitive solution for finished cement grinding as well.
The key advantages of vertical mills with respect to ball mills can be summed up in the following points:
Most probably, the market share of vertical mills will grow even further, probably becoming the main cement grinding system in new plants.” The above statement was Mapei’s Cement Additives Division’s vision in 2010.
Significantly lower specific energy consumption (kWh/t) (*). One single machine for drying, grinding and separating. Compact and “on-site” assembling, thus avoiding logistical problems and related costs. Great versatility, quick shift from one cement type to the other. Lower sensitivity for moisture in the raw materials (if sufficient drying energy is available). Low noise levels, no housing is theoretically required.
© by LOESCHE
(*) for cement grinding, reductions by 30-40% can well be expected.
Page 91
VRM for cement production – disadvantages over BM Known disadvantages of vertical mills over ball mills are: Particularly high SSA values are usually more challenging to achieve (*). Higher sensitivity for fine materials (the threshold is normally set around a maximum of 50% of material < 4 mm). Large amounts of water may have to be added to the grinding process in order to maintain low levels of vibration (**). An external heat source may be needed to order to ensure a proper gypsum de-hydration (particularly with ‘cold’ clinker). Higher initial investment costs. (*) The achievable SSA ultimately depend upon a series of factors, among which the clinker mineralogy and microscopic structure is probably the most important one. (**) This is particularly true in case of particularly dusty/fine or over-burnt clinker.
Vertical mills and ‘traditional’ grinding aids What happens when a ‘traditional’ GA is used in a cement vertical mill? Practical field experience has highlighted the fact that ‘traditional’ grinding additives (GA) are much less efficient in vertical mills when compared with their utilization in ball mills. This loss of performance is caused by the different ventilation conditions inside the VM, which lead to the following problems: “Stripping” (*) of the GA Evaporation of the GA
GA PERFORMANCE LOSS!
The two above mentioned issues are caused by the huge airflow and the high temperature.
© by LOESCHE
(*) Stripping is a physical process where one (or more) components from a liquid stream are removed by a vapour or vapour-like gaseous stream.
Page 92
VRM and grinding aids: an impossible marriage?
New formulations: Mapei ‘VM’ grinding aids
Fortunately not!
As vertical mills are used more and more often in cement plants, Mapei’s R&D developed specific grinding aids designed for this particular application. These products contain a blend of special high-boiling and low-volatility compounds that ensure their effectiveness by protecting traditional components (glycols, amines) from being influenced negatively by the harsh conditions inside vertical mills.
A ‘synergic approach’ has been proven able to overcome the “stripping” and “evaporation” of the GAs inside vertical mills: New GA formulations, specifically designed for applications in vertical mills
This new product line consists of the following product types: Innovative dosing point of GA
© by LOESCHE
Grinding Aids (MA.G.A./VM) Performance Enhancers (MA.P.E./VM) Workability Improvers (MA.P.E./VM W)
Page 93
Mapei ‘VM’ grinding aids: an overview
Typical Dosage Mill Output Strengths
MA.G.A./VM
MA.P.E./VM
MA.P.E./VM W
200 – 500 g/t
700 – 1,500 g/t
700 – 1,500 g/t
•••
••
•
••
•••
••
•
•••
••
•••
•
All cement types
Blended cements
Blended cements
Workability CO2 reduction
The grinding aid dosing point plays a crucial role in vertical mills. Therefore Mapei has developed an innovative dosing system that maximises the effect of the GA, avoiding both stripping and evaporation. Usually, vertical mills are equipped with a water introduction system for the stabilisation of the grinding bed: by using the existing pipelines, we can make sure that the grinding aid is ‘forced’ directly on the track and immediately comes in contact with the surface of the material to be ground.
© by LOESCHE
Typical application
New dosing technology: direct introduction
Page 94
New dosing technology: direct introduction Fresh feed conveyor (traditional dosing point)
New dosing technology: example of actual installation (1)
Finished product
Grinding Aid tank
Additive dosing pump
Water Pump Water tank
© by LOESCHE
Vertical Mill
Page 95
New dosing technology: example of actual installation (2)
Cement Grinding Aids: Mechanism of action (process)
© by LOESCHE
Once properly dosed on the grinding table, the GA is able to swiftly execute its primary task: to neutralize and disperse the electrostatic charges which form on the surface of ground material:
Page 96
Cement Grinding Aids: Mechanism of action (process) Neutralization of the electrostatic charges results in a significant de-agglomeration of the ground cement particles; the immediate result is a neat improvement of the classification process by means of the separator. As a consequence, a decrease of the mill Δp (differential pressure) takes places shortly (within 5-15 min.) after the introduction of grinding aids to the VRM, and is a clear indication that the product is working correctly. Depending on the plant requirements, this decrease of the VRM circulating load can be subsequently used to:
Cement Grinding Aids: Mechanism of action (process) An example of the enhanced separator performance is shown below (Tromp curve):
By pass
Blank
MA.G.A./VM 10
15%
9%
Imperfection
0,26
0,16
Acuity limit
18 µm
21 µm
© by LOESCHE
A) Increase the fresh feed B) Increase the separator speed C) A combination of the above
Page 97
Cement Grinding Aids: Mechanism of action (process) The resulting positive impact on the cement’s PSD is shown below:
Cement Grinding Aids: Mechanism of action (strengths) On top of the de-agglomerating effect, certain specific GAs (strength enhancers) also chemically promote the cement hydration process, mainly influencing the “first gel” phase formation (i.e. aluminate – based). Time
(min)
0
10
The effect is particularly evident in the 4-30 µm range
100
1000
C-S-H
Strengths enhancing GA
DRY CEMENT POWDER
FIRST GEL
“INTERMEDIATE PHASE”
SECOND GEL
© by LOESCHE
+ H2O
Page 98
Pre-hydration of cement in VRM In some particular cases (e.g. when the clinker is particularly ‘dusty’), the plant may be forced to inject higher amounts of water to stabilize the grinding bed.
Pre-hydration of cement in VRM A more sophisticated methodology to assess cement pre-hydration is TGA analysis.
While amounts of injected water < 1.5 – 2.0% (with respect to the VRM output) are considered to be ‘safe’, higher amounts may trigger cement pre-hydration inside the VRM.
A sample of cement is heated from room temperature up to 1000°C and the decreases of weight (due to release of water or CO2) are measured. It is then possible to quantify the amount of gypsum, calcium hydroxide, limestone, hydrated phases, etc.
A quick and convenient method for assessing pre-hydration is the “corrected loss-onignition” (Wk) determination:
Hydration of tricalcium silicate produces a family of different compounds usually described as C-S-H (calcium silicate hydates).
Wk = [LOI at 450° C] – [LOI at 120° C]
Water bound in such structures is usually lost over a wide range of temperatures, due to the extreme variety of compositions of the C-S-H. Generally speaking, we can associate the weight decrease between 200 and 400°C to the water lost from C-S-H.
© by LOESCHE
As a rule of thumb, Wk in excess of 0.3% indicates a pre-hydrated cement sample, for which substantial strengths losses at all ages are very likely to occur.
