Pre Calci Ner

March 29, 2018 | Author: Joko Dewoto | Category: N/A
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CALSINER CONTROL

Chekka Plant (Lebanon)

 Polysius Prepol  2 strings

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

El Soukhna Plant (Egypt)

Ekstraksi udara tersier pada kiln hood

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Ramos Arizpe Plant (Mexico)  F.L.Smidth  ILC kalsiner dengan dikontrol hot spot  Line 2 (depan) Line 1 (belakang)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Komponen – komponen Kalsiner

Unit 1 dari 5

Reaktor Tipe Vessel

Pola aliran pada reaktor tipe vessel menunjukan zona pencampuran dan zona resirkulasi (Kobe DDF kalsiner)

Kalsiner dengan orifice menciptakan pencampuran tambahan dan resirkulasi

PT. Sarana Agra Gemilang

kalsiner tanpa orifice

Manufacturing Workforce training - Production

People & Organization Development

Reaktor Tipe Tube

Reaktor Kalsiner Tipe Tube (KHD Pyroclon alternatives)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Burner Prekalsiner

Burner kalsiner dibawah penambahan meal splash box (Sumber : Polysius)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Burner Prekalsiner

Burner Prekalsiner untuk batu bara dan gas dengan udara axial dan radial

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Tertiary Air (udara tersier) Intake

Udara atas (untuk Nox rendah)

Dampak frontal oleh inlet dua udara tersier

Inlet tangential satu

F.L.Smidth

PT. Sarana Agra Gemilang

Polysius

Manufacturing Workforce training - Production

People & Organization Development

Tertiary Air (udara tersier) Intake

KHD Design

Pencampuran lambat dari udara tersier dan aliran gas pada kiln.

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Penambahan Meal Tipe cakram pembagi saluran mill

Penambahan Meal bagian atas ke kalsiner (untuk mengontrol temperatur pada bagian bawah kalsiner)

FLS ILC dengan dikontrol hot spot

Penambahan Meal ke kalsiner

Penambahan Meal ke riser

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Generator Turbulensi (misalnya PYROTOP)

PYROTOP compact (KHD)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Generator Turbulensi (misalnya Polysius)

Defleksi di chamber (Polysius)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Generator Turbulensi (misalnya Orifice)

kalsiner orifice

kalsiner orifice

ILC F.L.Smidth PT. Sarana Agra Gemilang

DDF Kobe Steel Manufacturing Workforce training - Production

People & Organization Development

Chamber Pembakaran

kalsiner loop

Burner

Keluaran gas

Chamber pembakaran Keluaran Meal

Polysius Prepol CC (El Soukhna, Egypt)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Chamber Pembakaran

Burner

Keluaran Gas dan meal

Penambahan Meal untuk proteksi meal

RSP kalsiner (FCB Ciments)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Chamber Pembakaran

RSP kalsiner (FCB Ciments)

RSP vessel

kalsiner loop

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

Keluaran Gas dan meal

People & Organization Development

Sistem Udara Tersier

Unit 2 dari 5

Pengendalian Udara Tersier dan Udara Sekunder

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Lokasi keluaran udara tersier

Ekstraksi udara tersier dari kiln hood

Ekstraksi udara tersierdari cooler roof

Temperatur udara tersier = Temperatur udara sekunder

Udara sekunder panas

PT. Sarana Agra Gemilang

Udara tersier dingin

Manufacturing Workforce training - Production

People & Organization Development

Keluaran udara tersier dari Cooler Roof Udara tersier Udara tengah

Udara buang

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Keluaran udara tersier dari Kiln Hood

Ekstraksi udara tersier dari kiln hood (Cerro Blanco Kiln 1)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Keluaran udara tersier dari Kiln Hood

Hon Chong plant (Kobe Steel) PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Dropout Chamber Tipe Cyclon dropout chamber Penambahan debu pada cooler

Design KHD

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Extracksi Debu dari “Elbow” Udara tersier

PT. Sarana Agra Gemilang

Macuspana plant, Mexico, FLS ILC kalsiner Manufacturing Workforce training - Production

People & Organization Development

Duct Udara tersier

Tertiary air duct dengan debu klinker

Hon Chong Guillotine damper, Midlothian, KHD

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Damper Udara tersier Tipe (Guillotine) Hanya bagian dari damper yang terkena Udara tersier

System Polysius dipasang di Lägerdorf PT. Sarana Agra Gemilang

Honeycomb diisi dengan konkret

Damper setelahr 10 bulan operasi (dua positions)

Manufacturing Workforce training - Production

People & Organization Development

Damper Udara tersier (Throttle Disc)

duct Udara tersier vertikal menuju chamber Pembakaran El Soukhna (ECC) PT. Sarana Agra Gemilang

Diinstalasi di : Lägerdorf, Chekka, Gladstone, El Soukhna, Ulco

Manufacturing Workforce training - Production

People & Organization Development

Damper Udara tersier (Desain Technip)

Sistem Technip Untuk alasan kenyamanan, damper udara tersier dipasang di bagian vertikal dari saluran udara tersier. Bagian damper dilindungi oleh beton refraktori. Flaps dalam baja cor tahan api dengan pengaku dan dilindungi oleh lapisan baja cor tahan api. As roda dari flaps yang berlubang dan didinginkan terus menerus selama operasi oleh Blowing Fan.

