[PPT] - SmartMill Technology Guaranteeing Particle Size, Quality and PowerPoint Presentation

SLIDE 1

SmartMill Technology

Guaranteeing Particle Size, Quality and Production with On-site Sorbent Milling

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Experience is our Technology℠ Experience is our Technology℠

SLIDE 2

STM Line of Mills

Milling & Feeding Technology

Roller Mills
Hammer Mills
Screen Mills
Jet Mills
Pin Mills
Cryogenic Mills
Laboratory Mills

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SLIDE 3

STM Line of Feeders, Injectors & Classifiers

Milling & Feeding Technology

Volumetric Feeders
Gravimetric Feeders
Dry Eductors
Wet Eductors
Distributors
Lump Breakers
Dynamic Classifiers

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SLIDE 4

Sodium Dry Injection Technology Experience

Sodium Sorbent Milling

In the 90s, STM led the

world in dry grinding for gas cleaning applications by helping a world-leading chemical supplier develop a novel gas cleaning approach using sodium sorbents.

Today, STM has more

sorbent mill installations than any other mill supplier, exceeding 500 installations.

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STM Serial No. 1. Reggio Emilia Incinerator, Italy Latest STM Hammermill Design

SLIDE 5

Behavior of Sodium Sorbents at Temperature

Na Sorbent Decomposition

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Sodium Sorbent Decomposition Sodium Bicarbonate 2NaHCO3 → Na2CO3 + H2O + CO2 Trona 2 [ Na2CO3 • NaHCO3 • 2H2O ] → 3Na2CO3 + 5H2O + CO2 Acid Gas Neutralization HCl Removal Na2CO3 + 2HCl → 2NaCl + H2O + CO2 SO2 Removal Na2CO3 + SO2 → Na2SO3 + CO2 and Na2SO3 + 1/2O2 → Na2SO4

Slide Courtesy of Solvay

SLIDE 6

Optimal System for Each Application

Gas Cleaning Systems

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Combustion Process Sodium Sorbent Type Sodium Bicarbonate Trona

Industrial and Hazardous Waste Incineration

Biomass
Cement
Power
Water Treatment

Metals Recovery Furnace

Cremation
General Combustion: Heavy Fuel Oil

and Natural Gas

Municipal and Hospital Waste

Incineration

Steel and Foundries
Glass

SLIDE 7

Characteristics of Various Sodium Sorbents

Gas Cleaning Comparison

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Sodium Bicarbonate Trona

Stoichiometric Ratio 0.8-1.4 1.8-2.5 Gas Temperature 120-400 °C 135-800 °C Reaction Time >2 Sec >4 Sec HCl Efficiency >99% >95% SO2 Efficiency >98% >90% SO3 Efficiency >98% >95%

SLIDE 8

Variations in Stoichiometry for a Given Efficiency

Na Performance curve

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Slide Courtesy of Solvay

SLIDE 9

Variations in Efficiency for a Given Stoichiometry

Na Performance curve

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Slide Courtesy of Solvay

SLIDE 10

Some of the Factors that Affect Acid Gas Removal

Efficiency Factors

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Given the same operating conditions and

reaction chamber geometry, stoichiometry and efficiency variations can be reduced down to one main operational parameter - Particle Size Distribution.

Achieving the correct sorbent particle size is

necessary to achieve the required efficiency.

Maintaining the correct particle size year-
ver-year is necessary to achieve compliance.

SLIDE 11

Particle Size for SO2 Removal

Sorbent Particle Size

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20 µm PARTICLE SIZE

x 10 = 0.93µm x 50 = 5.60µm x 90 = 20.15µm x 97 = 32.29µm x 98 = 37.55µm x 99 = 48.14µm

SLIDE 12

Particle Size for HCl Removal

Sorbent Particle Size

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30 µm PARTICLE SIZE

x 10 = 1.87µm x 50 = 14.64µm x 90 = 33.88µm x 97 = 44.47µm x 98 = 48.19µm x 99 = 53.62µm

SLIDE 13

Calcination occurs at elevated temperatures

Na Calcining

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SLIDE 14

Sorbent Injection

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Flowsheet for PC-fired Boiler with Duct Injection

SLIDE 15

Flowsheet for PC-fired Boiler with Reactor

Sorbent Injection

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SLIDE 16

Typical Reactor Designs

Sorbent Injection

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Single Pass Reactor Double Pass Reactor

SLIDE 17

Need for Distribution Analysis

CFD Optimization

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Throat Design Double Pass Reactor

