More than 50 years of expertise

Reducing emissions by monitoring the gas composition at the kiln inlet

= Saving Money

INTERNATIONAL NETWORK

ITECA SOCADEI SAS445 Rue Denis PapinEuropôle de l’ArboisCS 3047813592 Aix en Provence Cedex 3 FRANCE   + 33 (0)4 42 97 77 00     + 33 (0)4 42 97 77 33 info@iteca.fr www.iteca.fr

Europe - North, Central & South America - Asia - Middle East - Africa

Aix en Provence

Paris

ITECA SOCADEI - TODAY

CEMENT- Analysers for on line process control

- Centralised laboratories

- Production equipments (kiln seals…)

ColourOn line analysis

INSTRUMENTATIONDedicated to the solid bulk industry

(food, calcium carbonate, sugar, cement…)

3 DIVISIONS

Process optimization ON LINE CONTROLS

Quality control CENTRALIZED LABORATORIES

SUSTAINABILITY ENERGY SAVING PRODUCTION EQUIPMENTS

CEMENT DIVISION PRODUCTS RANGE

Quality

Sustainability

Process optimizatio

n

The most important gases to be monitored for kiln control are:

Oxygen : too low fuel may not be burning correctly wasting energy. too high possible to increase fuel input and raw material input and

therefore possible to increase production

CO : This gas is created in the flame, when the flame is not burning correctly

Dangerous, toxic loss of energy (incomplete combustion)

NOx : This gas is also created in the flame. Flame Surface T° NOx creation . NOx = indicator of the temperature of the clinkering zone in the kiln = indicator of the end quality of the clinker that is manufactured. All these gases can be measured using our sampling system, and the measurement of these gases already provides a great deal of valuable information on the operation of the kiln.

Kiln Inlet Gas Sampling & Analysis: WHY?

O2CO

NOx

Cooler

Precalciner

Kiln

Gas sampling

Output

Analyser

Our experience: all cement plants are facing the same

trouble Clogging of the sampling

probe in the Fume Box

Different sampling locations

Gas Sampling and Analysis

Requirements for an efficient kiln back end gas sampling

Low Maintenance - High availability

Withstand high dust concentration without blockage

Withstand high temperatures

Quick response time : high gas flow rate

Sturdy construction to withstand build-up fall

Gas Sampling and Analysis

Traditional technology : basic principle

Gas Sampling and Analysis

Gas is sampled and then filtered through a ceramic/metal/glass filter

The gas sampling is stopped and the filter and the probe are cleaned using compressed air

Filter

Traditional technology : limitations

Clogging problems (probe and filter): high maintenance

Sample contamination due to purge air : low availability

High maintenance on the membrane pump

Low gas flow rate (max 120 l/h) : slow response time

Bending due to blocks falling from the tower

Gas Sampling and Analysis

Gas Sampling and Analysis

Case study 1– ReliabilityContinuous operation for 20 consecutive days

4300 TPD Line with 63% alternative fuels

Gas Sampling and Analysis

O2 Drop

CO Rise

O2 no change

Tower

Iteca

Gas Sampling and Analysis

Tower

O2 no change

Iteca

O2 Drop

CO Rise

ITECA’s system: principleWet sampling

Closed circuit double cooling

system

Analysis CellCO, O2, NOx, CH4

Gas conditioning

Dryer

Gas analysis

Gas Sampling and Analysis

The sampled gas passes through the water spray, dust is trapped outside the probe before entering the line

Water spray 3 bars-30 l/h

Cooled jacket

Cooled probe

Cooled jacket

GAS

ITECA’s Wet sampling probe

No ceramic filter to clean or to replace

Gas Sampling and Analysis

Efficient probe cleaning system

Every 10-20 min (adjustable), high pressure

water (8 bars) is sent through the sampling line

to clean the probe

High pressure

water pulses

(4 to 5 l)

Efficient cleaning

+

No sample contamination from air purge

Cooled jacket

Cooled probe

Cooled jacket

Gas Sampling and Analysis

Sturdy sampling probeResistance to accidental fall of blocks

Sampling end

Connections to suction gas pump and

water Jacket Ø 168 mm

Sampling line Ø 34 mm

Weight (without water): 150 to 200 kg (depends on probe’s length)

Double cooling system: jacket + sampling line

Gas Sampling and Analysis

The probe is installed so that its tip is at least 500 mm beyond the inlet seal

Sampling Probe installationAvoid inlet seal false air influence

Gas Sampling and Analysis

Sampling Probe

Gas Sampling and Analysis

3D design to check the feasibility and find optimum probe location

Sampling Probe Automatic Extraction

High torque extraction

Secured system for the extraction of the probe in case of any problem on the power supply or the cooling circuit

Prevention system on a regular basis used to remove the coating

around the probe

Gas Sampling and Analysis

ITECA’s Sampling Probe Automatic ExtractionSafe and Reliable

Gas Sampling and Analysis

Secured system for the extraction of the probe in case of any problem on the power supply or the cooling circuit

Prevention system on a regular basis used to remove the coating around the probe

HIG

H T

OR

QU

E EX

TRAC

TIO

N

Gas Sampling and Analysis

ITECA’s Sampling Probe Automatic ExtractionSafe and Reliable

Oversized capacity closed cooling circuit (water T° < 65°C)

+ High cooling water flow rate : 2 500 l/h

Sampling probe really protected

Close loop cooling circuit

Gas Sampling and Analysis

No hot fluidNo high pressure

Persons really protected

Electrical control

Gas Analysis Gas Conditioning

Gas Conditioning and Analysis

Gas Sampling and Analysis

Gas Sampling and Analysis

Water / gas separation

circuit

Liquid ring pump

Gas suction : 1800 litres/hour

Water / gas separator : most of the water is

removed here

Cyclone separator :any remaining wateras liquid is removed

here

Water + Gas

Water

Gas

The gas is then dried inthe gas dryer by reducing

its temperature to 3°C

Dust filter

Gas flow regulators - One for each analyser (70 l/h /analyser)

+ evacuation

Command and display

Paramagnetic oxygen analyser

Infrared analyser : CO, NO, CO2

Gas dryer

Gas Analysis

Gas Sampling and Analysis

Working temperature : max 1400 °C

Working dust concentration : up to 2 kg/m3

Gas sampling flow rate : 1800 litres/hour

Response time (sampling and conditioning): 5

to 10 s

No sample contamination from air purge

No wear parts on the liquid ring pump

Heavy duty probe able to withstand build-up fall

Performances - Advantages

Gas Sampling and Analysis

Case study 2 – cement plant

Gas Sampling and Analysis

Pre-calciner kiln

Kiln capacity 4200 tpd

Partial fuel substitution with pet coke

The Iteca system was installed in parallel

with an existing traditional probe

Tests were conducted over an 8 month

period

Case study – cement plant

Gas Sampling and Analysis

Traditional

OXYGEN READING

ITECA

Air purges

Case study – cement plant

Gas Sampling and Analysis

NOx

ITECA GAS READING

CO

O2

Case study – cement plant

Gas Sampling and Analysis

ITECA

CO READING

TRADITIONAL

Case study – cement plant

Gas Sampling and Analysis

The reliability factor achieved was greater than 95% over an 8 month period

The gas sampling provided accurate and reliable data for O2, CO and NOx

The plant decided to purchase 2 more gas sampling systems from ITECA

Reduction of emissions, reducing consumption while increasing production:

BENEFITS ON BOTH SUSTAINABILITY and PROFITS

CONCLUSION

bernard.seemann@iteca.fr