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7th March 2011

Cemtech Dubai - 2011

Presentation by Chemtrols Group of Companies

Updations in Gas Cooling Technology

Continuous Emission Monitoring Systems

UPDATIONS IN GAS COOLING GAS CONDITIONING

IN THE TOP CYCLONES
Worldwide References
Principle of Operation
Case Studies

UPDATIONS IN GAS COOLING HYBRID GAS

CONDITIONING SYSTEMS
Worldwide References
Principle of Operation

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Lets remember the application areas

Drilling
Rig

Raw Mix
Component
Bins

Gas cooling
in GCT

Chimney

Quarry
Gas cooling
in Top Cyclone

Gas
Conditioning in
Downcomer
Duct

Limestone
bin

Seperator

Crusher

Clinker
silos

Pre-Blending
dome

Water
Injection to
Cement Mill

GCT
Gas Cooling Tower

Raw Mill

Cement Mill
Seperator

Homogenizing
silos
Pre-Heating Tower and
Pre-Calciner

Cement
silos

Kiln

Coal Storage

Cement
Dispatch

Coal Mill

application
areas

Clinker Cooler Bed

Gas cooling
in Cooler Bed

REFERENCES FOR GAS

COOLING IN TOP CYCLONES
WORLDWIDE REFERENCES
ALCEMENT KUWAIT
BUZZIUNICEM BARLETTA PLANT ITALY
QUINN CEMENT, IRELAND
REFERENCES IN INDIA
1.
VIKRAM CEMENT, KHOR 3 SYSTEMS
2.
ITALCHEMENTI, VISHNU CEMENT UNIT
3.
ULTRATECH CEMENT, AWARPUR CEMENT WORKS - 4 SYSTEMS
4.
ULTRATECH CEMENT, ADITYA CEMENT WORKS
5.
ULTRATECH CEMENT, NARMADA CEMENT WORKS
6.
MADRAS CEMENT, ALATHIYUR CEMENT WORKS 2 SYSTEMS
7.
MADRAS CEMENT, ARIYALUR CEMENT WORKS 2 SYSTEMS
8.
SANGHI CEMENT, SANGHIPURAM
9.
CHETTINAD CEMENT, PULIYUR CEMENT WORKS
10. CHETTINAD CEMENT, KARIKKALI CEMENT WORKS
11. J.K.LAKSHMI CEMENT , UNIT 1
12. SANGHI CEMENT, SANGHIPURAM 2 SYSTEMS (UNDER
MANUFACTURE)

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GAS COOLING IN THE TOP CYCLONES PRINCIPLE

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GAS COOLING IN THE TOP CYCLONES PRINCIPLE

In the Cyclone Water Spray
System cooling water is
injected close to the dip tube
against the gas flow in an
absolute fine mist form to cool
down the hot gas.
While the high pressure
water mist spray enables to
condition & cool the hot gas,
it also agglomerates & forces
the dust downwards back in
to the system, thus improving
the collection ratio &
efficiency.
The cooled gas leaving the Cyclone occupies less volume, enabling substantial
power savings for the PH fan.

LANCE LOCATIONS GAS COOLING IN THE

TOP CYCLONES

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THE MAJOR COMPONENTS OF GAS

COOLING SYSTEM IN THE TOP CYCLONES
PUMP STATION : pumps are VFD controlled. ENERGY SAVING

Use of vertical pumps where ever possible again Power Savings

THE MAJOR COMPONENTS GAS COOLING

IN THE TOP CYCLONES
LANCES & SPRAY NOZZLES : HIGH PERFORMACE HIGH PRESSURE LANCES, NO
COMPRESSED AIR IS NEEDED TO MAKE ULTRA FINE SPRAY. ENERGY SAVING

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Calculations for
GAS COOLING IN THE TOP CYCLONES
CHEMTROLS USES THEIR OWN SOFTWARE FOR
HEAT TRANSFER CALCULATIONS IN GAS COOLING

Calculations for
GAS COOLING IN THE TOP CYCLONES
CHEMTROLS USES THEIR OWN SOFTWARE FOR
HEAT TRANSFER CALCULATIONS IN GAS COOLING

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THE CONTROLS OF GAS COOLING IN THE TOP

CYCLONES

The overall control of whole system is conducted by PLC incorporating upto-date technological advances where microprocessors enable
incomparable control of the system, user friendly operation, reability, close
loop control and managing almost all components automatically.