Page 99
Pre-hydration of cement in VRM The following is a typical TGA graph of a moderately pre-hydrated cement sample:
Pre-hydration of cement in VRM (solution) Compared to water, cement grinding aids have proven themselves to be more effective in stabilizing the grinding bed and reducing the VRM vibrations. Introduction of GAs usually permits a significant reduction of the % of injected water, thus minimizing the risks associated with cement pre-hydration. % of injected water
100-200°C
200-400°C
450-550°C
>600°C
No additive
5.4
0.32%
0.19%
0.29%
1.35%
With MA.G.A./VM
1.7
0.26%
0.06%
0.27%
1.75%
© by LOESCHE
Weight decreases at different temperatures evaluated using TGA
Page 100
Key industrial case study (featured in ZKG; issue 3/2010)
In order to verify the effectiveness of Mapei’s grinding aids for vertical mills in comparison with traditional ones, our Technical Assistance Group performed a series of industrial evaluations: 1. 2. 3. 4.
“Blank” – without any additive “Test A” – traditional GA dosed on the fresh feed conveyor “Test B” – traditional GA dosed on the grinding plate “Test C” – MA.G.A./VM 12 dosed on the grinding plate
Key industrial case study (featured in ZKG; issue 3/2010) These tests have been performed during the production of a CEM I type cement (according UNI EN 197-1). VRM characteristics: - Supplier/Model: confidential - Absorbed power: 3.500 kW; - Ventilation: 680.000 m3/h - ∆p 50 mbar; - Water injection: 2,1% (referred to the initial fresh feed) - Roller pressure: 75 bar.
© by LOESCHE
During the tests the following parameters were kept constant: - GA dosage: 250 g/t (referred to the fresh feed in t/h) during test A, B and C; - Avg. vibration: between 2 and 4 mm/sec; - Blaine: ≈ 3.500 cm2/g
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Key industrial case study (featured in ZKG; issue 3/2010) Effect on the VRM’s hourly output (tph):
180 160
Mill Output (t/h)
140 120 100 80 60
Accordingly, a notable reduction of the specific energy consumption (kWh/t) was observed: 190
173
175
B A
200
40,0
C
35,0 Power Consumption (kWh/t)
200
Key industrial case study (featured in ZKG; issue 3/2010)
30,0
A
29,5
BB
C
28,1
C
20,0 15,0 10,0
A
5,0 0,0
© by LOESCHE
0
30,1
25,0
40 20
32,0
Page 102
Key industrial case study (featured in ZKG; issue 3/2010) On top of the higher output, the cement fineness was improved, too:
Key industrial case study (featured in ZKG; issue 3/2010) The cement’s compressive strengths were enhanced at all ages (2days depicted):
10,0
30,0
9,0
7,0
8,0
7,9
7,8
A
B
25,0 6,4
6,0 5,0 4,0 3,0
C
2-days Strenghts (MPa)
Residuals at 45 μm (%)
8,0
20,0
25,4
25,6
A
26,6
B
28,0
C
15,0 10,0
2,0 1,0
5,0
0,0
© by LOESCHE
0,0
Page 103
Key industrial case study (featured in ZKG; issue 3/2010) The cement’s compressive strengths were enhanced at all ages (7 days depicted):
Key industrial case study (featured in ZKG; issue 3/2010) The cement’s compressive strengths were enhanced at all ages (28 days depicted): 55,0
45,0 37,0
38,1
30,0 25,0 20,0 15,0 10,0
A
B
C
50,0 45,0 40,0
46,1
46,3 A
47,6 B
50,7 C
35,0 30,0 25,0 20,0 15,0 10,0
5,0
5,0
0,0
0,0
© by LOESCHE
7-days Strenghts (MPa)
35,0
39,1
28-days Strenghts (MPa)
40,0
38,7
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Key industrial case study (featured in ZKG; issue 3/2010) Conclusions: The reference product dosed at a traditional dosing point shows little or no effects on the production process and cement quality. When the same reference product is sprayed directly on the grinding track, certain improvements can be seen, demonstrating the validity of the dosing methodology proposed by Mapei.
Case study #2: Grinding station in Central America Mill supplier/model: confidential Starting conditions: Low mill output with respect to nominal capacity (55 t/h vs. 80+ t/h) Low compressive strengths (≈ 20% lower than target) Extremely high amount of injected water (up to 7-8%) Unsuitable granulometry of the clinker (“powderous” clinker) A basic grinding aid from a local supplier was dosed in the traditional way (conveyor belt)
© by LOESCHE
MA.G.A./VM 12 clearly stands out by showing strong improvements in terms of production and cement quality; the specific formulation is clearly suitable for this application.
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Case study #2: Grinding station in Central America
Case study #2: Grinding station in Central America
Customer requests:
Results of the preliminary industrial trial:
Increase the compressive strengths (especially early ones) by at least 15% Increase the mill output to at least 70 t/h
Proposed technical approach: Modification of dosing point (direct injection together with water flow) Industrial trial with MA.G.A./VM 05 dosed @ 500 g/t (0,05%) Our achievements:
Additive:
Dosage:
Dosing system:
Injected water (%):
Mill output (t/h):
24h – strengths (MPa):
48h – strengths (MPa):
Reference
0,07%
traditional
7.1
55-56
9.1
19.7
MA.G.A./VM 05
0,05%
MAPEI direct
3.7
75-77
11.0
21.9
© by LOESCHE
Reduction of water % Improvement of compressive strengths Increase of the mill output
Output was increased by >35% Early strengths were increased by 20% (1 day) and 10% (2 days) Water injection was reduced by ≈ 50% Grinding aid dosage was reduced by ≈ 30% with respect to reference
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Case study #3: Integrated plant in Eastern Europe (2012)
Case study #3: Integrated plant in Eastern Europe (2012)
Mill supplier/model: confidential
Customer requests:
Starting conditions:
Increase the cement fineness, keep vibrations as low as possible
The plant is producing a CEM I 42,5 R cement blend (Blaine ≈ 3700 cm2/g) Mill output is close to nominal capacity (≈ 120 t/h) The plant wants to produce a CEM I 52,5 R (Blaine > 4100 cm2/g)
Proposed technical approach:
Our achievement: Facilitate the transition from CEM I 42.5 R to CEM I 52.5 R
© by LOESCHE
Separator is already close to limit (99% of maximum rpm) Roller pressure may not be increased due to high vibration level (4-5 mm/s) Extremely high amount of water (up to 7%) is injected No grinding aid is used
Industrial trial with MA.G.A./VM 01, dosed @ 300 g/t (0,03%) together with the water flow directly below the rollers
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Case study #3: Integrated plant in Eastern Europe (2012)
Case study #4: Integrated plant in North Africa (2012)
Results of the preliminary industrial trial:
Mill supplier/model: confidential
Fineness was increased up to 4.200+ cm2/g with no loss of output Average vibrations were decreased Amount of injected water was reduced by 40%
Starting conditions:
Dosage:
Dosing system:
Injected water (%):
Mill output (t/h):
Maximum fineness (cm2/g):
Average vibrations (mm/s):
No additive
-
-
7.0
120 – 122
3910
3.6 – 4.8
MA.G.A./VM 01
0,03%
MAPEI direct
4.4
120 - 122
4213
2.1 – 3.2
The plant is producing an OPC-type cement blend (Blaine ≈ 2900 cm2/g) Normal mill output is 280 – 290 t/h (well below the nominal output) No grinding aid is normally used Another supplier made an industrial trial one week before Mapei
© by LOESCHE
Additive:
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Case study #4: Integrated plant in North Africa (2012)
