PYRO PROCESS UNIT Adnan Can Optimization & Capacity Upgrade - - PowerPoint PPT Presentation

PYRO PROCESS UNIT

Adnan Can

Optimization & Capacity Upgrade

Evaluation of the Existing Conditions Clinker Cooler Refrofit Cooler Vent Fan Replacement Preheater Cyclone Modifications Kiln Feed System Modification

Capacity Upgrade of an Existing Clinker Production Line, Nuh Cement

01-EVALUATING THE EXISTING CONDITIONS

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Nuh Cement Plant, Turkey

Evaluating the Existing Conditions of the 1st Line

Capacity : 2700-2800 tpd Specific Heat Consumption : 850-870 kcal/kg clinker Standard Cooler Loss : 140 kcal/kg clinker Clinker Temperature : 170°C + ambient Tertiary Air Temperature : 715°C

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Nuh Cement Plant, Turkey

Evaluating the Existing Conditions of the 1st Line

Pressure Drop at PH-Tower Exit : 82-84 mbar ID Fan Power Consumption : 12-13 kWh/t clinker Cooler Vent Fan Power Consumption : 2,5 kWh/t clinker Kiln Feeding System : Pneumatic Total Power Consumption of Kiln : 31 kWh/t clinker 01-EVALUATING THE EXISTING CONDITIONS

02- CLINKER COOLER

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Nuh Cement Plant, Turkey

Phase 1# Clinker Cooler Reftrofit Scope of Work

Complete Cooler Internals Cooler Casing Clinker Cooler (Roller Crusher to be installed) New Cooler fans with Silencer, Motor and Drives Dismantling and Erection Works Supervision, Commissioning and Training

03- COOLER VENT FAN

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Nuh Cement Plant, Turkey

Phase 2# Cooler Vent Fan Replacement

The fan rotor to be replaced with state-of-the-art design fan Complete procurement, dismantling and erection is in the scope 1 kWh/t clinker to be reduced

03- PREHEA TER CYCLONE MODIFICA TION

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Nuh Cement Plant, Turkey

Phase 3# Preheater Cyclone Modification Guaranteed Values

Capacity : 3200 tpd Preheater Tower Pressure : 69 mbar at 3200 tpd Energy Consumption Saving : 2 kWh/t clinker Specific Heat Consumption : 790 kcal/kg clinker

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Nuh Cement Plant, Turkey

Phase 3# Preheater Cyclone Modification Scope of Work

8 cyclones (O1A, O1B, O2, O3 & V1A, V1B, V2 and V3) to be modified together with riser ducts Dip tubes, splash boxes, meal flaps Complete manufacture, dismantling and erection Commissioning, Training and Optimization 03- PREHEA TER CYCLONE MODIFICA TION

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Nuh Cement Plant, Turkey

Phase 3# Preheater Cyclone Modification / Existing Cyclones

Preheater String 1# O2 & O3 Cyclones 03- PREHEA TER CYCLONE MODIFICA TION 03- PREHEA TER CYCLONE MODIFICA TION

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Nuh Cement Plant, Turkey

Phase 3# Preheater Cyclone Modification / Modified Cyclones

Preheater String 1# O2 & O3 Cyclones 03- PREHEA TER CYCLONE MODIFICA TION

04- CFD ANAL YSIS OF THE MODIFIED CYCLONE

CFD Analysis of the Modified Cyclones

Before the modification After the modification

Static Pressure Distribution

Before Modification : 2436 Pa After Modification : 1657 Pa

Before the modification After the modification

CFD Analysis of the Modified Cyclones

Tangential Velocity Distribution

04- CFD ANAL YSIS OF THE MODIFIED CYCLONE

Before the modification After the modification

CFD Analysis of the Modified Cyclones

Axial Velocity Distribution

04- CFD ANAL YSIS OF THE MODIFIED CYCLONE

05- CFD ANAL YSES RESUL TS FOR 2

NDST

AGE

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1657 Pa 2603 Pa 1788 Pa

Phase 3# Preheater Cyclone Modification / CFD Analyses Results for 2nd Stage

Nuh Cement Plant, Turkey

STATIC PRESSURE TOTAL PRESSURE Existing Cyclone Simple Modification Existing Cyclone Simple Modification

