1 / 26

Klaus-Martin Meier Edward Le Ted T Reese Cadence Environmental Energy

Maximizing the Benefits of Staged Combustion. Klaus-Martin Meier Edward Le Ted T Reese Cadence Environmental Energy. EUROPEAN CEMENT KILNS ARE WORLD LEADERS. Europe has 2 nd most plants in World. Europe is 3 rd largest producer of cement in World. World Leader in Alternative Fuel Use.

bradley
Download Presentation

Klaus-Martin Meier Edward Le Ted T Reese Cadence Environmental Energy

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Maximizing the Benefits of Staged Combustion Klaus-Martin Meier Edward Le Ted T Reese Cadence Environmental Energy

  2. EUROPEAN CEMENT KILNS ARE WORLD LEADERS • Europe has 2nd most plants in World • Europe is 3rd largest producer of cement in World • World Leader in Alternative Fuel Use • World Leader in Meeting Strict Environmental Compliance

  3. Production • Kilns currently running at lower utilization rates No current incentives for increasing production Opportunity lies in improving efficienciesand reducing operating costs

  4. Alternative Fuels • Europe operating at 28% fuel substitution rate High percentage of kilns invested in alternative fuel programs Opportunity exists in optimizing current alternative fuel programs

  5. Environmental Requirements Regulations will continue to tighten NOx emission requirements will become more stringent Is it realistic to expect less environmental compliance? Optimized performance will help to meet new requirements

  6. What Does Everyone Want? 1. 2. 3. Operation Efficiencies Lower Emissions Lower Fuel Costs

  7. What Does Everyone Want? 1. 2. 3. Improved Operation HOW DO YOU GET ALL THREE? Lower Emissions Lower Fuel Costs

  8. Staged Combustion Benefits Transition from Staged Fuel Combustion to… Staged Air Combustion

  9. Staged Air Combustion Benefits • Reduce Baseline NOx • Improve SNCR Efficiencies • Increase Alternative Fuel Use

  10. Staged Air Combustion Staged Air Combustion (SAC) puts mixing energy and combustion air in a critical kiln area Addresses: • gas stratification • temperature imbalance

  11. Staged Air Combustion SAC reduceskiln gas stratification Effectively utilizes the excess oxygen for CO reduction SAC ON SAC OFF Kiln Gas Stratification NO Kiln Gas Stratification

  12. Staged Air Combustion • BENEFITS • CO reduction • NOx reduction • Higher AF rates • Heat transfer • Reduces excess air in burning zone

  13. Staged Air Combustion Mixing Air Injection Preheater or Precalciner Kiln Whole tires or Alt. fuels at the feed shelf.

  14. National Cement - Ragland, Alabama USA • Kiln information • Clinker production = 108 tph • Heat consumption = 3.1 MMBtu/tkk • Type of fuels = Coal, TDF, Saw Dust, Glycerin

  15. Staged Air Combustion Process Modification

  16. Staged Air Combustion Operational Flexibility Multiple Benefits Emission Reduction Cadence Mixing Air Improved Alternative Fuel Usage Heat Consumption Improvement

  17. UncontrolledNOx 2500 2000 1500 1000 500 0 (mg/Nm3) PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln Normal Ranges

  18. ControlledNOx 2500 2000 1500 1000 500 0 (mg/Nm3) PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln Normal Ranges BAT (Best Available Technology) for NOx Abatement

  19. Meeting Environmental Compliance • BAT does not guarantee meeting NOx requirements CURRENT – 500 mg/Nm3 2500 2000 1500 1000 500 0 (mg/Nm3) PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln BAT (Best Available Technology) for NOx Abatement

  20. Meeting Environmental Compliance • Current NOx requirement is 500 mg/Nm3 SNCR AGENT REQUIRED 1000 800 600 400 200 0 NOx (mg/Nm3) PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln BAT (Best Available Technology) for NOx Abatement

  21. Meeting Environmental Compliance • NOx regulations expected to further decrease permit levels MORE SNCR AGENT REQUIRED 1000 800 600 400 200 0 AMMONIA SLIP HIGHER REAGENT COST DETACHED PLUME CONCERNS NOx (mg/Nm3) PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln BAT (Best Available Technology) for NOx Abatement

  22. Staged Combustion Benefits Preheater Cement Kiln • Alternative Fuel • 5-8% Increase Improve SNCR Efficiencies 20-25% Molar Efficiency Improvement • Reduce Baseline NOx • 725 650 mg/Nm3 (10%) • 850 715 mg/Nm3 (16%)

  23. Staged Combustion Benefits Lime / White Cement Kiln • Reduce Baseline NOx • 950 600 mg/Nm3 (37%) • 800 550 mg/Nm3 (31%) Improve SNCR Efficiencies

  24. Ash Grove Cement Capitol Aggregates BuzziUnicem California Portland Cement Essroc Cement Holcim Cement Lafarge Cement Lehigh Cement St. Lawrence Cement Over 21 line installations Proven Technology Over 37 years experience

  25. Aalborg Cement Denmark AkmenesCementas Lithuania JSC Krasnos Belarus Kirchdorfer Cement Austria Lafarge Cement England* Holcim Spain* Holcim Belgium* Expanding…

  26. Maximizing the Benefits of Staged Combustion Thank You! Come visit our team at Cadence Booth… Klaus-Martin Meier Edward Le Ted T Reese Cadence Environmental Energy

More Related