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More than 50 years of expertise
Reducing emissions by monitoring the
gas composition at the kiln inlet
= Saving Money
INTERNATIONAL NETWORK
ITECA SOCADEI SAS
445 Rue Denis Papin
Europôle de l’Arbois
CS 30478
13592 Aix en Provence
Cedex 3
FRANCE
+ 33 (0)4 42 97 77 00
+ 33 (0)4 42 97 77 33
[email protected]
www.iteca.fr
Europe - North, Central &
South America - Asia Middle East - Africa
Paris
Aix en Provence
ITECA SOCADEI - TODAY
3 DIVISIONS
- Analysers for on line process control
- Centralised laboratories
- Production equipments (kiln seals…)
Dedicated to the solid bulk industry
(food, calcium carbonate, sugar,
cement…)
On line analysis
CEMENT DIVISION
Process optimization ON LINE
CONTROLS
PRODUCTS RANGE
Process
optimization
Quality
Sustainability
Quality control  CENTRALIZED
LABORATORIES
SUSTAINABILITY
ENERGY SAVING  PRODUCTION EQUIPMENTS
Kiln Inlet Gas Sampling & Analysis: WHY?
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.
Gas Sampling and Analysis
Different sampling locations
Precalciner
Kiln
Cooler
Gas sampling
Our experience: all cement
plants are facing the same
trouble
 Clogging of the sampling
probe in the Fume Box
Output
Analyser
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
Filter
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
Gas Sampling and Analysis
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
Case study 1– Reliability
Continuous operation for 20 consecutive days
4300 TPD Line with 63%
alternative fuels
Gas Sampling and Analysis
Tower
O2 no change
Iteca
O2 Drop
CO Rise
Gas Sampling and Analysis
Tower
O2 no change
Iteca
O2 Drop
CO Rise
Gas Sampling and Analysis
ITECA’s system: principle
Wet sampling
Analysis Cell
CO, O2, NOx, CH4
Closed circuit
double cooling
system
Dryer
Gas analysis
Gas
conditioning
Gas Sampling and Analysis
ITECA’s Wet sampling probe
Cooled
jacket
Cooled probe
Cooled
jacket
The sampled gas passes through the water spray, dust
is trapped outside the probe before entering the line
GAS
Water spray
3 bars-30 l/h
No ceramic filter to
clean or to replace
Gas Sampling and Analysis
Efficient probe cleaning system
Cooled
jacket
Cooled probe
Cooled
jacket
High
pressure
water
pulses
(4 to 5 l)
Every 10-20 min
(adjustable), high pressure
water (8 bars) is sent
through the sampling line
to clean the probe
Gas Sampling and Analysis
Sturdy sampling probe
Resistance to accidental fall of blocks
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
Sampling end
Gas Sampling and Analysis
Sampling Probe installation
Avoid inlet seal false air influence
The probe is installed so that its tip is at least 500 mm beyond the inlet seal
Gas Sampling and Analysis
Sampling Probe
3D design to check the feasibility and find optimum probe location
Gas Sampling and Analysis
Sampling Probe Automatic Extraction
High torque extraction
for the extraction of
the probe in case of any problem on
the power supply or the cooling circuit
on a regular
basis used to remove the coating
around the probe
Gas Sampling and Analysis
ITECA’s Sampling Probe Automatic Extraction
Safe and Reliable
for the extraction of the probe in case of any problem on the power
supply or the cooling circuit
on a regular basis used to remove the coating around the probe
Gas Sampling and Analysis
ITECA’s Sampling Probe Automatic Extraction
Safe and Reliable
Gas Sampling and Analysis
Close loop cooling circuit
Oversized capacity closed
cooling circuit (water T° < 65°C)
+ High cooling water
flow rate : 2 500 l/h
No hot fluid
No high pressure
Gas Sampling and Analysis
Gas Conditioning and Analysis
Electrical control
Gas Analysis
Gas
Conditioning
Gas Sampling and Analysis
The gas is then dried in
the gas dryer by reducing
its temperature to 3°C
Cyclone separator :
any remaining water
as liquid is removed
here
Water / gas
separation
circuit
Water + Gas
Water
Gas
Water / gas separator :
most of the water is
removed here
Liquid ring pump
Gas Sampling and Analysis
Gas Analysis
Command and display
Infrared analyser : CO, NO, CO2
Gas flow regulators - One for
each analyser (70 l/h /analyser)
+ evacuation
Paramagnetic oxygen analyser
Gas dryer
Dust filter
Gas Sampling and Analysis
Performances - Advantages
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
Gas Sampling and Analysis
Case study 2 – cement plant
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
Gas Sampling and Analysis
Case study – cement plant
Air purges
OXYGEN READING
Traditional
ITECA
Gas Sampling and Analysis
Case study – cement plant
ITECA
GAS READING
NOx
O2
CO
Gas Sampling and Analysis
Case study – cement plant
CO READING
ITECA
TRADITIONAL
Gas Sampling and Analysis
Case study – cement plant
CONCLUSION
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:
[email protected]