Case study #4: Integrated plant in North Africa (2012)
Customer requests:
Results of the preliminary industrial trial:
Increase the hourly output as much as possible, without decreasing the cement’s fineness
Hourly output was increased by 16% with respect to the ‘blank’ (Hourly output was increased by 11% with respect to the reference product) Fineness of the finished product was not affected
Proposed technical approach: Industrial trial with MA.G.A./VM 02, dosed @ 350 g/t (0,035 %) together with the water flow directly below the rollers Our achievement:
Dosage:
Dosing system:
Injected water (%):
Mill output (t/h):
Average fineness (cm2/g):
No additive
-
-
1.1
280 – 284
2900
Reference
0,04%
traditional
1.0
296 – 298
2912
MA.G.A./VM 02
0,035%
MAPEI direct
1.0
328 - 330
2919
© by LOESCHE
Significantly increase the VRM’s hourly output
Additive:
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Case study #5: Integrated plant in SE Asia (2013-2015)
Case study #5: Integrated plant in SE Asia (2013-2015)
Mill supplier/model: confidential
Customer requests:
Starting conditions:
Increase the average 2 days strengths from 17-19 MPa to >24 MPa. Improve the workability of their OPC
The plant is producing OPC cement with their twin VRMs Average early compressive strengths are well below the market standard Workability issues are reported by several customers High amounts of injected water (> 5%) are negatively affecting the cement’s quality No grinding aid is used
Proposed technical approach: After several lab and industrial trials, we developed and proposed the product MA.P.E./VM 1001 W, to be dosed at 1.200 g/t according to our direct introduction methodology. Our achievement:
© by LOESCHE
Strongly increase the 2 days compressive strengths Solve the workability issues
Page 110
Case study #5: Integrated plant in SE Asia (2013-2015)
Case study #6: Integrated plant in SE Asia (2014) Mill supplier/model: confidential
Results after 14 months of regular utilization: The average 2-days strengths were increased from 17-19 MPa to 23-26 MPa. The plant is now injecting only 0.5% of water (sometimes none at all). Dosage:
Dosing system:
Injected water (%):
Mill output (t/h):
Average «corrected LOI»
Average 2 days compressive strengths:
No additive
-
-
> 5.0%
140-150
> 0.4%
17-19 MPa
MA.P.E./VM 1001 W
0,12%
MAPEI direct
max 0.5%
150+
< 0.2%
24-26 MPa
The plant is producing PCC (limestone based) with their recently installed (2013) VRM
Frequent VRM stops due to high average vibration level VRM output much lower than nominal one (100 – 110 tph vs. 125 tph) ‘Low’ outlet temperature due to high % of injected water (5.1 m3/h) The plant was testing a ‘traditional’ GA dosed on the fresh feed’s conveyor belt
© by LOESCHE
Additive:
Starting conditions:
Page 111
Case study #6: Integrated plant in SE Asia (2014)
Case study #5: Integrated plant in SE Asia (2014)
Customer requests:
Results of the preliminary industrial trial:
Increase the VRM output without compromising the PCC quality Increase the outlet temperature to 110° C Reduce the average vibration level and improve process stability
The VRM output was increased by 8% with respect to the reference GA Injected water was reduced by 45% Accordingly, outlet temperature increased to 109° C
Proposed technical approach:
Additive:
Dosage:
Dosing system:
Injected water (m3/h):
Mill output (t/h):
R45 residue (%):
VRM outlet temperature (C°):
Reference
0.045%
traditional
5.1
110
10.8
101 - 102
MA.G.A./VM 108
0.04%
MAPEI direct
2.9
119
9.3
109
Industrial evaluation of MA.G.A./VM 108 dosed at 400 g/t directly on top of the grinding table together with the water flow. Our achievements:
© by LOESCHE
Increase the VRM output while keeping the same fineness Reduce the % of injected water Improve the overall stability of the grinding process
Page 112
Conclusions:
Thanks for your attention ;)
Cement grinding aids can (and should) be successfully used for the production of cement with VRMs, provided the correct dosing technology and specifically designed products are used. By doing so, the performances of GAs in terms of: i. ii. iii. iv. ...
Output and/or fineness increase Process stabilization Compressive strengths increase Workability improvement
© by LOESCHE
Are definitely comparable (and often superior) to the ones usually obtained on traditional grinding systems (ball mills).
Page 113
Lubricants - Functions and the importance of maintenance by Moch Mustofa, PT. Mitra Asmoco Utama
© by LOESCHE
1
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PT Mitra Asmoco Utama
PT Mitra Asmoco Utama • Established in 1992. • PT. Mitra Asmoco Utama is the sole Authorized Distributor of Mobil™ in Jakarta, West Java and Banten.
• Winner of Circle of Excellent Award from ExxonMobil in 2007, 2010, 2012 and 2013. • Highly experienced and competent in the lubricant and distribution field.
3
© by LOESCHE
2
Page 115
PT Mitra Asmoco Utama
MAU Facilities
Warehouse:
Location : KBN Marunda, North Jakarta Size : 7,740m2 Capacity : 20 KB Location : Cikarang, West Java Size : 2,020m2 Capacity : 2 KB
5
© by LOESCHE
4
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Our Vision
Field Engineering Service Our team of Lube Engineers is ready to support our customer with their expertise :
To provide our customers With Quality Products, Quality Solutions and Ensure customer satisfaction.
• Lube training for customer • Engine inspection • Troubleshooting when emergency happened
7
© by LOESCHE
6
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Customers PT Mitra Asmoco Utama have been serving the packaging industry with Mobil products and technical expertise:
How Lubrication affects Machine Reliability & Productivity?
9
© by LOESCHE
8
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Lubricant and lubrication system overview
Proper Lubricant Selection What we should know ? • Lubricant Introduction :
– Basic lubricant production – Functions of lubricant – Lubrication regimes • Key Lubricant Parameters selections : – Viscosity – Lubricant types – Lubricant application
The most important to attention are : 1. Proper lubricant selection 2. OEM‟s (Original Equipment Manufacture) Recommendations 3. How to keep both oil & equipment performances
11
© by LOESCHE
10
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Lubricant Introduction
BASE OIL
LUBRICANT INTRODUCTION
ADDITIVE
- Mineral - Synthetic
13
© by LOESCHE
12
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Mineral Oil Production 1.
Synthetic Oil Production
2.
1.
2.
3.
3.
4.
4.
15
© by LOESCHE
14
Page 121
Base Stock Comparison Group I
Group III Mixture of variable length (C20-C40) and decreased number of saturated ring hydrocarbons (R).
R
Group II
A
H
Mixture of variable length (C20-C60) hydrocarbons with saturated ring (R), aromatic ring (A), and/or hetero atomic molecules (H) attached.
A H
Why Synthetic Are The Best ?
R H
A
R
R
Mixture of variable length (C20-C50) and saturated ring hydrocarbons (R).
R R
R
R
Group IV
R R
Group V A chemical reaction that makes organic esters and polyglycols. No wax molecules, no long- or short-chain hydrocarbons.
