Siemens Process Analytics in the Cement Industry

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Siemens Process Analytics in the Cement Industry
Process Analytics
Solutions for the Cement Industry

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Applications of gas analysis systems in Cement
Plants

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics

• Gas analyzer equipment in cement works must be
  able to withstand a very tough environment
• high gas temperature up to 1400 ?C
• high dust concentration up to 2000 g/m3
• high content of Alkalis, Sulfates and Chlorides
• in addition, high level of mechanical stress
  and strain

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
4
Siemens Process Analytics in the Cement Industry
Process Analytics
Conventional gas sampling systems with water
cooling have a number of serious weak points
? they block up easily because of the
condensation that forms due to the low operating
temperature ? lime deposits and corrosion with
water as coolant ? caking of material on the
probe causes excessive mechanical
stress ? High cost for maintenance and low
reliability

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
The problems with the gas analysis in cement
rotary kilns can be minimized or eliminated by
using our patented gas sampling system

Applications
The Problem and our Solution
Kiln inlet
FLK sampling system
? Formation of condensation The operating
temperature of 200 ?C at which our probe operates
is above the dew point of the flue-gas and the
acid. ? Lime deposits and corrosion with water
as coolant Using a special synthetic liquid as
coolant prevents lime deposits and corrosion
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
The problems with the gas analysis in cement
rotary kilns can be minimized or eliminated by
using our patented gas sampling system

Applications
The Problem and our Solution
Kiln inlet
? Caking of material on the probe Minor deposits
are removed during regular automatic retraction
and cleaning with compressed air. ? High
maintenance costs Thanks to the high operating
temperature and the effective method of
cleaning our system can achieve periods of
maintenance free operation up to three months
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
FLK Gas Sampling System

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Gas Sampling probe

Applications
Kiln inlet
FLK sampling system
Gas flow
? for gas temperatures up to 1400 ?C ? gas
sample temperature up to 200 ?C ? lateral
intake chamber to reduce entry of dust ?
self-cleaning of dust deposits during retraction
and insertion ? variable probe length to meet
the customer requirements ? high mechanical
stability due to oval design
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Automatic Retraction unit

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
? in case of faults the probe is retracted
automatically from the kiln ? redundant
motorized retraction due to electrical and
pneumatic motor ? heavy duty and maintenance
free mechanical design
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Dedusting Filter

Applications
Kiln inlet
FLK sampling system
? electrically heated operation ? operating
temperature controlled by thermostat ?
maintenance free sinter metal filter
? preheating of compressed air
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Purge unit

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
? automatical cleaning of gas paths ? adjustable
cleaning cycles ? minimum pressure recognition
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Siemens Process Analytics in the Cement Industry
Process Analytics
Heat exchanger

Applications
Kiln inlet
? synthetic coolant ? high boiling point
? environmentally friendly ? closed
coolant circulation, pressure free
operation ? monitoring of temperature, flow
and level ? operating temperature
adjustabel (130?C 220 ?C) ? fast and easy
installation and commissioning
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Heat exchanger

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Control- and monitoring unit

Applications
? Compact cabinet ? with SIMATIC S7-300
or Allen Bradley SLC500 ? central power
distribution ? Function ? controlling of
purge cycles and gas sampling ? monitoring
of temperature, flow and level ?
automatical probe retraction in case of
faults
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
? easy to change parameter settings without
programming expertise
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Siemens Process Analytics in the Cement Industry
Process Analytics
Gasflow and cooling circuit

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Gas treatment and Analysis

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Gas treatment and Analysis
Process Analytics
Applications
Up to 8 gas components in one analyser cabinet
with theMulti-Component gas analyser ULTRAMAT23
Kiln inlet
FLK sampling system
? Up to 3 IR absorbable gas components plus
oxygen ? Easy-to-use menu driven operation ?
AUTOCAL with ambient air
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics
FLK Gas sampling system
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics

FLK Gas sampling system
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics

FLK Gas sampling system
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics

FLK Gas sampling system
Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics

FLK Gas sampling system / Benefits

• ? Synthetic heat transfer liquid instead of water
• Gas sample temperature up to 200 ?C
• no condensation-build up in the sampling probe
• no lime deposits and corrosion
• no freeze over of the coolant
• high availability and less maintenance
  compared with water cooled systems

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation

• ? Short commissioning time
• the system comprise just 6 components
• components ready to connect
• typical commissiong time 3 to 5 days

Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics

• Economic performance analysis of typical Customer
  benefits
• Optimized burning process
• 1 excess of Oxygen means 10 kcal of extra
  energy consumption per kilo of clinker
• In the case of a kiln with a capacity of 3000
  tons/dayoperating 300 days a year, this
  means9.000.000.000 kcal of extra energy
  consumption perannum
• or
• 1.097.560 kg of extra coal consumption assuming
  an energy content of 8200 kcal per kilo of
  coal

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
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Siemens Process Analytics in the Cement Industry
Process Analytics

• Economic performance analysis of typical Customer
  benefits
• Optimized burning process
• With a coal price of 45 per ton this means
• 1.097,560 tons of extra coal x 45 49.365
  higher energy costs
• This saving means that the payback period on the
  investment in FLK GAS is less than 2 years
• And remember too that this does not even take
  into account the savings that can be made on
  maintenance compared with water-cooled systems

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI
32
Siemens Process Analytics in the Cement Industry
Process Analytics

• Economic performance analysis of typical Customer
  benefits
• Optimized burning process

Applications
Kiln inlet
FLK sampling system
Gas flow
Gas conditioning
Installation
Benefits
ROI