SLIDE 18

Some of the Factors that Affect Acid Gas Removal

Efficiency Factors

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Gas Flow Factors
Temperature
Mixing (turbulence)
Distribution
Sorbent Factors
Particle Size
Purity
Material Integrity

SLIDE 19

On-site Particle Size Reduction vs. Pre-milled

Milled Sorbent Challenges

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Pre-milled
Storage silo release
Materials handling and transport
Particle size (clumping)
On-site Milling
Maintenance
Particle size consistency
Operational issues (difficult to keep clean)

SLIDE 20

Dose, Mill, Classify, Propel

Basic Milling Technology

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Components or a typical milling circuit

Propulstion Element Dosing Element Grinding Element Separation Element Raw Sorbent Feed Milled Sorbent Positive Pressure Propulsion Air to Duct or Reactor Heat Exchanger

SLIDE 21

What mills have been used before?

Basic Mill Technology

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Pin Mill
Uses pins rotating on rotors
Screen Mill
Uses hammers rotating against a screen
Hammer Mill
Uses hammers rotating against a track

SLIDE 22

Mills that should not be used and why

Basic Mill Comparison

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Pin Mill:
Prone to build-up
Difficult to clean pins online
Requires frequent and long interventions
No classifier to separate fine particles
Screen Mill:
Prone to build-up
Difficult to clean online
Requires frequent cleanings
No classifier to separate fine particles

SLIDE 23

Mills that could be used and why

Basic Mill Comparison

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Compact Hammer Mill:
Easy to keep clean with glycol addition
Requires little maintenance
Built-in propulsion fan - negative pressure
Self classifier to separate fine particles
Twin Rotor Hammer Mill:
Not as prone to build-up
Easy to clean and maintain
Twin rotors for higher production
Separate dynamic classifier

SLIDE 24

Self-classifying, compact design

Compact Mill

Flow-through, self-classifying mill

coupled to a transport air fan. The self-classifying design makes it a good choice for applications where narrow particle size distribution is not critical.

Ideal for low-cost retrofit applications.
Operational advantages:
Low energy consumption
Minimal maintenance needs
Compact, small space requirement
Ease of installation
Automatic operation

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SLIDE 25

Design limitations of a compact hammer mill

Compact Mill Limitations

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Limited size single rotor
Limits production rate
Requires higher velocity
Typically used in smaller

installations

In-line classifier
Imperfect control over particle

size distribution

D50 particle size ±10-15 µm
D90 particle size ±35-40 µm

SLIDE 26

Air classifying, twin rotor design

Basic Twin Hammer Mill

Twin rotor, air-classifying mill with a

separate transport air fan. The twin rotor design makes it a good choice for applications where mill temperature and particle integrity is not critical, such as calcium-based materials.

Ideal for medium/large gas cleaning

plants and for low-cost retrofit applications.

Operational advantages:
Low energy consumption
Minimal maintenance needs
Compact, small space requirement
Ease of installation
Automatic operation

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Basic Hammer Mill

SLIDE 27

Mills that could be used and why

Hammer Mill Limitations

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Older generation mill
Medium size twin rotors
Limits production rate
Requires higher rotor velocities
Dynamic classifier
Better control over particle size

distribution

D97 particle size ±15-20 µm
Significant heat build-up
Like all ACMs, heat build-up makes

it less desirable for milling sodium

SLIDE 28

Competitive Mill - Positive Pressure and Excess Heat

Other Hammermills

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Older generation mill
Shroud baffle assembly
Requires that first pass milled material flow around it
Designed to create circuit for rejects to return to mill hammers
Turbulence around shroud baffle plate causes excess heat
Dynamic classifier
Good control over particle size distribution
D97 particle size ±15-20 µm
Significant material build-up
Heat causes build-up making it less desirable for milling sodium

SLIDE 29

Popular Air Classified Mill Design for Sorbent Milling

Typical ACM

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SLIDE 30

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Typical ACM

Air Classified Mill Internals

SLIDE 31

Air Classified Mill - Design

Typical ACM

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Classifier Shroud Baffle Assembly Outlet - Air + Material Milling Air Inlet Rotor w/hammers Milling Liner Material + Transport Air Inlet

SLIDE 32

Competitive Mill - Positive Pressure Operation

Other Hammermills

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Air + Material Milling and Classifying Air