2436 Pa

06- NUH CEMENT PLANT

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Nuh Cement Plant, Turkey

07- KİLN FEED SYSTEM MODİFİCATİON

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Nuh Cement Plant, Turkey

Phase 4# Kiln Feed System Modification Scope of Work

Pneumatic Feeding System to be replaced with mechanical method (bucket elevator, airslide) Basic and Detailed Engineering Complete set of equipment Steel structure and manufacture All erection, commissioning, supervision and training

08- MODIFICA TIONS A T NUH CEMENT

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Nuh Cement Plant, Turkey

09- OVERALL GUARANTEES OF ALL PROJECT

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Nuh Cement Plant, Turkey

Overall Guarantees of All Project

Capacity : 3200 tpd Specific Heat Consumption : 790 kcal/kg clinker Energy Consumption : 26 kWh/t clinker Energy Consumption Saving : 5 kWh/t clinker Clinker Temperature : 65°C + ambient

10- ACHIEVED V ALUES

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Nuh Cement Plant, Turkey

Achieved Values

Capacity : 3400 tpd Specific Heat Consumption : 750 kcal/kg clinker Energy Consumption : 24 kWh/t clinker Energy Consumption Saving : 7 kWh/t clinker Clinker Temperature : 55°C + ambient

11- BEFORE AND AFTER

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Nuh Cement Plant, Turkey

Evaluation of the Existing Conditions Raw Meal Drying and Grinding Unit Kiln De-Dusting Unit Pyro Process Unit

Ongoing Capacity Upgrade Project of an Existing Clinker Production Line, Gazakh Cement Plant

11- GAZAKH CEMENT PLANT

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Gazakh Cement Plant, Azerbaijan

Evaluating the Existing Conditions

Capacity : 2500-2700 tpd Specific Heat Consumption : 870 kcal/kg clinker Raw Mill Capacity : 205 tph Fineness of the Mill Product :≥15.5% R90µm Separator Efficiency : 75%

12- RAW MEAL DRYING AND GRINDING UNIT

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Gazakh Cement Plant, Azerbaijan

Raw Meal Drying and Grinding Unit Scope of Work

New drying equipment for the raw meal Complete replacement of the separator and cyclones New Raw Mill Fan complete with motor and drive New raw meal transport unit Raw meal weighing unit modifications Complete procurement, dismantling and erection Supervision, commissioning and training

13- KILN DE-DUSTING UNIT

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Gazakh Cement Plant, Azerbaijan

Kiln De-Dusting Unit Scope of Work

Bag Filter modifications New Bag Filter Fan with motor and drive Complete procurement, dismantling and erection works Commissioning, Training and Optimization

14- PREHEA TER UNIT

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Gazakh Cement Plant, Azerbaijan

Preheater Unit Scope of Work

Preheater cyclone modifications TA Duct and Calciner connection modification New dip tubes, riser ducts and splash boxes New ID Fan, complete with motor and drive Complete manufacture, dismantling and erection Commissioning, Training and Optimization

15- GUARANTEES

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Gazakh Cement Plant, Azerbaijan

Overall Guarantees of All Project

Production Capacity : ≥240 tph Mixed Raw Material Moisture : Max 8% Mixed Raw Material Feed Size : 90% <25 mm Raw Meal Moisture Content : ≤1% Separator Efficiency : ≥85%

Raw Mill Unit

15- GUARANTEES

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Gazakh Cement Plant, Azerbaijan

Overall Guarantees of All Project

Clinker Production Capacity : ≥3300 tpd Heat Consumption : ≤765 kcal/kg clinker Preheater Pressure Drop : ≤60 mbar ID Fan Power Consumption : 9 kWh/t clinker Top Stage Cyclone Efficiency : 93%

Rotary Kiln Unit

15- GUARANTEES

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Gazakh Cement Plant, Azerbaijan

Overall Guarantees of All Project

Free Lime : ≤1.5% (daily avg.) C3S : ≥55 (Std. Bogue formula) LSF : 93-97 Silica Ratio : 2.0 - 2.8 Al2O3 : 1.0 – 1.8 New Process Fans’ Efficiency : ≥80%

Quality Parameters

16- HIGHLIGHTS OF THE PROJECT

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Gazakh Cement Plant, Azerbaijan

Supply of the equipment will be at 6 months Flame-off flame-off period is planned to be 35 days

Highlights of the Project

GRACIAS