Hon Chong

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Variabel - variabel Kiln Orifice

Design FLSmidth

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Variabel Kiln Orifice

Desain FLSmidth

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Pembakaran dan Kalsinasi

Unit 3 dari 5

Kalsinasi

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

True and Apparent Calcination

PC

PC

PH

PH

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Kehalusan Fuel yang disarankan (Coal dan Petcoke)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Waktu tinggal (resident time) gas yang disarankan untuk Burnout

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

“Hot Spot "untuk penyalaan Bahan Bakar Reaktif Rendah

Pemisah meal

Lokasi pengukuran Temperature pengontrolan area “Hot Spot“

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Pembentukan dan Penguraian NOx

Unit 4 dari 5

Thermal NOx dan Fuel NOx

Operating conditions and nitrogen content in fuel

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Lokasi pembentukan NOx pada PC Kiln

Fuel NOx Thermal NOx

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Volatilitas bahan bakar dan Reduksi NOx pada kalsiner

e.g. petcoke, anthracite

e.g. plastics, brown coal, lignite

Only reactive fuels (e.g. lignite) react so intensely at start of combustion that local reducing conditions occur

Source: Menzel (Polysius), Bertschinger (JCF): International Cement Review, June 1997, p.65ff

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Penambahan Bahan Bakar Bertahap (Contoh Kobe DDF)

kalsiner Burner

de NOx Burner

PT. Sarana Agra Gemilang

de NOx Burner

Manufacturing Workforce training - Production

People & Organization Development

Penambahan Bahan Bakar Bertahap (Contoh KHD LowNOx)

Meal

DeNOx Zone (Reduction Zone) Main Burner

Low NOx Burner

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Penambahan Udara Bertahap

Memperpendek zona di kalsiner Memperpendek zona di kalsiner

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Titik Injeksi untuk SNCR (Contoh Lägerdorf)

Injection levels

Tertiary Air

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Utilitasi AFR pada kalsiner

Unit 5 of 5

Titik umpan AFR pada kalsiner

Hanya AFR cair dan halus (TAD blockage) Titik umpan AFR Burner kalsiner

B1 AFR cair dan padat

B2

Titik umpan Meal

Lump fuel, ban utuh (max 10%) PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Sistem Umpan ban (tire) secara umum untuk Prekalsiner

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Penanganan keping ban (tire chip ) dan Ferrocarbon di LD

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Suspensi Finger untuk ban (Devil’s Slide)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Suspensi Finger untuk ban (Devil’s Slide)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Mendukung Tire Finger (Cadence Environmental)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Hotdisc (F.L.Smidth) Tertiary air Inline kalsiner

Lump fuel feed

Scraper removes ash

Inline kalsiner

Controlled meal inlet

Controlled meal inlet Exit of hot gas and ash

Lump fuel and tertiary air feed

PT. Sarana Agra Gemilang

Kiln orifice

Manufacturing Workforce training - Production

People & Organization Development

Hotdisc (F.L.Smidth)

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Instalasi Hotdisc di Kjopsvik, Norway

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Fixed Bed Gasifier (Polysius, Wildegg Plant )

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Fixed Bed Gasifier (Polysius, Wildegg plant)

Gas panas ke kalsiner

Konsumsi udara tersier Reaktor vessel Ekstraksi abu ke risser

Movable bottom PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

CFB Gasifier (Lurgi, Rüdersdorf Plant)

 Spesifikasi Gasifier  Ø 3.5 x 23.5 m  Luas area bawah : 2.3 m2  Kapasitas panas: 100 MW  Temperatur operasi.: 950 - 1000 °C  Tekanan Operasi : +120 mbar  Nilai panas untuk gas panas: 3.7 MJ/Nm3  Kecepatan umpan dengan MSW: 15 - 18 t/h  Konsumsi energi El. : 1.6 kWh/t cli  Input udara total : 34’000 Nm3/h  Biaya proyek : 35 Mio DEM

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

Tipe Gasifier Polysius (Wildegg plant) Sistem Kiln  2’000 t/d kiln, 4 stage preheater dengan MSC prekalsiner  Bahan bakae : batu bara , s: coal, whole tires, granulated plastics Gasifier Polysius  Bahan bakar : hanya ban utuh y  Fixed bed gasifikasi  3 t/h kecepatan umpan , 40% thermal subst. (75% of PC bahan bakar)  Valve umpan rotari  Vessel: Ø 2.7 x 3.5 m  produk: 7’500 Nm3/h gas 1.5 t/h abu (coke & wire)  Iinvestasi : 4 Mio USD incl. Sistem penanganan bahan bakar

PT. Sarana Agra Gemilang

Manufacturing Workforce training - Production

People & Organization Development

TERIMA KASIH

PT. Sarana Agra Gemilang

People & Organization Development

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