The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Green Solutions – FLSmidth Contribution
by R.S.Mani
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
FLSmidth is in 130th year…
� Supplying Cement Plants world wide from 300 TPD to 13000 TPD
� Upgrading the Cement Plant to improve the Productivity, Power Consumption, Fuel Consumption, Emission and Quality
� Supplying the most modern equipments, which are the result of their substantial investment in R&D, to meet the various demands of the customers
� Close contact with customer to solve their problem through Customer Service - A dedicated group to focus on customer needs
� Initiatives for Greener tomorrow, focusing more on the reduction in the emission
� Approximately 2.5% of turnover is spent on R&D for various green initiatives
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
FLSmidth initiatives for Greener tomorrow
In last few years, few of the major sectors being focused are
Pyro Section1) Reduction in Specific fuel consumption2) Reduction in Specific power consumption3) Solution for Alternative fuels4) WHR power generation5) Reduction in emission levels
Grinding, Filters and Automation
1) Adapting vertical mills for Raw and Coal Grinding2) Adapting vertical mills and HRP for Cement Grinding3) Highly efficient pollution control equipment4) Fuzzy logic system
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Pyro Section
� High efficient and low pressure drop cyclones
� Best utilization of the gases coming from Kiln
� Lowest specific gas volume there by reducing
Hot gases being vented out to atmosphere
� Low pressure drop and result in Low power consumption
Result:Saving in Fuel and Power Consumption
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
ILC CalcinerILC Calciner
Result: Saving in Fuel and Power consumption
�High material and gas retention time in calciner due to its large volume and moderate swirl.
� Regulation range of up to 60% bypass of kiln gas using ILC-I version.
� Well-suited for low-grade fuels.
� Long refractory life due to low thermal kiln load and stable kiln coating.
� Lowest NOx emission among traditional calciner kiln systems
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
COOL TECHNOLOGYFLSmidth Cross-Bar™ Cooler – “The best got better”
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Pyro Section
High efficient Cross bar coolers to recuperate maximum heat with ABC inlet
� Horizontal design with optimized transport method
� Separate clinker conveying and cooling systems
� Stationary, sealed grate line and Self-adjusting mechanical flow regulators
� Modular concept
Savings in SFC up to 50 Kcal/Kg.clk
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Duoflex Burner
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
A Duoflex for burning liquid waste and coal A Duoflex for burning rice husk and a gas burner in addition
Duoflex Burner Features
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Oil Gun for Liquid AF
� Solution to Alternative liquid
fuels
� High momentum burners with
Provision for alternative fuels
� Oil Burner atomized for firing
hazardous liquid fuels
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Hot Disc
Solution to Alternative fuels
HOTDISC – To burn Anything and Everything
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
EmissionsEmissions
Disc
Reactor
Disc
Reactor
Kiln BurnerKiln Burner CoolerCooler
FilterFilter
Solid Waste Fuel
Receiving
Solid Waste Fuel
Receiving
Pneumatic
Conveying
Pneumatic
Conveying
Solid Fuel
Processing
Solid Fuel
Processing
DosingDosing
StorageStorage
LWDF
Receiving
LWDF
Receiving
StorageStorage
Kiln
Bypass
Kiln
Bypass
EmissionsEmissions
Overall aspects:
• Control/regulation
• Clinker production
• Heat consumption
• Availability
• Chemistry
• Emissions
Overall aspects:
• Control/regulation
• Clinker production
• Heat consumption
• Availability
• Chemistry
• Emissions
PumpPump
Preheater/
Calciner
Preheater/
Calciner
An integrated Alternative fuel solution
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
13
Pipe ConveyorPipe Conveyor
Pfister RotoscalesPfister Rotoscales
HOTDISCHOTDISC
OBA Burner SetOBA Burner Set
DUOFLEX BurnerDUOFLEX Burner
FLSmidth Key products for Alternative fuels
HopperHopper
COMBUSTION EQUIPMENTS
COMBUSTION EQUIPMENTS
HANDLING EQUIPMENTS
HANDLING EQUIPMENTS
DOSINGEQUIPMENT
DOSINGEQUIPMENT
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Why WHRS required?
step to energy
conservation
Reduction in Carbon
Emission
Effective utilization
of energy
More independence from
rising energy prices
Minimizing the
utilization of CPP
Clean & Green
Environment
Waste Heat Recovery
CDM Benefits
Lower operation costs
by own power
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Why with FLSmidth?..