4 CASE STUDIES & APPLIED

INSTALLATIONS

CASE STUDY 1
J.K.LAKSMI CEMENT
CASE STUDY 2
KUWAIT CEMENT
CASE STUDY 3
CHETTINAD CEMENT
CASE STUDY 4
SANGHI CEMENT

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CASE STUDY 1 : J. K. LAKSMI CEMENT

WITHOUT WATER SPRAY

CASE STUDY 1 : J. K. LAKSMI CEMENT

WITH WATER SPRAY

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CASE STUDY 1 : J. K. LAKSMI CEMENT

BEFORE
COOLING SYSTEM
INSTALLATION

AFTER
COOLING
SYSTEM
INSTALLATION

REMARKS

167,3 t/h

199,58 t/h

19,3% capacity
increase

Cylone Exit Temp

(C)

322C

214C

108C
temperature drop

O Content

6,94%

5,21%

ID Fan (rpm)

786,85

686,43

Less 12,7%

ID Fan (KW)

918,24

711,87

Less by 206 KW

Hybrid Bag DP
mmWC

199,36

180,94

Less DP

PARAMETERS

Kiln Feed

CASE STUDY 2 : KUWAIT CEMENT

WITHOUT GAS
COOLING SYSTEM

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CASE STUDY 2 : KUWAIT CEMENT

WITH GAS COOLING
SYSTEM

CASE STUDY 2 : KUWAIT CEMENT

WITHOUT GAS
COOLING SYSTEM

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CASE STUDY 2 : KUWAIT CEMENT

WITH GAS COOLING
SYSTEM

CASE STUDY 2 : KUWAIT CEMENT

BEFORE
GAS COOLING
SYSTEM
INSTALLATION

AFTER
GAS COOLING
SYSTEM
INSTALLATION

405 t/h

437 t/h

327 C / 345 C

274 C/271 C

3.8% / 3.6%

3.8% / 3.9%

99% open

20% open

ID Fan (rpm)

982

961

ID Fan (KW)

1321

1326

Bag filter discharge

Screw conveyor
Load

15A

14A

PARAMETERS

Kiln Feed
Cylone Exit Temp
(C)
O Content
Dilution Damper pos.

REMARKS

8% capacity
increase
53 / 74 C

Improved
collection in
the Cyclone

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CASE STUDY 3 : CHETTINAD CEMENT

GENERAL PROCESS
LAYOUT

CASE STUDY 3 : CHETTINAD CEMENT

THESE FIGURES HAS BEEN REPORTED IN THEIR WEBSITE
NO

BEFORE

AFTER

GAS COOLING
SYSTEM
INSTALLATION

GAS COOLING
SYSTEM
INSTALLATION

Preheater Temp.
(C)

342

290

Preheater Fan
(KW)

995

965

30 KW savings

Bag House Fan

(KW)

650

450

200 KW
savings

Reverse Air Fan

3 hrs savings

164

102,5

61.5 KW
savings

30

30 KW
additional
power

PARAMETERS

REMARKS

52C
Temperature drop

(Running Hrs)

Reverse Air Fan

(KW)

Pumps Power
Consp (KW)

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CASE STUDY 4 SANGHI CEMENT

ILC STRING
FRESH AIR
RM

Bag-filter

SLC STRING

Junction
BH Fan 1,288,000
m3/hr@2600C

CM-1

C2 STRING

CM-2

CASE STUDY 4 SANGHI CEMENT

1

Raw Mill Bag house

Design capacity
1,280,000 provided by
Dilution air
SIL
PRESENT
CONDITION

Calculated water flow rate for cooling

in m3/hr

Resultant temperature due to mixing of gas

streams 123 & 4 = 1234
Resultant volume of gas Nm3/hr - 1234
Resultant volume of gas Am3/hr - 1234
Gas drawn for one Coal Mill