Reject Material Return: Turbulence=Heat Heat=Build-up

SLIDE 33

Competitive Mill - Positive Pressure Operation

Example Installation

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SLIDE 34

Competitive Mill - Build-up due to Overheating of SBC

Example Installation

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SLIDE 35

Competitive Mill - 2 Mills Replaced with 1 STM Bicarmill

Example Installation

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SLIDE 36

Competitive Mill - Horizontal ACM Design

Heat Build-up

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SLIDE 37

Competitive Mill - Vertical In-Line Design

Heat Build-up

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SLIDE 38

Bicarmill - Horizontal Design

No Heat Build-up

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SLIDE 39

Dose, Mill, Classify, Propel

Basic Milling Technology

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Components of a smart milling circuit

Propulstion Element Dosing Element Grinding Element Separation Element Raw Sorbent Feed Milled Sorbent Negative Pressure Propulsion Air to Duct or Reactor

SLIDE 40

Basic Mill System Elements

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Traditional milling systems are made up of several components, each engineered, purchased, installed, wired and controlled separately. Until recently, there was no option that provided a single, integrated milling solution.

Traditional Sorbent Milling Component Arrangement

+ +

Fan/blower Chiller Feeder Mill Classifier Booster Fan

+ + +

Sorbent Injection PLC

SLIDE 41

Mill System Components

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Fan/blower - Blows fine sorbent to the injection lances Chiller - Cools the incoming air to prevent sorbent from reacting in the mill Feeder - Required for metering the needed amount of sorbent into the mill Mill - Finely grinds the sorbent to improve the efficiency of the scrubbing Classifier - Allows fine sorbent through and returns the large material to the mill Booster Fan - Boosts the pressure of the sorbent transport air PLC - Regulates each element of the milling circuit

SLIDE 42

Site-Assembled Mill Systems

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Fan/blower - $15,000 Chiller - $15,000 Feeder - $40,000 Mill - $90,000 Classifier - $20,000 Booster Fan - $10,000 PLC - $50,000

Cost of an Assembled Sorbent Milling System

Cost of components-only 1000 kg/h sorbent milling system:

$240,000

and that does not include installation, wiring, engineering nor 8400 hour guarantee!

SLIDE 43

Site-Assembled Mill Systems

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Mechanical Installation - $40,000 Engineering - $30,000 Engineering Review - $20,000 Electrical Installation - $30,000

Total Installed Cost of a Traditional Mill System

Installed cost for 1000 kg/h sorbent milling system:

$240,000+$120,000= $360,000

But still does not provide an 8400 hour guarantee!

SLIDE 44

Bicarmill Smart Mill

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Housing all of the necessary components into a single, pre-engineered compact system, the Bicarmill is the guaranteed solution to on-site milling of sodium sorbent, all at a price that is much lower than the combined components of any mill on the market today.

Total cost of a complete 1000 kg/h Bicarmill system:

$189,000

including an 8400 hour continuous

peration guarantee!
Bicarmill™ -

The Complete Package

SLIDE 45

Bicarmill Smart Mill Features

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Build-up Control - Exclusive glycol additive ensures a clean machine Remote Telemetry - Signals before critical failures occur Particle Size Guarantee - Integrated controller guarantees the optimum particle size Maintainability - Designed for ease of maintenance Auto-lubrication - Lubricates on-line to ensure long bearing life Weather Enclosure - Fully enclosed machine protects vital equipment Chemical Integrity - Optimal chemistry is maintained for maximum efficiency

SLIDE 46

Bicarmill Smart Mill Features

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Maintenance Provisions - Enclosure fitted with maintenance I-beams for part removal Negative Pressure Operation - No messy dust emissions from milling system Air Flow Control - Ensures proper airflow and provides early fault detection Smart Mill - Controls every function of the milling, dosing and transport circuit Cool Operation - Mill design has little turbulence, and therefore cool operation Vibration Control - Ensures proper mill operation by modifying glycol injection rate Air Temperature Control - Ensures proper temperature and provides corrective action

SLIDE 47

Bicarmill Smart Mill

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The STM Bicarmill smart milling system is a complete package, ready to set down for two-wire installation, one power and one control signal - pre-engineered, pre-wired, pre-programmed, pre- installed - a single, integrated milling solution, guaranteed to operate for a minimum of 8400 hours!