Polyalphaolefin (PAO) – mixture of oligomers from dimers to about 10-mers (~C20-C100)
Alcohol
+
R - OH
+n
Alkylene oxides
Polyalkylene oxide
O H-C-C-H H R1
H H R-O- C-C-O-H H R1 n
Lower traction coefficient and less friction under heavy load Lower operating temperature and oxidation with longer oil life 17
© by LOESCHE
16
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Characteristics Base Stock Comparison
Function of lubricant
19
© by LOESCHE
18
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Lubrication Regimes (stribeck curve)
KEY PARAMETERS LUBRICANT SELECTION
21
© by LOESCHE
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Viscosity Grade Chart
Viscosity Illustration : Proper Viscosity is a Function of Speed, Load and Temperature Viscosity :
High
High
High
Viscosity :
Low
Low
Low 23
© by LOESCHE
22
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Factors affect the viscosity
Variation of lubricant viscosity as a function of temperature and pressure mineral oil
Temperature A fluid's viscosity strongly depends on its temperature. Along with the shear rate, temperature really is the dominating influence. Pressure In most cases, a fluid's viscosity increases with increasing pressure. Compared to the temperature influence, liquids are influenced very little by the applied pressure
Reference :Thomas G. Mezger, 'The Rheology Handbook', 3rd revised Edition, (C) 2011 Vincentz Network, Hanover, Germany
25
© by LOESCHE
24
Pressure influence on viscosity: approx. +30 MPa in pressure => +10 % in viscosity
Page 126
Lubricant Types
Lubricant Application
Oils – Mineral Oil – Synthetic Oil • Greases – Soap (Calcium, Sodium, Barium, Aluminum, Lithium ) – Non soap (Urea, Clay, Polymers) • Dry/Solid Lubricants – Graphite – Molybdenum disulphide – PTFE and other similar polymers • Gases (usually used in gas bearing) – Air – Any gases which will not attack or decompose •
Note : „o‟ signify the additive is not in all formulations but is optional for specific applications. Reference: Machinery lubricant bulletin
27
© by LOESCHE
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Page 127
Industrial Hydraulic Oil Standards DIN 51524 H
ISO 6743 HH
HL (Part 1)
HL
HLP (Part 2)
HM
HVLP (Part 3) HV
Composition
Industrial Gear Oil Standards AGMA 9005
Field Application
Inhibitor (R&O)
Base Oil
System with no special requirements Base Oil,R&O, System with moderate VI=100 pressure Base Oil, R&O, Anti System with high pressure Wear, VI=100 and temperature Base Oil, R&O, Anti Wider temperature range than Wear, VI>140 HLP with HVI
DIN 51517 ISO 12925-1
Composition
C (Part 1)
Base Oil
CL (Part 2) CKB
Base Oil, R&O
CLP (Part Antiwear (EP) 3)
CKC
Compounded CGLP
CKD (CKC Plus) CKE (CKB Plus) CKS CKT
PAO, Ester, PAG+RO PAO, Ester, PAG+RO+EP
high load and temperature More sliding, wormgear Under extreme temp, ligt to moderate load Under very extreme temp, heavy load 29
© by LOESCHE
28
Base Oil, R&O, Anti Wear, EP Excellent oxidation/thermal stability Excellent friction modifier
Field Application For constant circulation and immersion lubrication For constant circulation and immersion lubrication Enclosed gear, for constant circulation and immersion lubrication, high load
Page 128
ASTM test method and the recommended value. The reader should refer to these methods for details of
A listing of recommended properties of new oil is shown in Table 1. Included with this listing are the the tests. The oil and is an Grade 32 (ISO VG 32) ASTM test method theInternational recommendedStandards value. TheOrganization reader should Viscosity refer to these methods for details of oil. The properties typical Standards of turbineOrganization lubricating oils exceptGrade for the the tests. Thelisted oil isare anrather International Viscosity 32oxidation (ISO VG test 32) requirements. oil. The properties listed are rather typical of turbine lubricating oils except for the oxidation test requirements.
Note that the values in Table 1 are only recommended values. Oil that has been shown to perform
successfully in the field may 1still usedrecommended even if all values Table havebeen not shown been satisfied. Note that the values in Table arebeonly values.in Oil that1has to perform successfully in the field may still be used even if all values in Table 1 have not been satisfied.
For several years there have been investigations to decide on appropriate (New Fluid) laboratory tests,
For several years there havebetween been investigations to give decidesatisfactory on appropriate (New Fluid) tests,and those long-term servicelaboratory in a turbine, which could distinguish fluids, which long-term between service in laboratory a turbine, and those and field which between which givecomplete satisfactory whichcould did distinguish not. To date, therefluids, has not been correlation testing which did not. To date, there has not been complete correlation between laboratory testing and field experience. experience.
OEM’s Recommendations
Lubricant characteristics required Table 1. Recommended Properties of High Temperature Lubricating Oil for Gas Turbines
Table 1. Recommended Properties of High Temperature Lubricating Oil for Gas Turbines (for New (for New Oil) Oil)
ASTM Test Method ASTM Test Method No.No.
• Most
of OEM’s Recommendations includes :
Current Current Recommended Recommended Value Value
Test Test
D287 D287
Gravity ( API) Gravity (o API)
29-39 29-39
D1500 D1500
ColorColor
2.0 (max.) 2.0 (max.)
o
– Lubricant characteristics required
D97 D97
PourPour PointPoint (oF/oC) (oF/oC)
+10/-12+10/-12 (max.) (max.)
D445
– Lubricant brands recommended
D974
Viscosity Viscosity 40oC (centistokes) 40oTotal C (centistokes) (TAN) Acid (TAN) Total Acid Number Number Rust prevention — A
0.20 (max.)
D445 D974
D665
– Lubricant operating conditions
D665
D93
– Lubricant service life recommended
D93
D130
D130
D892
D892 D943
D943
28.8-35.2
0.20 (max.)
Pass
Rust prevention — A
Pass
Flash point (COC) C) (oF/oFlash point (COC)
420/215 (min.)
Copper corrosion
1B (max.)
o
o
( F/ C)
Copper corrosion
Foam
Foam Turbine oil oxidation test (hrs)
420/215 (min.)
5,000 (min.)
5
5
31
© by LOESCHE
© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.
1B (max.)
50/0 (max.) 50/0 (max.) 50/0 (max.) 50/0 (max.) 50/0 (max.) 5,000 (min.) 50/0 (max.)
Turbine oil oxidation test (hrs)
© General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.
