Escolar Documentos
Profissional Documentos
Cultura Documentos
Proceedings
Convening
Networking
Sharing knowledge
Page 2
by LOESCHE
Final programme
21 April 2015
19:00 - 22:00
22 April 2015
08:30 - 09:00
09:00 - 09.15
Welcome address
Hendra Tjhai, Detlef Bluemke, PT Loesche Indonesia
09:15 - 09:30
09:30 - 10:30
10:30 - 10:45
10:45 - 12:00
12:00 - 13:00
13:00 - 14:00
14:00 - 15:00
Machine monitoring
Sebastian Muschaweck, Dr. Franz Muschaweck, DALOG Diagnosesysteme GmbH
15:00 - 15:30
15:30 - 17:00
by LOESCHE
18:00
Page 3
Final programme
23 April 2015
09:00 - 09:15
09:15 - 10:15
10:15 - 10:30
10:30 - 12:00
11:45 - 13:00
13:00 - 14.00
14:00 - 15:00
15:00 - 15:15
15:15- 16:30
19:00
by LOESCHE
16:30 - 17:00
Page 4
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
email: detlef.bluemke@loesche.com
email: hendra.tjhai@loesche.com
Jeane Haro
by LOESCHE
email: jeane.haro@loesche.com
Page 5
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
email: theodora.bruns@loesche.de
email: regina.krammer@loesche.de
Christian-Martin Ruthenberg
by LOESCHE
email: ruthenberg@loesche.de
Page 6
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
email: ruthenberg@loesche.de
email: detlef.bluemke@loesche.com
Stefan Wlfel
Sebastian Muschaweck
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: stefan.woelfel@loesche.de
email: Sebastian.Muschaweck@dalog.net
by LOESCHE
Page 7
Lecturers
Dr. Franz Muschaweck
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
Masters 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: Franz.Muschaweck@dalog.net
email: p.recchi@mapei.it
Moch Mustafa
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.
email: s.kern@atec-ltd.com
by LOESCHE
email: zysk@loesche.de
Page 8
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.
by LOESCHE
Page 9
by LOESCHE
Page 10
Table of contents
Introduction
Introduction
LOESCHE in brief
by LOESCHE
Page 11
Introduction
Introduction
America
Europe
LOESCHE GmbH
(Head Office)
LOESCHE
Equipamentos Ltda.
Rio de Janeiro, Brazil
LOESCHE
Automatisierungstechnik GmbH
Lnen, Germany
Dsseldorf, 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
by LOESCHE
Asia
Page 12
Introduction
Introduction
America
Europe
Asia
A TEC Asia Sdn. Bhd.
Kuala Lumpur, Malaysia
A TEC
Plant Construction
GmbH Eberstein, Austria
A TEC Technology
Services (Beijing),
Co., Ltd.
Beijing, China
Europe
Aixprocess GmbH
Aachen, Germany
Aixergee GmbH
Aachen, Germany
Aixenviro Gbr
Aachen, Germany
Greco Combustion
Systems Europe GmbH
Krems, Austria
by LOESCHE
Page 13
Table of contents
Introduction
Quarry
Summary/Conclusions
Cement
Kiln
Cement grinding
by LOESCHE
Raw meal/Coal
grinding
Page 14
Working principle
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
10
11
by LOESCHE
Page 15
Table of contents
Introduction
12
13
by LOESCHE
Page 16
14
15
by LOESCHE
Page 17
alite
grinding table
belite
16
17
by LOESCHE
Page 18
alite
alite
belite
100 um
alite
alite
C4AF
C3A
belite
belite
microcracks
100 um
100 um
19
by LOESCHE
Page 19
Influencing parameters
Classification of microcracks
alite
euhedral
belite
C4AF
alite in void
intra-
20 um
20 um
fracture surface,
hard to grind clinker
40 um
trans-
pore space
spatial distribution
porosity
20
21
by LOESCHE
intergranular
Page 20
Clinker microstructure
Clinker microstructure
alite
alite
belite
belite
200 um
100 um
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.