Continuous Innovation
Process & Plant
Design Expertise
Complete integrated
Plant Supply
Extended focus on customer
satisfaction
One Source
Extensive experience in cement
Low
est C
ost o
f ove
rall
owne
rshi
p
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Did you know WHR on a 5000 t/d cement plant can…?
Waste Heat Recovery
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Available potential in Indian Cement plant
Installed Cement Capacity in India : ~ 280 MTPA
Average Gas emission in preheater : 2.0 to 2.4 Kg/kgcl at 280-340°C
Average Gas emission in cooler vent : 1.4 to 1.6 Kg/kgcl at 260-320°C
Average power Generation Possible : 25 to 35 KWH/MT
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Heat recovery power cycles-
FLSmidth can offer
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Steam Rankine cycle
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Limitations with Steam Rankine cycle
� Single component system
� Power generated is low at Low temperatures
� Steam in a turbine can only expand until it reaches a temperature of ~100C, when it condenses at atmospheric pressure. This limits the efficiency of a system
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Kalina Cycle Areas of Application
What are the areas of applications?
HighTemp.
LowTemp.
Waste Heat Recovery in Industries
� Gas compressor stations
� Iron + Steel Industry
� Cement Industry
� Chemical Industry
� Incineration Plants
� Diesel Plants
Hot Brine Heat Recuperation
� Geothermal Plants100°C
500°C
Primary
Source
Steel Plant (Japan)
Waste Incineration (Japan)
Geothermal Plant (Iceland)
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Kalina-Cycle Heat Acquisition Advantage
Closer temperature profile means improved efficiency
IMPROVED HEAT TRANSFER FROM HOT TO COLD STREAMS
“Hot”-Side (Flue Gas or Vapor)
NH3-H2OSteam
Temperature
Heat Transferred
Mixture
isothermal boiling
saturated liquid- pinch points
Key: mixture boils at a variable temperature
saturated vapor
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Kalina Cycle Conceptual Flow Diagram for Cement Applications
25
53
52
54
26
30
31
38
16
17
18
1
2
8
7 3
415 10
11
12 19
56
13
14
21
22
60 '
62 "
64 65
61 '
6343
44
45
23
58 5924
1
2 3
5 6
7 8
HRVG’s
Turbine
Cooler Gases
Preheater Gases� Unique ammonia/water process invented in
1980’s
� Ammonia and water mixture is controlled in a patented manner to achieve improved heat transfer and higher efficiency
� “Improved” Rankine cycle, not complete different cycle
� Based on proven principles as used in refrigeration plants for over 100 years, now applied to a power cycle
� Ammonia is environmentally stable with proven safety record
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Pyro Section – Waste Heat Recovery system
Projects under execution by FLSmidth
Plant Start-upYear
Clinker capacity
Size of power plant
System type
D.G.KhanPakistan
Q4 2012 6700 t/d 8.6 MWdT PH – 95 Deg CdT Cooler–250 Deg C
Kalina(PH+Cooler
end tap)
Vicat SagarIndia
Q4 2012 6600 t/d 8.4 MWdT PH – 124 Deg C dT Cooler–312 Deg C
Steam(PH+Cooler
mid tap)
Star Cement, Dubai*Aditya Birla Group
Q1 2013 7500 t/d 4.75MW Kalina(Cooler vent only)
* Concept to Commissioning in 15 months
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mills and Auxiliaries
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Vertical Mills
� Adapting vertical mills for raw, coal and cement grinding
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Classifiers for the Mills
� Installing High efficiency Classifier to reduce the SPC forVertical Mills and Ball Mills
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Mills and Pollution Control Equipments
In bag filter
Introduced long bag technology with 10 mtr long bagsUnique gas distribution arrangement for enhanced bag life
and minimum emissionsHybrid (ESP+FF) solution for lesser pressure drop and lesser downtime
ESP
Heavy duty tumbling hammer with Spheroidal tip for longer life & effective rapping
Unique Gas Distribution Screen (throttle plate with guide
vanes) for proper distribution, effective use of collection area and to prevent re-entrainment
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
ECS/Process Expert
A Complete Process Optimizer
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
ECS/Process Expert is a high-level Advanced Process Control and Optimization solution for complex and critical processes
FLSmidth’s international team of professional experts designed solutions specifically for various process applications. With more than 40 years of plant automation experience, FLSmidth has installed over 700 control systems and 450 laboratory systems – and so understands the needs of today’s plants.