30
28.8-35.2
Page 129
Filling Quantity First Change Further Changes Refilling Quantity Check Quantity / Refill Specifications of Lubricant:
Lubricant characteristics required
16.4 ltr. each 3000 h check oil-quality 17000 h or every 5 years see measuring-line every month Synthetic Oil CLP HC 220
200 g / Bearing 16000 h
-
16000 h
-
90 g / Bearing 8000 h Grease
30 g 4000 h Grease
Lubricant characteristics required Lubricant
Remarks
Appertaining Documents (Drawing-no. or Manual)
see SEW-gearbox manual chapter 8
Check also nameplate of gearbox for oil-viscosity and quantitiy
Supplier Manual (KREISEL / SEW)
Mill Fan DHRV 50-1800 K Components
Number of Components Filling Quantity First Change Further Changes
Refilling Quantity Check Quantity / Refill Specifications of Lubricant: Lubricant: Remarks Appertaining Documents (Drawing-no. or Manual)
Supplier Manual (KREISEL)
Supplier Manual (KREISEL)
Number of Groups: 1 each
Non-locating Bearing 1 each 6 ltr. (max.) each -
Locating Bearing 1 each 7.2 ltr. (max.) each -
every year (T < 80°C) every 3 months (T > 100 °C)
every year (T < 80°C) every 3 months (T > 100 °C)
Recommended oil for T < 80 °C (Bearing temperature)
Recommended oil for T < 80 °C (Bearing temperature)
Oil Level: Oil Level: 75 mm (min.) 75 mm (min.) 110 mm (max.) 100 mm (max.) every week every week Hydraulic Oil Hydraulic Oil HLP 68 HLP 68 see supplier manual see supplier manual page 21-22 page 21-22
Supplier Manual (VENTI-OELDE)
Supplier Manual (VENTI-OELDE)
33
© by LOESCHE
32
Mobil Mobil Mobiltemp 78 Mobiltemp 78 see supplier manual see supplier manual page 27 page 27
Page 130
Lubricant brands recommended
Lubricant brands recommended List of lubricants for LOESCHE-machines (except gearboxes): Mineral Oils (CLP) / Synthetic Oils (PG) Lubricant
Latest Technical Instruction TI 1000 – 1109 Lubricating Oil for type 2, 3, 4 and 6 GE Jenbacher engines Natural Gas
Bio Gas
Landfill Gas
Document-No.: 4.Q-2980-00-4 en Date / Revision: 2014-01-28 / Q2 Generated by: Gödde
Code-no. Viscosity ISO-VG in DIN 51519 lubrication at 40° C (mm²/s) instructions
Mineral Oil CLP 100 (CLP(CC)) Mineral Oil CLP 150 (CLP(CC))
M1
VG 100
Mobilgear 600 XP 100
-
M2
VG 150
Mobilgear 600 XP 150
-
Mineral Oil CLP 220 (CLP(CC))
M3
VG 220
Mobilgear 600 XP 220
Omala F 220
Mineral Oil CLP 320 (CLP(CC))
M4
VG 320
Mobilgear 600 XP 320
Omala F 320
GEARMASTER CLP 320
Mineral Oil CLP 460 (CLP(CC))
M5
VG 460
Mobilgear 600 XP 460
Omala F 460
GEARMASTER CLP 460
Mineral Oil CLP 680 (CLP(CC))
M6
VG 680
Mobilgear 600 XP 680
-
GEARMASTER CLP 680
Polyglycol Oil PG 100 (CLP PG) Polyglycol Oil PG 150 (CLP PG) Polyglycol Oil PG 220 (CLP PG) Polyglycol Oil PG 320 (CLP PG) Polyglycol Oil PG 460 (CLP PG)
S1
VG 100
Glygoyle 100
-
S2
VG 150
Glygoyle 150
Omala S4 WE 150
S3
VG 220
Glygoyle 220
Omala S4 WE 220
GEARMASTER PGP100 GEARMASTER PGP150 GEARMASTER PGP220 GEARMASTER PGP320 GEARMASTER PGP460
Polyglycol Oil PG 680 (CLP PG)
S4
VG 320
Glygoyle 320
Omala S4 WE 320
S5
VG 460
Glygoyle 460
Omala S4 WE 460
S6
VG 680
Glygoyle 680
Omala S4 WE 680
GEARMASTER CLP 100 GEARMASTER CLP 150 GEARMASTER CLP 220
GEARMASTER PGP680
CARTER EP 150 CARTER XEP 150 CARTER EP 220 CARTER XEP 220 CARTER EP 320 CARTER XEP 320 CARTER EP 460 CARTER XEP 460 CARTER EP 680 CARTER XEP 680 -
Optigear BM 100 Tribol 1100/100 Alpha SP 150 Optigear BM 150 Tribol 1100/150 Alpha SP 220 Optigear BM 220 Tribol 1100/220 Alpha SP 320 Optigear BM 320 Tribol 1100/320 Alpha SP 460 Optigear BM 460 Tribol 1100/460 Alpha SP 680 Optigear BM 680 Tribol 1100/680 -
CARTER SY 150
-
CARTER SY 220
Tribol 1300/220 Tribol 800/220 Tribol 800/320
CARTER SY 320 CARTER SY 460 CARTER SY 680
Tribol 1300/460 Tribol 800/460 Alphasyn PG 460
Tribol 800/680
Page 1 of 6
35
© by LOESCHE
34
Page 131
Lubricant service life recommended ASTM and OEM Used Oil Limits
Source
Viscosity @ 40°C TAN
ASTM D4378
Ahistom - Gas and Steam
GE - Gas
Solar
MHI - Steam & Gas
Siemens/ Westinghouse
ASTM D4378
HTGD901117
GEK 32568f
ES9-224
MS04-MA-CL001 and CL002
K-8962-11
+/- 5% of new oil
Exceeds ISO VG Class
25 to 41
+20% or -10% of new oil
26 to 39
0.3 to 0.4 over new oil
RPVOT
< 25%
Water
> 0.1 %
Flash Point - ASTM D92
30°F drop from original
0.2 rise above new oil
0.4 < 25% of new
0.6 max for mineral oils; 0.8 0.4 increase over new for SHC > 25% of new oil
500 ppm
2,000 ppm max
Cleanliness
17/14
Abrupt Change
Demulsibility
30 minutes max
Metals
15-25 ppm: >30 ppm limit
Air Release
8 minutes for ISO VG 32
Rust Prevention - ASTM D665
Foam
> 25% of original
+/- 10% of new oil
OPTIMIZING OF MAINTENANCE PROGRAM
0.3 to 0.4 over new oil 25% of new oil 200 ppm max
light fail in D665A
Seq I exceeds 450/10
17/14 max
< 20 minutes Trend/consult
10 minutes max (guideline)
4 minutes max
Seq I - 300/10; Seq II - 300/10 (guideline)
Seq I - 400/10
37
© by LOESCHE
36
Page 132
Types of Maintenance
Types of Maintenance • Proactive Maintenance – Taken from preventive and predictive maintenance by analyzing the root cause, not only find the source of the problem but also look for the cause of the problem and to prevent the same problems recur.
•
Predictive Maintenance – Based on monitoring and measuring the condition of the assets to determine whether they will fail during some future period and then taking appropriate action to avoid the consequences of that failure
• Preventive Maintenance – Actions performed on a time- or machine-run-based schedule
•
Reactive/Breakdown Maintenance – “Run it till it breaks” maintenance mode. – No actions or efforts are taken to maintain the equipment as the designer originally intended to ensure design life is reached 39
© by LOESCHE
38
Page 133
The Human Body Parallel to Machine Maintenance
Source : Allied bulletin
MAITENANCE STRATEGY
TECHNIQUE NEEDED
COST PER HP PER YEAR
HUMAN BODY PARAREL
Proactive Maintenance
Monitoring and correction of failure root causes, e.g. contamination
$0.10
Cholesterol and blood pressure monitoring with diet control
Predictive Maintenance
Monitoring of vibration, wear debris
$8
Detection of hearth disease using EKG or ultrasonic
Preventive Maitenance
Periodic component replacement
$13
By-pass or Transplant surgery
Breakdown Maitenance
Large maintenance budged
$18
Heart attack or stroke
Source : Noria bulletin
Potential Failures – Where to Detect them ?