alite
belite
200 um
belite
200 um alite
22
23
by LOESCHE
Page 21
Clinker microstructure
15
25
35
45
25
by LOESCHE
Page 22
Table of contents
Introduction
good grindability
poor grindability
poor grindability
poor grindability
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
27
by LOESCHE
Page 23
Main aims
General concept
Compact design
Environmental impact
Operational costs
LM (2+2/3+3) with
modified s-rollers
28
29
by LOESCHE
Page 24
30
31
by LOESCHE
Page 25
Flexibility
33
by LOESCHE
Page 26
41
by LOESCHE
Page 27
Reduction in
energy consumption
AV-Produkt
Clinker
82%
Gypsum Type I(natural) 4%
Limestone
7%
Fly ash
7%
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%
Increase of through-put
8,21%
-7,17%
-11,12%
-25,00%
42
-20,00%
-15,00%
-10,00%
-5,00%
0,00%
5,00%
10,00%
43
by LOESCHE
BLL-Produkt
Clinker
65%
Gypsum Type I(natural) 5%
Limestone
25%
Fly ash
5%
Page 28
Grit cone
45
by LOESCHE
Page 29
Conventional design
high velocity differences
46
47
by LOESCHE
Page 30
Central Europe
LM 46.2+2
Product
GGBS
CEM I
CEM II/B-M
~ 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
reduced CAPEX
~ 4-8% lower
Espec
LM (2+2/3+3) with
modified s-rollers
~ 5-7% lower
Espec
reduced thermal
energy consumption
48
49
by LOESCHE
Compact design
Page 31
Table of contents
Introduction
Environmental impact
Operational costs
Yes
Yes
Yes
50
51
by LOESCHE
Yes
Page 32
Water and energy are the basis for life and the world as we know it today
State-of-the-art
cement grinding plant
Presented by
Detlef Blmke
PT Loesche Indonesia
Detlef.Bluemke@loesche.de
www.loesche.com
52
53
by LOESCHE
Page 33
by LOESCHE
Page 34
Agenda
Evaluation of performance
Coal/petcoke mill
Mineral mill
by LOESCHE
Page 35
Differences
56
Feed material
Moisture content
Grain size distribution
Flow characteristics
Grindability
.4
88
by LOESCHE
Page 36
Agenda
Differences
Machine
Grinding force (according to grindability)
Table speed (centrifugal force)
Dam ring (grinding bed)
S-rollers (deaeration)
Louvre and armour ring (drying)
by LOESCHE
Page 37
Agenda
Grinding
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
by LOESCHE
Page 38
Process circuits
Process circuits
10
11
by LOESCHE
Page 39
Process circuits
Agenda
Damper S
(Stack)
Damper R
(Recirculation)
Control values
Evaluation of performance
Damper Z1
(Fresh air)
12
13
by LOESCHE
Page 40
Damper S
(Stack)
Damper S
(Stack)
Damper R
(Recirculation)
Damper R
(Recirculation)
Damper Z1
(Fresh air)
Damper Z1
(Fresh air)
14
15
by LOESCHE
Page 41
Damper S
(Stack)
Damper S
(Stack)
Damper R
(Recirculation)
Damper R
(Recirculation)
Damper Z1
(Fresh air)
Damper Z1
(Fresh air)
16
17
by LOESCHE
Page 42
Control Values
Agenda
Raw material
Coal
Clinker
Differential
pressure
Outlet
temperature
Gas flow
Inlet pressure
18
19
by LOESCHE
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
20
21
by LOESCHE
Page 44
Summary
Different LOESCHE mill types
Control values
Evaluation of performance
22
23
by LOESCHE
Page 45
Preventive maintenance
Wear & repair
by LOESCHE
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
by LOESCHE
Page 47
Overview
Mill stand
Example of a
LOESCHE Mill LM 3+3
Visual check:
condition of bolts of bearing
caps
condition of weldings
oil accumulations on
concrete foundation
M-Roller
M-Rocker arm
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
by LOESCHE
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
by LOESCHE
Page 49
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
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
by LOESCHE
Page 50
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
11
by LOESCHE
Page 51
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
Maintenance:
change stop-plates of buffers
change bellows
check bearing clearance
change gaskets of hyd. cylinders
Interval:
visual check weekly
Maintenance:
shift interval according to the
specific wear behavior of the mill
Illustration
Illustration
12
13
by LOESCHE
Page 52
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
15
by LOESCHE
Bladder
accumulator
Page 53
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
approx.