+

Feeder Mill Classifier Fan/blower

+

Sorbent Injection Controller

+

STM Bicarmill™

SLIDE 48

Negative Pressure and Heat / Build-up Control

Bicarmill Smart Hammermill

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Newest generation, integrated hammer mill
No shroud baffle assembly - negative pressure
Has its own circuit for rejects to return to mill hammers
No turbulence to create excess heat
Dynamic classifier
Better control over particle size distribution
D97 particle size ±10-15 µm
No material build up
No heat build-up makes it desirable for milling sodium

SLIDE 49

Enclosed Smart Mill with 8400 Hour Uptime Guarantee

STM Smart Mill Technology

Classifying mill coupled to a transport air

fan, complete with controller for all functions of a milling circuit.

Is able to guarantee online operation

without stopping for a minimum of 8400 hours.

Main features of a smart mill:
Packaged machine with controller
Low noise emissions
Automatic operation - on-board instrumentation
Low maintenance - all external access
High reliability and quality
Alarming features

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BicarMill Smart Mill

SLIDE 50

Equipment Specifications and Capacity

Technical Data Bicarmill

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Model Installed Power Absorbed Power Acid Gas GUARANTEED Particle Size Capacity* Air Flow Pressure Noise Rotor Size kW kW Type Range µm Range kg/h m3/h mm H2O dbA

300 18.4 16.6 HCl SO2 d90<30µm - d50<10µm d90<20µm - d50<5µm 10-250 10-150 800 500 <75 400 29.2 26.3 HCl SO2 d90<30µm - d50<10µm d90<20µm - d50<5µm 40-450 30-300 1500 800 <75 630 64.2 57.8 HCl SO2 d90<30µm - d50<10µm d90<20µm - d50<5µm 80-1000 60-600 2700 800 <75 800 98.0 88.2 HCl SO2

d90<30µm - d50<10µm d90<20µm - d50<5µm

100-1400 70-900 4700 1000 <75 1000 129.0 116.1 HCl SO2 d90<30µm - d50<10µm d90<20µm - d50<5µm 100-1800 70-1200 6000 1000 <75 1250 205.0 188.7 HCl SO2

d90<30µm - d50<10µm d90<20µm - d50<5µm

120-3000 80-2000 9750 1000 <75 1500 284.0 261.2 HCl SO2 d90<30µm - d50<10µm d90<20µm - d50<5µm 150-4200 100-2800 13500 1000 <75

*Capacities Stated for Sodium Bicarbonate at GUARANTEED particle size distribution

SLIDE 51

Smart Bicarbonate Hammermill Functions

Features of a Smart Mill

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Auto-greasing Operation Built-in Temperature Sensor Built-in Vibration Sensor Built-in Airflow Sensor

Temperature control - unreacted particle
Airflow control - temperature control
Dosing control - accurate dosing rate
Classifier control - guaranteed particle size
Auto-glycol injection - build-up control

SLIDE 52

The Guts

Smart Hammermill

Full-feature classifying mill

coupled to a negative pressure transport air fan.

Operational features:
High energy efficiency
Low noise emissions
Minimal maintenance needs
Compact, small space requirement
High reliability and quality
Ease of maintenance

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Basic Smart Mill Mechanical Components

SLIDE 53

Integrated feeding and milling

Smart Mill Schematic

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SLIDE 54

Airflow Schematic

Smart Mill

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Ambient Air Mill Exhaust Negative Pressure Sorbent Propulsion Integrated Feeder

SLIDE 55

Mill internals w/Pneumatic Cylinder Removal Assist

Smart Mill

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SLIDE 56

Smart Mill with Automatic Control System

BicarMill 630

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SLIDE 57

Internal View of Doser and Mill with Pneumatic Open Assist

Smart Mill

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SLIDE 58

Internal View of Doser and Mill with Hoist Assembly

Smart Mill

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Full yearly

programmed maintenance requires approximately 2 hours for complete replacement of all wear parts.

SLIDE 59

Rotor Disc Removal with Hoist Assembly

Smart Mill

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SLIDE 60

Smart Mill with Multiple Dosing Units

Smart Mill Indirect Injection

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A - Dosing System B - Mill C - Filter/Reciever D - Suction Fan E - Rotary Valve F - Double Dosing System G - Eductor Venturi H - Regenerative Blower I - Mill to Filter Duct L - Filter to Fan Duct M - Air Recycle Loop N - Injection Point Piping

SLIDE 61

Typical Installation on Dry Sorbent Injection System

Smart Mill Installation

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SLIDE 62

Gas Cooling, Milling & Dosing Technologies for the Environment

STM EcoSystems 83 Princeton Ave., Suite 3D Hopewell, NJ 08525 Sales Contact: Joe Riley

Tel. 609.273.3331

info@stmecosystems.com www.stmecosystems.com

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