*power generation Example 41
© by LOESCHE
40
Page 134
Modern Maintenance Technologies Modern Maintenance Strategy
Early Identification of a Detect Source : Allied bulletin
Source : Noria bulletin 43
42
© Copyright Noria Corporation
272
Ref: JCF
© by LOESCHE
Success Elements of an Integrated Condition-based Maintenance Program
Page 135
Optimizing Investment in Equipment Reliability
Case Study 1 : Improper Lubricant Selection Previous conditions
• Using mineral ISO VG 150 • High temp oil around 60°C • Delay to reach peak oil pressure (250 bar) • Oil pump work harder • More oil leakage
New conditions
• Using Mobil Vacuoline 528 ISO VG 150 • Reduce oil temp from 60°C to 52°C • Fast to reach peak oil pressure (250 bar) • Oil pump work normal • Reduce energy loss
45
© by LOESCHE
44
Page 136
Case Study 2 : Energy Efficiency
Q&A
47
© by LOESCHE
46
Page 137
Thank You
© by LOESCHE
48
Page 138
Pyroprocess evaluation - waste treatment with the new Rocket Mill by Dr. Stefan Kern, A TEC Production & Services GmbH
A TEC SOLUTION FOR AF
© by LOESCHE
THE FUTURE OF ALTERNATIVE FUEL PREPARATION
Page 139
OUTLINE Introduction The A TEC Rocket Mill Technical solutions for AF at main burner Reference project
Can we achieve 100% TSR with solid alternative fuels in cement plants? What is necessary to achieve the remaining percentage of substitution rate to achieve 100% TSR with solid AF? Where?
kiln burner
How?
• New kiln burner • Quality improvement of AF
© by LOESCHE
The A TEC kiln burner for up to 100 % solid AF
INTRODUCTION
Page 140
INTRODUCTION
A TEC ROCKET MILL
General requirements for using AF
General requirements for using AF Maximum reduction of fuel costs
High clinker quality
High clinker quality
Stable condition in operation
Stable condition in operation
Low maintenance
Low maintenance
CO2 reduction
CO2 reduction
© by LOESCHE
Maximum reduction of fuel costs
Page 141
A TEC ROCKET MILL
A TEC ROCKET MILL
Advantages of the A TEC Rocket Mill
General information
Quality improvement of fuel Reduction of inorganics (ash) Reduction of moisture (drying) Higher specific surface (improved shredding technology)
Rotating chains Screen with 15mm hole size Direct drive
© by LOESCHE
Higher calorific value of final product
Two Grinding chambers
Page 142
A TEC ROCKET MILL
A TEC ROCKET MILL
Grinding tools
Advantages of the A TEC Rocket Mill
Four horizontally rotating chains Special chain links
Reduction of inorganics (ash) Easy discharge of inorganics
© by LOESCHE
Perforated screens
Page 143
A TEC ROCKET MILL
A TEC ROCKET MILL
Advantages of the A TEC rocket Mill
Higher specific surface (improved shredding technology)
Simultaneous drying in Rocket Mill
Samples below show final size < 15 mm
Total moisture reduction approx. 10 % Additional drying with process waste gas (optional)
Cutting Mill
Rocket Mill
30000 25000
LHV [kJ/kg]
20000 15000
Lower calorific heat value
10000 5000 0 45
40
35
30 25 20 Moisture [%]
15
10
5
© by LOESCHE
50
Page 144
A TEC ROCKET MILL Final Product The maximum size of final product with a screen with ø 15 mm is max. 15 mm approx. 50% < 5 mm.
Increased specific surface („fluffy“ like cotton) Drying effect during the grinding process approx. 10 %
Positive impact on pyroprocess Better burnout of AF in kiln
Higher substitution rates at kiln burner Stable sintering zone Higher clinker quality •
Reduction of Fe2+ content (brown clinker)
•
Less sulphur circulation
© by LOESCHE
Additional drying with process waste gas
ROCKET MILL - Clinker Process
Page 145
A TEC‘s TECHNICAL SOLUTIONS
ROCKET MILL WITH DRYING
Option 1: Improvement of existing main burner solid alternative fuel system
Assumption AF firing at main burner existing
Road Map Rocket Mill for AF preparation
© by LOESCHE
Higher AF rate with existing combustion equipment
Page 146
A TEC‘s TECHNICAL SOLUTIONS
OPTION 1 + STORAGE & FEEDING
Option 2: Installation of main burner AF system
Assumption Pre-treated AF material available
Road Map Rocket Mill for AF preparation A TEC main burner or main burner modification
© by LOESCHE
Storage, dosing and feeding system
Page 147
STORAGE & FEEDING
A TEC‘s TECHNICAL SOLUTIONS Option 3 Optimization of existing AF treatment plant
Assumption Existing AF treatment line
Road Map Replacement of several shredding/cutting stages by Rocket Mill
© by LOESCHE
A TEC main burner or main burner modification (optional)
Page 148
ROCKET MILL
A TEC ROCKET MILL
Existing Treatment Line pre-shredder > 300 mm
Fe separator
screen (opt.)
opt. heavy separation
< 300 mm
shredder
< 20 mm
< 20 mm
< 100 mm
Possible New Treatment Line pre-shredder > 300 mm
Fe separator
screen (opt.)
Technical data
fine shredder (cutting)
Final product size
< 15 mm
< 60 mm
Screen size
Ø 15mm
rectangular 40 x 50mm
Output size
< 15 mm / ~ 50% < 5 mm
< 60 mm / ~ 40% < 20 mm
Throughput
~ 6 t/h
~12 t/h
Specific power consumption
65 - 70 kWh/t < 15 mm final
40 - 55 kWh/t < 60 mm final
Dimension opt. heavy separation
Weight
Rocket Mill < 15 mm
< 300 mm
54.000 kg
Drive Unit
2 x 315 kW
Rotor Speed
~ 580 min-1
Capacity
~ 6 t/h < 15mm final product
Discharge
2 x Conveyor screws
© by LOESCHE
< 15 mm
8.530 x 4.160 x 6.000 l x b x h (mm)
Page 149
A TEC ROCKET MILL - RESULTS
A TEC ROCKET MILL - RESULTS
Coal savings on the existing system w&p with AF from the rocket mill
Maintenance & Wear costs
Due to the higher quality of AF produced with the rocket mill, the coal amount could be reduced.
Life time wear parts
Comparison of clinker production with same clinker quality and roughly same kiln feed:
Wear costs
Kiln Feed [t/h] Coal at Main Burner [t/h] Coal per Kiln feed [kg/t] April Juli
122,11 115,01
1,91 1,61
15,6 14,0
4 - 4,20
€/t
Time for changing one set of wear parts
approx. 1-2
h/unit
Maintenance/cleaning
5
h/week
required man power approx. 0,015
h/t
Maintenance
© by LOESCHE
This allows savings in coal consumption of around 200 kg/h with 120 t/h kiln feed.
chain approx. 250h chain fitting approx. 250h screen approx. 900h
Page 150
ADVANTAGES ROCKET MILL Size reduction from 200 mm to 15 mm in one grinding step Saving of one shredding step Easy to operate Easy to maintain No knifes
Drying effect during operation Separation of FE and non-FE materials
FLEXIFLAME ECO PRO® ADVANCED COMBUSTION TECHNOLOGY
Different output fuel particle sizes for main burner and calciner
© by LOESCHE
possible
Page 151
OLD TECHNOLOGY FOR SOLID ALTERNATIVE FUEL FIRING 1. Pipe beside the burner in the kiln hood
OLD TECHNOLOGY FOR SOLID ALTERNATIVE FUEL FIRING When higher substitution rates are attempted with old technology:
2. One or more pipes above the burner
• Unstable flame 3. One or more pipes inside the burner
• Wrong kiln thermal profile • Higher kiln inlet temperatures • Fuel falling onto clinker bed • Reduction zone near clinker • Excessive sulphur recirculation
60-70% Thermal Substitution Rate at Main Burner Possible •
Higher oxygen zone
•
No control
•
Lower mixing
• Rings formation • CO emissions • Cement Strength
•
High oxygen zone
•
Low control
•
Low oxygen zone
Low mixing
•
High control
•
High mixing
© by LOESCHE
•
Clinker quality, operational and environmental problems!!!