10mm
Roller
Grinding plate
16
17
by LOESCHE
Page 54
18
19
by LOESCHE
Page 55
20
21
by LOESCHE
Page 56
22
23
by LOESCHE
Page 57
24
25
by LOESCHE
Page 58
Wear on roller
26
27
by LOESCHE
Page 59
28
29
by LOESCHE
Page 60
30
31
by LOESCHE
Page 61
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
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
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
33
by LOESCHE
32
Flaps / guide
vanes
Illustration
Illustration
Q.. en Maintenance Rev.A
Classifier drive
Visual check:
check for proper attachment of bolts
check for wear
Page 62
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
Classifier
drive
Lifter
Bearing
cartridge
Classifier
Auxiliary parts for table
Hydraulic jack
Illustration
34
Illustration
35
by LOESCHE
Page 63
36
by LOESCHE
Page 64
More than
just conventional
Condition Monitoring
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
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.
Page 66
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
FACTS!
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
Failure
prevention!
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.
Failure
prediction!
Page 69
Acceleration
Sensor
What exactly is
condition
monitoring?
Planetary bearing
fault detected Nov.
2011
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
Strain Gage
What exactly is
torque
monitoring?
Antenna Ring
Antenna Head
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 71
Torque
Torque
Torque
Torque
Torque
1
2
3
4
5
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
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
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
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
stable
operations
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 Reporting...
Profit from our Experience and Knowledge!
Analysis
Torque vs. Mill Operation Parameters in High Resolution
Mill Feed
Reporting
Torque
Mill DP
Hydraulic Press.
Findings Conclusions
Recommendations
Motor Power
Trends, Analyse
Mill Vibration.
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
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
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
Thank You!
DALOG
Diagnosesysteme GmbH
Mhlbachstrae 21
86356 Neus / Germany
Phone: +49 (0) 821 74 777 10
Fax:
+49 (0) 821 74 777 19
E-Mail: info@dalog.net
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
by LOESCHE
Page 79
Agenda
Transportation
Classifying
Drying
Grinding
Summary
by LOESCHE
Page 80
Transportation
Flow
Drying
Temperature
Classifying
Speed
Pressure
Constantly
controlled &
stable
Grinding
Pressure
Consistent
product
Temperature
Speed
by LOESCHE
Page 81
Agenda
Process Parameters
Pressure
Process Parameters
Dependencies
Examples
Summary
Flow
Material
Reject
Gas
Water
(Fuel)
Product
by LOESCHE
Temperature
Page 82
Process Parameters
Agenda
Roller
Classifier
Damper
Hopper filling
Process Parameters
Dependencies
Examples
Summary
Drives
Mill main
Classifier
Mill main fan
by LOESCHE
Page 83
Dependencies
Agenda
Processes inside a mill
Process Parameters
Temperature
Dependencies
Examples
Summary
Pressure
Speed
Flow
10
11
by LOESCHE
Page 84
12
13
by LOESCHE
Page 85
Minimum value
Max value
6.85 m
10.23 m
7.81 mm/s
14.24 mm/s
4536 kW
5490 kW
14
15
by LOESCHE
Page 86
Finding:
3,38 m -> 88 m/s
Design:
4,79 m -> 61,5 m/s
16
17
by LOESCHE
Page 87
Agenda
Processes inside a mill
Damper S
(Stack)
Process Parameters
Dependencies
Damper R
(Recirculation)
Examples
Summary
Damper Z1
(Fresh air)
18
19
by LOESCHE
Page 88
Summary
Processes inside a mill
transport, grinding, drying and classifying
Process parameters
flow, pressure, temperature and speed
Dependencies
Examples
20
21
by LOESCHE
Page 89
by LOESCHE
Page 90
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 Mapeis Cement Additives Divisions vision in 2010.
by LOESCHE
Page 91
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
Fortunately not!
