Preheat Process

April 6, 2018 | Author: tricky777 | Category: N Ox, Industrial Processes, Energy Technology, Industries, Chemistry
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preheater process...

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Page 1

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Preheater and Calciner Process Training

Krupp Polysius Corp.

Page 2

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

The modern kiln plant Preheater

Calciner Clinker cooler C M

Raw mill Rotary kiln

Krupp Polysius Corp.

Page 3

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

Preheater

Krupp Polysius Corp.

140 TEI, 140

Page 4

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

DOPOL 90

Krupp Polysius Corp.

Page 5

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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Gas and material flow in a preheater

Krupp Polysius Corp.

Page 6

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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DOPOL 90 B-type cyclone 1 2 3

4 5

Krupp Polysius Corp.

1 2 3 4 5

Cyclone Intermediate piece Dip pipe Gas duct Meal chute

Page 7

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

Cyclone types

Dedusting cyclone System cyclone Calciner cyclone

DOPOL® 90

Krupp Polysius Corp.

140 TEI, 140

Page 8

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

The modern kiln plant Preheater

Calciner Clinker cooler C M

Raw mill Rotary kiln

Krupp Polysius Corp.

Page 9

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

DOPOL 90 - preheater design

Krupp Polysius Corp.

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Page 10

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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Technical data Number of cyclone

4

5

6

°C

370

315

280

Nm³/kg clinker

1,372

1,353

1,345

%

8

6,5

5

mbar

33

38

45

Fuel consumption

kcal/kg clinker

740

718

705

Cooler efficiency

%

74,6

73,1

72,1

Clinker temperature

°C

100

100

100

Nm³/kg clinker

1,7

1,7

1,7

Nm³/kg clinker

0,84

0,87

0,88

°C

295

305

312

- for exhaust gas fan

kWh/t clinker

5,6

5,7

6,1

- for total kiln plant

kWh/t clinker

15,1

15,2

15,7

- exhaust gas only (with coal mill)

%

7,6

5,6

4,3

- exhaust gas only

%

8,5

6,5

5,3

- exhaust gas with exhaust air

%

11

9,5

8,7

Exhaust gas - temperature - volume - dust relative to clinker - pressure loss

Cooling air Cooler vent air - volume - temperature Electrical power consumption

Permitted RM moisture

Krupp Polysius Corp.

Page 11

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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Drying capacities - preheater systems

Exhaust gas temp. [ °C ]

500

AS 6 AS 5

AS 4

AS 3

AS 2



200

12 8

PH exhaust only -->

100

4

0 700

750

800

850

Fuel consumption [ kcal/kg cli ]

Krupp Polysius Corp.

0 900

Drying capacity [ % - H2O ]

600

Page 12

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

Calciner

Krupp Polysius Corp.

140 TEI, 140

Page 13

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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Calciner types

PREPOL AS

PREPOL AS-CC

Krupp Polysius Corp.

PREPOL MSC

PREPOL MSC-CC

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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

PREPOL AT

Krupp Polysius Corp.

140 TEI, 140

Page 15

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

PREPOL AS

Calciner loop

Fuel injection TA-duct

Krupp Polysius Corp.

140 TEI, 140

Page 16

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

PREPOL AS-CC Calciner loop

Combustion chamber

Krupp Polysius Corp.

TA-duct

140 TEI, 140

Page 17

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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Combustion - Chamber (CC) Burner

Meal inlet

Central inlet for tertiary air

Meal inlet Tangential inlet for tertiary air inlet

CC-Chamber outlet (Connection to the calciner)

Krupp Polysius Corp.

Tangential inlet for tertiary air inlet

Tertiary duct

Page 18

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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PREPOL MSC

Deflection chamber

Top air duct

Meal staging PC - burner

Kiln inlet burner

Krupp Polysius Corp.

Tertiary air duct

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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

PREPOL MSC-CC Deflection chamber

Top air duct

Tertiary air duct

PC - burner Kiln inlet burner

Krupp Polysius Corp.

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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

Tertiary air duct

Krupp Polysius Corp.

140 TEI, 140

Page 21

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

MSC Calciner with Tire Feed Chute

Krupp Polysius Corp.

140 TEI, 140

Page 22

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Tertiary air from cooler

w > 26 m/s

w < 8 m/s

w < 8 m/s

Krupp Polysius Corp.

w < 6 m/s

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Tertiary air from kiln hood

w > 2 6 m / s

w < 5 m / s

Krupp Polysius Corp.

w < 5 m / s

Page 24

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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Tertiary air connection kiln hood secondary air temperature

cooler

measures

lower

higher

thermal stress on outlet segments

+ lower

- higher

better cooling and form of segments

burn out in the calciner

+ better

- worse

CC - Calciner

precalcination rate

- lower

+ higher

bypass losses

- higher

+ lower

load of sintering zone

- higher

+ lower

- higher

+ lower

- bigger

+ smaller

length of burner

- longer

+ shorter

NOx - formation

(+ lower)

(- higher)

Investment cost

- higher

+ lower

thermal stress on tertiary air flap and refractory size of kiln hood

Krupp Polysius Corp.

adapted dimensionnig and quality of refractory

optimized burner adjustment

Page 25

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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“Low-dust” kiln inlet

Krupp Polysius Corp.