Page 152
OLD TECHNOLOGY FOR SOLID ALTERNATIVE FUEL FIRING
UNDERSTANDING SAF COMBUSTION
SECONDARY AIR • High oxygen availability: 95100% of required amount • Low control and mixing
•
Option 1 Option 2 Option 3
PRIMARY AIR Low oxygen availability: 812% of required amount • High control and mixing
High Oxygen
OR
High Control
!!!
COMBUSTION UNDERSTANDING
NEW CONCEPT
© by LOESCHE
NEW CONCEPT REQUIRED
Page 153
UNDERSTANDING SAF COMBUSTION
UNDERSTANDING SAF COMBUSTION
How do different Solid Alternative Fuel particles burn?
Importance of particle shape:
area of sphere with the same volume sphericity area of real particle
AERODYNAMIC AND BURNING CHARACTERISTICS Material
Wood cube
3D plastic
2D plastic
Slow ignition
Fast ignition
Super fast ignition
Low volatile
High volatile
High volatile
Long time burn out
Fast burn out
Very fast burn out
Keeps shape
Becomes a sphere
Forms droplets
High ash content
Low ash content
Low ash content
Sewage sludge Wood chips Fluff
Form grains chips foils
Length
Width
Height
[mm]
[mm]
[mm]
15,0 15,0
4,0 15,0
3,0 0,2
Diam. Superficial Area
Volume
Superf. Area Equiv. Sphere
[mm]
2
[mm ]
3
[mm ]
[mm2]
2,0
12,6 234,0 462,0
4,2 180,0 45,0
12,6 154,2 61,2
ᴪ 1,00 0,66 0,13
© by LOESCHE
Videos: Courtesy of LEAT Bochum / Aixergee
Page 154
UNDERSTANDING SAF COMBUSTION
UNDERSTANDING SAF COMBUSTION
Combustion Mechanism:
How to control different combustion mechanisms:
FLAME BOUNDARY
FLAME BOUNDARY
VOLATILES DIFUSION INTO OXYGEN VOLATILIZATION ON EXTERNAL LAYER
INDIVIDUAL PARTICLES COMBUSTION VOLATILES DIFUSION INTO OXYGEN
NO VOLATILIZATION ON INTERNAL LAYER
FLAME BOUNDARY VOLATILES DIFUSION INTO OXYGEN VOLATILIZATION ON EXTERNAL LAYER
NUMBER OF PARTICLES
REGION I EXTERNAL SHEAT COMBUSTION
REGION I
VOLATILIZATION ALSO ON INTERNAL LAYER
C+O2 = CO2
2H+½O2 = H2O REGION II
REGION IV
REGION III INTERNAL GROUP COMBUSTION
FLAME BOUNDARY
• Poor mixture between fuel and oxidant
between fuel and
• High oxygen, low velocity – secondary air induction
oxidant
• Combustion complementing
• Low oxygen (8-12%
velocity • Hot gas recirculation
INDIVIDUAL PARTICLES COMBUSTION
CLOUD DISPERSION
EXTERNAL RECIRCULATION:
• Intense mixing
comb. air), high
VOLATILIZATION ALSO ON INTERNAL LAYER
REGION II INTERNAL SHEAT COMBUSTION
INTERNAL RECIRCULATION:
• Ignition fuel zone • Flame stability
REGION IV INDIVIDUAL PARTICLE COMBUSTION
© by LOESCHE
Picture: Courtesy of Aixergee
Page 155
FLEXIFLAME ECOPRO® High Oxygen
Key Point
AND
High Control
FLEXIFLAME ECOPRO®
!!!
• Injection of solid alternative fuel through a ring channel
• Ring channel wide enough to avoid blockages • Even fuel and air distribution • Wear protection
New concept for solid alternative fuels injection:
• High momentum • High flame control
Through the burner: HIGH CONTROL
• Up to 100% solid alternative fuel
FLEXIFLAME ECOPRO®
© by LOESCHE
Near secondary air: HIGH OXYGEN
Main characteristics
Page 156
INTRODUCTION
PYROPROCESS EVALUATION
© by LOESCHE
LOESCHE Technical Seminar 21 – 23 April, 2015 Jakarta, Indonesia
Page 157
CEMENT PLANT SCHEME
OUTLINE Preheater Performance & Preheater Modification
Minimizing of coating / Blockage avoiding: Bypass Systems & Shock blowers
© by LOESCHE
Calciner Combustion & NOX / CO Control
Page 158
PH PERFORMANCE & MODIFICATION
PH PERFORMANCE & MODIFICATION
• Increase of production capacity (clinker production)
• Reduction of fuel consumption • Reduction of electrical power consumption • Reduction of emissions (NOX, CO, SOx, dust)
ATEC “TRIPLE-E” (E3) Policy
© by LOESCHE
optimized EFFICIENCY optimized ENERGY BALANCE ENVIRONMENTAL protection
Page 159
PH PERFORMANCE & MODIFICATION
PH PERFORMANCE & MODIFICATION Typical Bottlenecks Down comer duct and GCT: - Pressure drop
- Separation efficiency - Pressure drop
Riser ducts:
- Meal distribution - Retention time
Calciner:
- Low NOx - Retention time - RSP calciner
Tertiary air duct:
- NOx Reduction - Pressure drop
© by LOESCHE
ID fan: - Fan capacity
Cyclones:
Page 160
PH PERFORMANCE & MODIFICATION
PH PERFORMANCE & MODIFICATION Preventive Maintenance • Prevent false air in the system
© by LOESCHE
• Maintain proper operation of Pendulum Flaps
Page 161
PH PERFORMANCE & MODIFICATION
© by LOESCHE
PH PERFORMANCE & MODIFICATION
Page 162
PH PERFORMANCE & MODIFICATION
PH PERFORMANCE & MODIFICATION
A TEC Pendulum Flap
A TEC Splashbox
To avoid counter gas flow through meal pipes between two stages of the preheater. Proper working pendulum flap provides: • Reduction of gas flow through meal pipe • Improvement of cyclone separation efficiency • Reduction of specific heat consumption False air via meal pipe
+ 4% gas volume - 3% separation efficiency + 20 kJ/kgclinker
For meal distribution from meal pipe in gas riser duct Proper meal distribution on whole riser duct square area Maximized heat transfer gas -> meal Pressure drop reduction of riser duct • ideal position of the splash box is appr. 0.5 – 0.8 m above the cyclone ceiling • utilises approx. 65 – 75% of the riser duct cross section compared to standard splash box with < 50% • up to 4°C reduced temperature in riser duct depending on application
© by LOESCHE
No flap in bottom stage
• • • •
Page 163
PROJECT EXAMPLE (Dp) Project Example:
PROJECT EXAMPLE (Dp)
Cement Plant Este, Italy
RESULTS / REALIZED PARAMETERS Gas Quantity: Gas Temperature: Clinker Production:
Project Example:
BEFORE MODIFICATION
AFTER MODIFICATION
4-stage preheater
4-stage preheater
Difference
Cement Plant Este, Italy
Guarantee
250,000 Am³/h 520 °C 1,200 t/d
Pressure Drop Reduction:
1,300 t/d
+ 100 t/d 12 mbar
Static Pressure Drop: 23.0 mbar 44.5 mbar 21.5 mbar 55.0 mbar 16.0 mbar 71.0 mbar