As vertical mills are used more and more often in cement plants, Mapeis 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
by LOESCHE
Page 93
Typical Dosage
Mill Output
Strengths
MA.G.A./VM
MA.P.E./VM
MA.P.E./VM W
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
Page 94
Finished product
Grinding Aid
tank
Additive dosing
pump
Water Pump
Water tank
by LOESCHE
Vertical Mill
Page 95
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
By pass
Blank
MA.G.A./VM
10
15%
9%
Imperfection
0,26
0,16
Acuity limit
18 m
21 m
by LOESCHE
Page 97
(min)
10
100
1000
C-S-H
Strengths
enhancing
GA
DRY
CEMENT
POWDER
FIRST GEL
INTERMEDIATE
PHASE
SECOND
GEL
by LOESCHE
+ H2O
Page 98
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 quick and convenient method for assessing pre-hydration is the corrected loss-onignition (Wk) determination:
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 400C to the water lost from C-S-H.
by LOESCHE
Page 99
100-200C
200-400C
450-550C
>600C
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
Page 100
In order to verify the effectiveness of Mapeis grinding aids for vertical mills in
comparison with traditional ones, our Technical Assistance Group performed a series
of industrial evaluations:
1.
2.
3.
4.
by LOESCHE
Page 101
180
160
140
120
100
80
60
173
175
B
A
200
40,0
35,0
Power Consumption (kWh/t)
200
30,0
29,5
BB
28,1
20,0
15,0
10,0
5,0
0,0
by LOESCHE
30,1
25,0
40
20
32,0
Page 102
10,0
30,0
9,0
7,0
8,0
7,9
7,8
25,0
6,4
6,0
5,0
4,0
3,0
Residuals at 45 m (%)
8,0
20,0
25,4
25,6
26,6
28,0
15,0
10,0
2,0
1,0
5,0
0,0
by LOESCHE
0,0
Page 103
45,0
37,0
38,1
30,0
25,0
20,0
15,0
10,0
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
35,0
39,1
40,0
38,7
Page 104
by LOESCHE
Page 105
Customer requests:
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
Page 106
Customer requests:
Starting conditions:
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)
Our achievement:
Facilitate the transition from CEM I 42.5 R to CEM I 52.5 R
by LOESCHE
Industrial trial with MA.G.A./VM 01, dosed @ 300 g/t (0,03%) together with the
water flow directly below the rollers
Page 107
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
by LOESCHE
Additive:
Page 108
Customer requests:
Increase the hourly output as much as possible, without decreasing the cements
fineness
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
Additive:
Page 109
Customer requests:
Starting conditions:
Increase the average 2 days strengths from 17-19 MPa to >24 MPa.
Improve the workability of their OPC
by LOESCHE
Page 110
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
by LOESCHE
Additive:
Starting conditions:
Page 111
Customer requests:
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
Page 112
Conclusions:
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.
...
by LOESCHE
Are definitely comparable (and often superior) to the ones usually obtained on
traditional grinding systems (ball mills).
Page 113
by LOESCHE
Page 114
by LOESCHE
Page 115
MAU Facilities
Warehouse:
by LOESCHE
Page 116
Our Vision
by LOESCHE
Page 117
Customers
PT Mitra Asmoco Utama have been serving the packaging industry with Mobil
products and technical expertise:
by LOESCHE
Page 118
11
by LOESCHE
10
Page 119
Lubricant Introduction
BASE OIL
LUBRICANT INTRODUCTION
ADDITIVE
- Mineral
- Synthetic
13
by LOESCHE
12
Page 120
2.