Page 26

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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Calciner volume loading T h e r m a l c a l c i n e r l o a d i n g i n k c a l / m ³ / h F u e l t y p e

P R E P O L A S

P R E P O L A T

N a t u r a l g a s

< 1 5 0 0 0 0

< 1 0 0 0 0 0

F u e l o i l

< 1 8 0 0 0 0

< 1 2 0 0 0 0

h i g h r e a k t i v e C o a l

< 1 3 0 0 0 0

< 8 7 0 0 0

l o w r e a k t i v e C o a l

< 9 0 0 0 0

< 6 0 0 0 0

e . g . P e t C o k e

Krupp Polysius Corp.

< 8 0 0 0 0

Page 27

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

Fuel design and distribution

Krupp Polysius Corp.

140 TEI, 140

Page 28

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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O2-concentration [%]

Coal - activity

Time [s]

Krupp Polysius Corp.

Page 29

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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NOx - generation in clinker burning process

Calciner: Fuel - NOx - exess air - nitrogen content - reactivity

Sintering zone: Thermal NOx - temperature - exess air - retention time

Krupp Polysius Corp.

Page 30

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Combustion conditions for NO reduction by fuel, air and meal staging Meal

> 1,05

H2 O NO N2 CO2

0,4 - 0,6 Q

NHi H2 O CO2 N2 NO CH i CO NO

> 0,1 Q Fuel

CHi

Air

CO2 H2 O N2 CO

0,9 <

< 1,05

0,9 <

< 1,05

NO NH i

Stage 4

Q = total fuel = excess air figure

Stage 3 0,4 - 0,6 Q Stage 2 Stage 1

Krupp Polysius Corp.

Page 31

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

NOx at kiln inlet [gNO2/kgcli]

NOx and O2 at kiln inlet

O2 at kiln inlet [%]

Krupp Polysius Corp.

140 TEI, 140

Page 32

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

NOx - generation in calciner [NO2/kgcli]

NOx - generation and volatiles

Volatile matter in fuel [%]

Krupp Polysius Corp.

140 TEI, 140

Page 33

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

NOx [NO2/kgcli]

NOx and Nitrogen in fuel

Nitrogen in fuel [%]

Krupp Polysius Corp.

140 TEI, 140

Page 34

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

NO2 [mg/Nm3] @ %O2

Nox and calciner temperature

Calciner temperature [ºC]

Krupp Polysius Corp.

140 TEI, 140

Page 35

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

NOx - emission [gNO2/kgcli]

Operating results MSC plants

Krupp Polysius Corp.

140 TEI, 140

Page 36

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

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Operating results MSC plants 2 .5

A S -MS ope Cra - ope t ion ra 2 8 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

1 .5 5 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

NOx-Emison[gNO2/kgCli]

1

3 5 %

3 2 % 5 3 %

0 .5

0

Krupp Polysius Corp.

3 0 %

2 8 %

Page 37

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

NOx - emission [gNO2/kgcli]

Operating results MSC plants

Krupp Polysius Corp.

140 TEI, 140

Page 38

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Operating results MSC plants 2.5

KI - A MS S -C op er op at er io at nion AS - oper ation 2

8 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

1.5

5 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

NOx-Emison[gNO2/kgKl]

1

3 5 %

3 2 %

0.5

0 P l a n t

F u e l

5 3 %

2 8 %

3 0 %

A 8 0 % P e t C o k e 2 0 % C o a l

V o l a t i l e s i n f u e l

1 5 %

Krupp Polysius Corp.

B L i g n i t e

4 5 %

C C o a l B l e e c h i n g E a r t h P a p e r w a s t e F l y A s h 2 7 , 3 %

D C o a l T y r e s P l a s t i c

E O i l P a p e r w a s t e P l a s t i c C a r b o n M a r l

~ 2 5 %

> 4 0 %

Page 39

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

NOx - emission [gNO2/kgcli]

Operating results MSC plants

Krupp Polysius Corp.

140 TEI, 140

Page 40

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Operating results MSC plants 2.5

KI - A MS S -C op -er op at er io at nion AS - oper ation 2

8 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

1.5

5 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

NOx-Emison[gNO2/kgKl]

1

3 5 %

3 2 %

0.5

0 P l a n t

F u e l

5 3 %

2 8 %

3 0 %

A 8 0 % P e t C o k e 2 0 % C o a l

V o l a t i l e s i n f u e l

1 5 %

Krupp Polysius Corp.

B L i g n i t e

4 5 %

C C o a l B l e e c h i n g E a r t h P a p e r w a s t e F l y A s h 2 7 , 3 %

D C o a l T y r e s P l a s t i c

E O i l P a p e r w a s t e P l a s t i c C a r b o n M a r l

~ 2 5 %

> 4 0 %

Page 41

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

NOx - prognosis NOx - emission

Krupp Polysius Corp.

140 TEI, 140

Page 42

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

CO - prognosis

Krupp Polysius Corp.

140 TEI, 140

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