22.0 mbar 34.0 mbar 12.0 mbar - 9.5 mbar 44.5 mbar 3.5 mbar - 12.5 mbar 48.0 mbar - 23.0 mbar
- 7.0 mbar - 8.0 mbar - 15.0 mbar
GENERAL ARRANGEMENT DRAWINGS
© by LOESCHE
Exit 2nd stage: Exit 3rd stage: D p 3rd stage: Exit 4th stage: D p hot gas duct: ID fan inlet
Page 164
BLOCKAGE AVOIDING
BLOCKAGE AVOIDING Reasons for the installation of a bypass system Operation of pyroprocess with high chlorine and alkali fuels and/or raw materials Avoiding build ups and heavy coating in the area of the kiln riser duct and meal pipe to the kiln
© by LOESCHE
Impact on clinker quality
Page 165
BLOCKAGE AVOIDING
BLOCKAGE AVOIDING
© by LOESCHE
Possible flowsheet of a standard Bypass System
Page 166
BLOCKAGE AVOIDING
BLOCKAGE AVOIDING
Shock blowers in the
operation without bypass original operation
Preheater / Precalciner system
© by LOESCHE
operation with bypass
Page 167
Theoretical Background 1. NOX formation 2. NOX reduction 1.Primary NOX reduction 2.Secondary NOX reduction
A TEC Proposal for < 200 mg/Nm³ NOX emissions
CALCINER COMBUSTION & NOX Thermal NOX formation
Oxidation of nitrogen from combustion air Occurs at high temperatures (> 1300 °C)
𝑁𝑁2 + 𝑂𝑂 → 𝑁𝑁𝑁𝑁 + 𝑁𝑁 𝑁𝑁 + 𝑂𝑂2 → 𝑁𝑁𝑁𝑁 + 𝑂𝑂 𝑑𝑑𝑑𝑑𝑑𝑑 𝑑𝑑𝑑𝑑
= 5,74 ∙ 1014 𝑒𝑒𝑒𝑒𝑒𝑒
−561000 𝑇𝑇
Fuel NOX formation
𝑁𝑁2 𝑂𝑂2
0,5
Depending on the nitrogen content of the fuel
Prompt NOX formation
900 NOX concentration (10 % O2), mg/Nm³
CALCINER COMBUSTION & NOX
700 500 300 100 800
1300
1800
Temperature, °C
Figure: Formation of thermal NOX vs. combustion temperature
© by LOESCHE
Caused by fuel radicals – not considerable here
Page 168
CALCINER COMBUSTION & NOX
CALCINER COMBUSTION & NOX
Primary NOX reduction
Fuel composition
Plant configuration
N content
Kiln type
H2O content Volatile matter
Raw material
NOX
Calciner Clinker cooler
Reduction of the combustion (peak) temperature Reduction of air amount in the hot combustion area
Suitable state of the art process modifications Low-NOX burner Staged combustion
etc.
Clinker spec. Free lime Avoid „overburning“
© by LOESCHE
moderate LSF
Preheater configuration
Avoiding NOX formation
Page 169
CALCINER COMBUSTION & NOX
CALCINER COMBUSTION & NOX
Low-NOX burner
Staged combustion for precalciner plants
low NOX levels
Burner operation for low NOX production:
• Lower amount of central air (PA) Posssible effects by operation of a classical low-NOX burner on the process:
• Flame length increases • Lower temperature • Risk of incomplete solid fuel combustion or char formation
CO CXHY (hydrocarbon radicals) CXHY + z NO = x CO2 + y/2 H2O +z/2 N2
Calciner l>1 Calciner l1
© by LOESCHE
• Impact on clinker quality possible
• Creation of a reducing atmosphere to reduce NOX in calciner by:
Page 170
CALCINER COMBUSTION & NOX
CALCINER COMBUSTION & NOX
Fuel Combustion
Fuel Combustion
Volatile compounds CO CO2 H2 CH4 C2H2 C2H4 CXHY
H2O
drying
heat
+ O2 CO2 + H2O
Dry fuel
Bituminous coal
Wood
PE
~ 0 % (theor.)
~ 30 %
~ 85 %
~ 100 %
CO + O CO2
char gasification O2
heat
Char
Fixed carbon (char)
Ash
Dominated by pyrolysis step: High release of CxHy radicals
© by LOESCHE
Raw fuel particle
pyrolysis
Influence of the volatile matter content of the fuel
Page 171
CALCINER COMBUSTION & NOX
CALCINER COMBUSTION & NOX
Fuel Combustion
Fuel Combustion
Influence of the volatile matter content of the fuel
Influence of the Nitrogen (N) content of the fuel
Char
Bituminous coal
Wood
PE „Fixed carbon“ Nitrogen
~ 0 % (theor.)
~ 30 %
~ 85 %
N
„Volatile“ Nitrogen e.g. H-C-N, high vol. N comp.
HCN, NH3
+ ox
NHi radicals
Primary oxidation to NO
+ ox
Oxidation to NO
+ NO
Reduction of NO NO + NH3 N2 + H2O
© by LOESCHE
Reducing zone dominated by CO formation
~ 100 %
Combustion
e.g. stable aromatic comounds
Page 172
CALCINER COMBUSTION & NOX
CALCINER COMBUSTION & NOX
Staged combustion for precalciner plants
Selective non-catalytic reduction (SNCR)
Split of tertiary air •
Creating reducing and oxidizing zone
•
Sufficient residence time
•
Maintaining high temperature in reducing zone • •
Fuel N: Equilibrium NO reduction
•
Meal split
Use of high volatile fuels •
CXHY radicals more reactive for NO reduction
•
Fuel N: positive effect possible
Ammonia (NH3) Ammonia water Urea (CH4N2O)
Limited temperature range
NH3 loss comb. to NOX
NH3 slip
Temperature too low •
Emission of NH3
Temperature too high •
Formation of additional NO
900
1000
Temperature, °C
1100
Figure: Influence of the temperature on the SNCR process
© by LOESCHE
•
Increased reaction speed for NO reduction
Injection of NOX-reducing agent NOX abatement, relative
•
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CALCINER COMBUSTION & NOX
CALCINER COMBUSTION & NOX
Selective non-catalytic reduction (SNCR) NO Reducing gross reactions
NH3 loss comb. to NOX
4 NH3 + 6 NO 5 N2 + 6 H2O
For NH3 injection: 800 – 1050 °C CH4N2O + 2 NO + 0,5 O2 2 N2 + CO2 + 2 H2O
For urea injection: 50 – 100 °C higher
NOX abatement, relative
NH3 slip
Basic reaction scheme with NH3 +NO +OH +O
NH2 +ox
NO
900
1000
Temperature, °C
1100
Figure: Influence of the temperature on the SNCR process
© by LOESCHE
NH3
N2
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CALCINER COMBUSTION & NOX
CALCINER COMBUSTION & NOX A TEC Post Combustion Chamber CFD-modelling
Larger unburned fuel particles can stay in the upsteam section Expansion of residence time Eccentrically entrance downstream
upsteam
Velocity reduction upstream
downstream
Increase of cross section upstream
CALCINER
Installed at calciner top
A TEC PCC
The A TEC Post Combustion Chamber
© by LOESCHE
High turbulence
Page 175
THANK YOU
© by LOESCHE
www.atec-greco.com
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