1.
2.
3.
3.
4.
4.
15
by LOESCHE
14
Page 121
Group III
Mixture of variable length
(C20-C40) and decreased
number of saturated ring
hydrocarbons (R).
Group II
A
H
R
H
Mixture of variable
length (C20-C50) and
saturated ring
hydrocarbons (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.
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
by LOESCHE
16
Page 122
Function of lubricant
19
by LOESCHE
18
Page 123
KEY PARAMETERS
LUBRICANT SELECTION
21
by LOESCHE
20
Page 124
Viscosity
Illustration : Proper Viscosity is a Function of Speed,
Load and Temperature
Viscosity :
High
High
High
Viscosity :
Low
Low
Low
23
by LOESCHE
22
Page 125
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
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
26
Page 127
ISO
6743
HH
HL (Part 1)
HL
HLP (Part 2)
HM
HVLP (Part 3) HV
Composition
Field Application
Inhibitor
(R&O)
Base Oil
Composition
C (Part 1)
Base Oil
CL (Part 2) CKB
CLP (Part
Antiwear (EP) 3)
CKC
Compounded CGLP
CKD (CKC
Plus)
CKE (CKB
Plus)
CKS
CKT
by LOESCHE
28
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.
OEMs Recommendations
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
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.)
D97
D97
PourPour
PointPoint
(oF/oC)
(oF/oC)
+10/-12+10/-12
(max.) (max.)
D445
D974
Viscosity
Viscosity
40oC (centistokes)
40oTotal
C (centistokes)
(TAN)
Acid
(TAN) Total Acid
Number
Number
Rust prevention A
0.20 (max.)
D445
D974
D665
D665
D93
D93
D130
D130
D892
D892
D943
D943
28.8-35.2
0.20 (max.)
Pass
Rust prevention A
Pass
420/215 (min.)
Copper corrosion
1B (max.)
( F/ C)
Copper corrosion
Foam
Foam
Turbine oil oxidation
test (hrs)
420/215 (min.)
5,000 (min.)
31
by LOESCHE
1B (max.)
50/0 (max.)
50/0 (max.)
50/0 (max.)
50/0 (max.)
50/0 (max.)
5,000 (min.)
50/0 (max.)
30
28.8-35.2
Page 129
Filling Quantity
First Change
Further Changes
Refilling Quantity
Check Quantity / Refill
Specifications of Lubricant:
200 g / Bearing
16000 h
16000 h
90 g / Bearing
8000 h
Grease
30 g
4000 h
Grease
Remarks
Appertaining Documents
(Drawing-no. or Manual)
see SEW-gearbox
manual chapter 8
Supplier Manual
(KREISEL / SEW)
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)
Non-locating
Bearing
1 each
6 ltr. (max.) each
-
Locating
Bearing
1 each
7.2 ltr. (max.) each
-
every year
(T < 80C)
every 3 months
(T > 100 C)
every year
(T < 80C)
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
Bio Gas
Landfill Gas
Document-No.: 4.Q-2980-00-4 en
Date / Revision: 2014-01-28 / Q2
Generated by: Gdde
Code-no. Viscosity
ISO-VG
in
DIN 51519
lubrication
at 40 C
(mm/s)
instructions
Mineral Oil
CLP 100 (CLP(CC))
Mineral Oil
CLP 150 (CLP(CC))
M1
VG 100
M2
VG 150
Mineral Oil
CLP 220 (CLP(CC))
M3
VG 220
Omala F 220
Mineral Oil
CLP 320 (CLP(CC))
M4
VG 320
Omala F 320
GEARMASTER
CLP 320
Mineral Oil
CLP 460 (CLP(CC))
M5
VG 460
Omala F 460
GEARMASTER
CLP 460
Mineral Oil
CLP 680 (CLP(CC))
M6
VG 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
Source
Viscosity @ 40C
TAN
ASTM D4378
GE - Gas
Solar
Siemens/
Westinghouse
ASTM D4378
HTGD901117
GEK 32568f
ES9-224
MS04-MA-CL001 and
CL002
K-8962-11
25 to 41
26 to 39
RPVOT
< 25%
Water
> 0.1 %
0.4
< 25% of new
500 ppm
Cleanliness
17/14
Abrupt Change
Demulsibility
30 minutes max
Metals
Air Release
Foam
OPTIMIZING OF
MAINTENANCE PROGRAM
17/14 max
< 20 minutes
Trend/consult
4 minutes max
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
MAITENANCE STRATEGY
TECHNIQUE NEEDED
Proactive
Maintenance
Monitoring and
correction of failure root
causes, e.g.