Neural Networks
Robust - MPCs
Adaptive Controllers
Smart PIDs
MultiVariable Controls Estimators
Fuzzy Controllers
MatlabDeployment of Advanced Process Control Technologies….like
Process Optimisation...one of the many “Green Initiatives”
Help optimising the production process for a low carbon foot print
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Kiln and Cooler Processes
Vertical Roller Mills ( Raw , Coal , Cement)
Ball Mills with/without Pre-Grinders
FLSmidth’s ECS/Process Expert EXACTLY
address optimisation needs...
2-8% Produc
tion Benefit
s
1-5% Power /
Fuel Savings
20-30% Qu
ality Impro
vements
Proven Technology with Typical Benefits
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Payback for WHRS Kalina Vs Steam
Parameter Kalina Cycle design Steam design (same conditions)
Production (tpd) 7500 7500
Cooler ventGas volume (Nm3/hr)Temperature (°C)
340,000320 to 94
340,000320 to 190*
Steam/vapourQuantity (t/h)Temperature (°C)
42.5301
20.2300
Gross power(MWH) 4.75 3.9
Difference +22%
Annual revenue MINR 338.6 278
Installation Cost 850 615
Payback 2.5years 2.2years
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Typical Cooler Upgrade Investment & Pay Back
� Cooler Capacity : 4000 TPD
� Cooler upgrade investment : 130 MINR*
� Expected fuel saving ~ 45 Kcal /Kg Clinker
� Guaranteed Clinker temperature = 65 + Amb Deg C
� Savings via fuel = 45*4000*330*5000 / 4500= 66 MINR / Annum
� Pay back in years = 130/ 66 = 1.9 years
100 % trouble free operation and planned maintenance
(*- Inclusive of Cooler , MF-HRB,E & I, Civil, Erection and Supervision)
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Cement mill Upgrade with HRP in Semi-finish Mode
Existing Capacity : 120 TPH
Capacity Increment : 100 TPH
Savings in Sp. Power consumption : ~ 5 kWh/t
Benefit by capacity increment : 100 x 20 x 1000 x 330 = 660 MINR
Savings of power savings : 220 x 5 x 4.5 x 20 x 330 = 32.6 MINR
Total savings : = 660 + 32.6 = 693 MINR
Investment –
Mechanical : ~ 330 MINR
E&I : ~ 55 MINR
Civil : ~ 80 MINR
Misc : ~ 10 MINR
TOTAL : ~ 475 MINR
Payback : 475 / 693 ~ 9 months
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Vertical Raw Mill Upgrade with HRP Kit
Existing Capacity : 450 TPH
Capacity Increment : 55 TPH
Savings of capacity increment : 55 x 20 x 1000 x 330/1.6
= 227 MINR
Investments
Mechanical : ~ 120 MINR
E& I : ~ 15 MINR
Civil : ~ 50 MINR
TOTAL : ~ 185 MINR
Payback : 185 / 227 ~10 months
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Vertical Raw Mill Upgrade with HRP Kit / Ball Mill Kit
Existing Capacity : 450 TPH
Capacity Increment : 55 TPH
Savings of capacity increment : 55 x 20 x 1000 x 330/1.6
= 227 MINR
Investment With HRP With Ball Mill
Mechanical ~ 120 MINR ~ 60 MINR
E& I ~ 15 MINR ~ 10 MINR
Civil ~ 50 MINR ~ 30 MINR
TOTAL ~ 185 MINR ~ 100 MINR
Payback 185 / 227 ~10 months 100 / 227 ~ 5 months
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Let us contribute towards a clean and green environment by Improving the Cement Plant
Performance
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
How do we do it…
Let us keep our plant Clean & Green
One Source One Partner
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Contacts for Upgradation, AF, WHRS
Upgradation projects
� Mr.Anil Kumar – 9940110576 – [email protected]
� Mr.Logesh baskaran – 9566110327 – [email protected]� Mr.Rishi Kumar - 9500037491 – [email protected]� Mr.Sachin Chinchore -9500075942 – [email protected]� Mr.Jayaram Sudhakar -9500046285 - [email protected]
Alternative fuels
� Mr.Avanish karrahe - 967090223 – [email protected]� Mr.Venkatesh Seshadri – 9500075947 – [email protected]
Waste Heat Recovery System
� Mr.Avanish karrahe - 967090223 – [email protected]� Mr.Vaideesh Narayanan - 9500075947 – [email protected]
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
THANK YOU