1,010,967

Volume of gas at Bag.House inlet with 1 Coal mill running

1,754,130

Volume of gas at Bag.House inlet with 2 Coal mills running

1,574,130

Moisture addition %

0.00

Total water requred

m3/hr

Temperature drop
considered

Case-1: Plant operation at 9500 TPD without water spray - RM Stopped

Heat Balance Calculation

249

1,934,130
180,000

Note: The junction duct gets pressurised even after operation of both coal mill as baghouse gas
handling capacity is 1,288,000 m3/hr @ 2600C and available gas at inlet is 1,574,000 m3/hr @
2500C

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CASE STUDY 4 SANGHI CEMENT

Heat Balance Calculation

Raw Mill Bag house

Design capacity 1,280,000 provided by
Dilution air
SIL

Present Fan
Operating flow rate

Calculated water flow rate for cooling

in m 3/hr

Resultant temperature due to mixing of gas streams 123 & 4 =

1234

248

Resultant volume of gas Nm3/hr - 1234

933,731

Resultant volume of gas Am3/hr - 1234

1,782,818

Gas drawn for one Coal Mill

180,000

Volume of gas at Bag.House inlet with 1 Coal mill running

1,602,818

Volume of gas at Bag.House inlet with 2 Coal mills running

1,422,818

Moisture addition %

1.07

Total water requred

m3/hr

Temperature drop
considered

Case-2: Plant operation at 9500 TPD with water spray in ILC top stage cyclone (present
operating condition)- RM Stopped

Note: The junction duct gets pressurised even after operation of both coal mill as baghouse gas handling
capacity is 1,288,000 m3/hr @ 2600C and available gas at inlet is 1,422,818 m3/hr @ 2500C

CASE STUDY 4 SANGHI CEMENT

Heat Balance Calculation

Dilution
air

Calculated water flow rate for cooling in m3/hr

Resultant temperature due to mixing of gas streams

123 & 4 = 1234
Resultant volume of gas Nm3/hr - 1234
Resultant volume of gas Am3/hr - 1234
Gas drawn for one Coal Mill
Volume of gas at Bag.House inlet with 1 Coal mill running
Volume of gas at Bag.House inlet with 2 Coal mills running

Moisture addition %

12

13

Raw Mill Bag

house Design
capacity
1,280,000
provided by SIL
Present Fan
Operating
conditions

Total water
requred m3/hr

Temperature drop
considered

Case-3: Plant operation at 9500 TPD with water spray in ILC, SLC & C2 string top cyclone - RM
Stopped

32

251
683,870
1,312,258
180,000
1,132,258
952,258
5.74

Note: The junction duct will not get pressurised after installation of the water spray system in SLC
& C2 string and operation of both coal mills.

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CASE STUDY 4 SANGHI CEMENT

Heat Balance Calculation

Raw Mill Bag house fan

Design capacity 1,280,000 m3/hr @
Dilution air
2600C

Maximum Operaring
conditions

Calculated water flow rate for cooling in m 3/hr

Resultant temperature due to mixing of gas streams 123 & 4 =

1234
Resultant volume of gas Nm3/hr - 1234
Resultant volume of gas Am3/hr - 1234
Gas drawn for one Coal Mill

802,138
1,506,384
180,000

Volume of gas at Bag.House inlet with 1 Coal mill running

1,326,384

Volume of gas at Bag.House inlet with 2 Coal mills running

1,146,384

Moisture addition %

2.98

Total water requred

m3/hr

Temperature drop
considered

Case-5: Plant operation at 10,500 TPD with water spray in ILC, SLC & C-2 (Maximum
Operating capacity)- RM Stopped

19

240

Note: The junction duct will not get pressurised by operating both coal mills as baghouse gas handling capacity
is 1,288,000 m3/hr @ 2600C and available gas at inlet is 1,146,385 m3/hr @ 2400C

SUMMARY GAS COOLING IN TOP CYCLONE

ENERGY SAVING IN ID FAN= YES

ENERGY SAVING IN THE FOLLOWING FANS IN DOWNSTREAM
PROCESS = YES
PRODUCTION INCREASE = YES
REDUCTION IN THE RECYCLING RATIO IN THE LINE = YES
INCREASED CYCLONE RETENTION EFFICIENCY = YES