contamination
$0.10
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
by LOESCHE
40
Page 134
42
272
Ref: JCF
by LOESCHE
Page 135
New conditions
45
by LOESCHE
44
Page 136
Q&A
47
by LOESCHE
46
Page 137
Thank You
by LOESCHE
48
Page 138
by LOESCHE
Page 139
OUTLINE
Introduction
The A TEC Rocket Mill
Technical solutions for AF at main burner
Reference project
kiln burner
How?
by LOESCHE
INTRODUCTION
Page 140
INTRODUCTION
Low maintenance
Low maintenance
CO2 reduction
CO2 reduction
by LOESCHE
Page 141
General information
Rotating chains
Screen with 15mm hole size
Direct drive
by LOESCHE
Page 142
Grinding tools
by LOESCHE
Perforated screens
Page 143
Cutting Mill
Rocket Mill
30000
25000
LHV [kJ/kg]
20000
15000
10000
5000
0
45
40
35
30
25
20
Moisture [%]
15
10
by LOESCHE
50
Page 144
by LOESCHE
Page 145
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
Page 146
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
Page 147
Assumption
Existing AF treatment line
Road Map
Replacement of several shredding/cutting stages by Rocket Mill
by LOESCHE
Page 148
ROCKET MILL
Fe
separator
screen (opt.)
opt. heavy
separation
< 300 mm
shredder
< 20 mm
< 20 mm
< 100 mm
Fe
separator
screen (opt.)
Technical data
fine shredder
(cutting)
< 15 mm
< 60 mm
Screen size
15mm
rectangular 40 x 50mm
Output size
Throughput
~ 6 t/h
~12 t/h
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
Page 149
Due to the higher quality of AF produced with the rocket mill, the
coal amount could be reduced.
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
approx. 1-2
h/unit
Maintenance/cleaning
h/week
h/t
Maintenance
by LOESCHE
Page 150
Different output fuel particle sizes for main burner and calciner
by LOESCHE
possible
Page 151
Unstable flame
3. One or more pipes
inside the burner
No control
Lower mixing
Rings formation
CO emissions
Cement Strength
Low control
Low mixing
High control
High mixing
by LOESCHE
Clinker quality,
operational and
environmental
problems!!!
Page 152
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
Page 153
UNDERSTANDING SAF
COMBUSTION
UNDERSTANDING SAF
COMBUSTION
Wood cube
3D plastic
2D plastic
Slow ignition
Fast ignition
Low volatile
High volatile
High volatile
Keeps shape
Becomes a sphere
Forms droplets
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
Volume
Superf. Area
Equiv. Sphere
[mm]
[mm ]
[mm ]
[mm2]
2,0
12,6
234,0
462,0
4,2
180,0
45,0
12,6
154,2
61,2
1,00
0,66
0,13
by LOESCHE
Page 154
UNDERSTANDING SAF
COMBUSTION
UNDERSTANDING SAF
COMBUSTION
Combustion Mechanism:
FLAME BOUNDARY
FLAME BOUNDARY
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+O2 = H2O
REGION II
REGION IV
REGION III
INTERNAL GROUP COMBUSTION
FLAME BOUNDARY
oxidant
Combustion complementing
velocity
Hot gas recirculation
INDIVIDUAL PARTICLES
COMBUSTION
CLOUD DISPERSION
EXTERNAL RECIRCULATION:
Intense mixing
VOLATILIZATION ALSO ON
INTERNAL LAYER
REGION II
INTERNAL SHEAT COMBUSTION
INTERNAL RECIRCULATION:
REGION IV
INDIVIDUAL PARTICLE COMBUSTION
by LOESCHE
Page 155
FLEXIFLAME ECOPRO
High Oxygen
Key Point
AND
High Control
FLEXIFLAME ECOPRO
!!!