THE ONLY MANUFACTURER IN THE

WORLDCALCULATIONS, ENGINEERING, DESIGN,
MANUFACTURING, AUTOMATION,
INSTALLATION & COMMSSIONING

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HYBRID GAS COOLING SYSTEMS

CALCULATIONS, ENGINEERING,
DESIGN, MANUFACTURING, AUTOMATION,
INSTALLATION & COMMSSIONING

GAS CONDITIONING IN GCT

HIGH PRESSURE
PRINCIPLE I
SPILLBACK SYSTEM

Single fluid
water ~38 bars
SPILLBACK LANCES
No atomising air

PRINCIPLE-II
New generation
HYBRID SYSTEM
Single fluid
water ~38 bar
SPILLBACK LANCES +
HIGH PRESSURE
LANCES
No atomising air

DUAL FLUID
PRINCIPLE
DOUBLE FLUID SYSTEM
Double fluid
water + air mixture
~5-7 bar
AIRMIST LANCES
Atomising air required
Full automation

HYBRID SYSTEMS LOWEST ENERGY

CONSUMPTION

REFERENCES
HYBRID GAS COOLING
SYSTEMS
WORLDWIDE REFERENCES
SET BALIKESIR, ISTANBUL
DENZILI CEMENT, ISTANBUL 2 SYSTEMS
1.
2.
3.
4.
5.

REFERENCES IN INDIA
ITALCEMENTI, ZUARI CEMENT , YERUGUNTALA
MAIHAR CEMENT, SARALANAGAR 2 SYSTEMS
ORIENT CEMENT , DEVAPUR WORKS 3 SYSTEMS
ULTRATECH CEMENT, HIRMI CEMENT WORKS 2 SYSTEMS
KANORIA CEMENT, BAGALKOT CEMENT WORKS

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HYBRID GAS COOLING SYSTEM

This is a combination of Spillback & High Pressure lances in the tower

replacing the conventional Single nozzle or cluster lances.
These can be fitted in the same protection pipe of the Chemtrols High
performance single nozzle lance.
50% to 70% lances will be high pressure fixed volume spray No returnflow control The lances are with 5 nozzles.
Balance lances are spillback with return-flow control -These lances are
cluster with 3 nozzles.
This combination allows better atomization and performance of the
system.
The flow control of water will be from 50% to 100% of the total water
injection rate. During the stable plant operation this variation is sufficient
for control.
If higher rangability is required, the high pressure lances can be arranged
in 2 or 3 stages with ON/OFF valves for each stage.

HIGH PERFORMANCE LANCES

In-built
non-return
valve

return
line

zero leakage tongue

& groove connection
protection
pipe

FILTER ELEMENT
feed line

butterfly bolts

Integral MINIBASKET FILTER

1.
2.
3.

The most important component in the gas conditioning system is the New generation high
performance lances, which has an inbuilt filter and an NRV as integral part of the lance.
These are user friendly, light and robust for the application.
The inbuilt filter ensures non-clogging feature to the nozzle & increases the nozzle life doublefold.

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HIGH PERFORMANCE LANCES

HIGH PERFORMANCE RETURN-FLOW

LANCES

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COOLING LANCES HIGH PRESSURE - UCC

HIGH PRESSURE
LANCE SPRAY

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CLUSTER LANCE
SPRAY

HYBRID SYSTEM

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HYBRID GAS COOLING TOWER OUTSIDE VIEW

OTHER ACTIVITIES OF CHEMTROLS

Dust Suppression Systems, Plain water &
Dryfog for Raw material Preparation section
DeNOx Systems for Cement plants by
CHEMTROLS-ERC a Joint venture with ERC
Germany.
CEMS Continuous Emission Monitoring
Systems for Cement Plants by Chemtrols
Industries Ltd.

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Continuous Emission Monitoring Systems

List of Process Applications in Cement Plants

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Operation condition at various measurement points

CEMS Typical layout

Analyzer
Cabinet with
air conditioning

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CEMS Typical layout

Gas Analysis KILN Stack

Due to various types of

Alternate Fuels, the
following Gases are
generated and are to be
measured.
SO2
NOx
NH3
HCl
Hydrocarbons

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THANK YOU & WELCOME YOUR

QUESTIONS

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