High momentum
High flame control
FLEXIFLAME ECOPRO
by LOESCHE
Main characteristics
Page 156
INTRODUCTION
PYROPROCESS EVALUATION
by LOESCHE
Page 157
OUTLINE
Preheater Performance & Preheater
Modification
by LOESCHE
Page 158
by LOESCHE
optimized EFFICIENCY
optimized ENERGY BALANCE
ENVIRONMENTAL protection
Page 159
- Separation efficiency
- Pressure drop
Riser ducts:
- Meal distribution
- Retention time
Calciner:
- Low NOx
- Retention time
- RSP calciner
- NOx Reduction
- Pressure drop
by LOESCHE
ID fan:
- Fan capacity
Cyclones:
Page 160
by LOESCHE
Page 161
by LOESCHE
Page 162
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
by LOESCHE
Page 163
RESULTS / REALIZED
PARAMETERS
Gas Quantity:
Gas Temperature:
Clinker Production:
Project Example:
BEFORE
MODIFICATION
AFTER
MODIFICATION
4-stage preheater
4-stage preheater
Difference
Guarantee
250,000 Am/h
520 C
1,200 t/d
1,300 t/d
+ 100 t/d
12 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
by LOESCHE
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
Page 165
BLOCKAGE AVOIDING
BLOCKAGE AVOIDING
by LOESCHE
Page 166
BLOCKAGE AVOIDING
BLOCKAGE AVOIDING
operation
without bypass
original
operation
by LOESCHE
operation with
bypass
Page 167
Theoretical Background
1. NOX formation
2. NOX reduction
1.Primary NOX reduction
2.Secondary NOX reduction
2 + +
+ 2 +
= 5,74 1014
561000
2 2
0,5
900
NOX concentration (10 % O2), mg/Nm
700
500
300
100
800
1300
1800
Temperature, C
by LOESCHE
Page 168
Fuel
composition
Plant
configuration
N content
Kiln type
H2O content
Volatile matter
Raw material
NOX
Calciner
Clinker cooler
etc.
Clinker spec.
Free lime
Avoid overburning
by LOESCHE
moderate LSF
Preheater configuration
Page 169
Low-NOX burner
low NOX
levels
CO
CXHY (hydrocarbon radicals)
CXHY + z NO = x CO2 + y/2 H2O +z/2 N2
Calciner
l>1
Calciner
l<1
high NOX
levels
Kiln
l>1
by LOESCHE
Page 170
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
by LOESCHE
pyrolysis
Page 171
Fuel Combustion
Fuel Combustion
Char
Bituminous coal
Wood
PE
Fixed carbon Nitrogen
~ 0 % (theor.)
~ 30 %
~ 85 %
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
~ 100 %
Combustion
Page 172
Meal split
Ammonia (NH3)
Ammonia water
Urea (CH4N2O)
NH3 loss
comb. to NOX
NH3 slip
Emission of NH3
Formation of additional NO
900
1000
Temperature, C
1100
by LOESCHE
Page 173
NH3 loss
comb. to NOX
4 NH3 + 6 NO 5 N2 + 6 H2O
NH3 slip
NH2
+ox
NO
900
1000
Temperature, C
1100
by LOESCHE
NH3
N2
Page 174
upsteam
downstream
CALCINER
A TEC PCC
by LOESCHE
High turbulence
Page 175
THANK YOU
by LOESCHE
www.atec-greco.com
Page 176