Gas Analysis Technology

- optimization & upgrade

Agenda:
Gas Analysis for Optimization & Upgrade
Introduction to gas analysis
Kiln inlet analyzer for optimization
Upgrade of existing kiln inlet analyzer system

Optimization benefits

Upgrades of gasanalysis
At filter
In coal mill department
For emission monitoring
Maintenance and support

By Christian Markussen
Area Sales Manager / Product Specialist

Gas Analysis where and why?

Where ?
Kiln inlet
Calciner exit
Preheater exit
Coal mill department
Stacks
WHY ?
Process optimization
Safety control
Emission control

Specialised in sample handling

GASloq system layout

Gas conditioning
Analyzers
System controller
Cabinet or site shelter

Optimization and upgrades

- requires gas analysis

4. Coal mill dept.

Optimization with ECS/ProcessExpert

Fundamental data
Temperature
Pressure
Feed rate
Fuel rate
Raw material analysis
Clinker material analysis
Combustible analysis
Gas analysis

Gas analysis for kiln optimization

Kiln Inlet or Calciner Exit

Simple - Strong - Reliable

Main focus is easy maintenance

Kiln inlet reality

The most difficult place to measure
The equipment has been known as
Complicated tubing, valves etc.
Weak probes are bending
Time consuming probe are blocking

The measurement is known as

Top 3 of Most Wanted signals

Kiln inlet is the

best spot for:
Optimized fuel consumption

Optimize quality
Stable and safe kiln operation
Kiln stop prevention
Emission reduction

 O2 /CO Targets:
Optimized fuel consumption
Optimize quality
Stable and safe kiln operation
Kiln stop prevention
Emission reduction
Safety
The operators are depending on the kiln inlet analyser system in order to
fully reach the kiln design capacity at optimum operating conditions

Oxygen analysis is on TOP 3 of any operators Most

Wanted signal list

NO Targets:
Clinker quality improvement

Burning zone temperature trend

Lower emission

SO2 Targets:
Volatile control

Prevent kiln stops

Reduction of material build-ups
Reduction of ring formation in kiln
Reduction of manual kiln clean-out
Reduction of kiln system corrosion

CO analysis combined with O2 is very powerful in

evaluating kiln performance

Selection of correct sample point

The sampling point has to be taken in respect to:

Representative gas
No influence from any false air
Mechanical impact from material fall through
Risk of material build-up
Dust impact
Condensation from volatiles
Practical installation with regard to available
platform location and minimized obstacles
outside

KilnLoq solution

Air cannon gas analysis

Simple: An Air cannon is one large air receiver, one
valve and one pipe
Strong: An Air cannon is very strong and powerful in
construction and operation
Reliable: An Air cannon is installed, connected and
then forgotten
Air cannon
Air blaster One pipe design

Air receiver

Valve

Pipe/Nozzle

Patented - One Pipe design

The normal filter construction compared
to the coaxial One Pipe filter design:

The Shock Blaster Effect

Process
dust

Filter
surface
cleaning

ONE PIPE
cleaning.
Works as
efficient as a
shock blaster

Amplification
chamber

Effectiv probe tip cleaning

Easy Maintenance
Full admission all the way
to probe end by removing
access port

Inspection of probe
and maintenance can
be made without
dismantling

Access only possible due to

the ONE PIPE probe design

KilnLoq probe and extraction device

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Avoid bending of the KilnLoq Probe

Built to last

KilnLoq has many features that prevent the probe from

bending

Heavy multi layer steel construction more than 8 times

stronger
Automatic periodical extraction of probe to minimize material
build-ups
Automatic shock blaster control integrated
Remote or local extraction of probe during kiln clean out
Measurement of heat input to probe from process
Probe position feature minimises insertion length
Using water as cooling

Easy Maintenance

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Upgrade of existing kiln inlet analyzer system

We can assist you
Determine the best
measuring point
Evaluating reuse of
existing equipment
Integrate existing
analyzer units and even
fix these
Find the most
competitive deal

Performance Status on KilnLoq

In operation since spring 2003

More than 200 KilnLoq systems commissioned

More than 240 systems sold

Highest run factor on the marked

in most cases higher than 95%

An average of 60 min weekly preventive maintenance

8 KilnLoq systems in Pakistan

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Optimization benefits
An reduction of 1% O2 in the kiln = 2% higher clinker
production
An reduction of 1% O2 in the kiln = 1% lower fuel
consumption
A shortage in oxygen level of 1% in the kiln inlet will cause
kiln stops, wear, excessive manual clean-outs

Oxygen analysis is on TOP 3 of any operators Most

Wanted signal list

Conclusion Kiln inlet

Reduce fuel cost or get higher production

Reduce production stops

Proven technology more than 200 references

Correct and continuous analyser signals

Highest run factor on the marked

Easiest maintenance on the marked

Getting a simple, strong and reliable gas analyser

system

Very short payback time typical less than 200 days

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Upgrades of filter or use of alternative

fuels may require new gasanalysis

Filter protection system

Safety & Interlocking

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Filter protection system

CO/CH4 and O2:
GASloq 1200
Low installation costs
Low
True
installation
continuous
through
simple costs
samplingFLS
by Airloq
double
standard
plug
and play modular
probe gives
maximum
modular
design
design
safety
High operation
powered probe
Easy
through
High run
factor
due to
cleaning
air gives
large HMIby
colour
touch
simple
layout
better
run
factor
for
the
screen
equipment
High resistance to
No moving parts
contamination
andin
probe ensures
trouble
corrosion
from the
free service
process
gas and DDOP probe
maintenance
Focus on design for easy
Build-in air receiver
maintenance
ensures the highest
possible pressure at any
time

Probe Cleaning Panel

Double Dry nOn cooled Probe (DDOP)

Made of stainless steel

Maximum temperature 600C
Maximum dust: 200 g/m3
Weather protection

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Equipment for Measuring at Coal Mill Area

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Coal Mill Area

Supervision of coal mill department in silos and dust
collectors
Detects impending spontaneous combustion of coal
Operation data for inert coal mill process
Single or Multi Scanning capabilities

Coal Mill Area Analyser Systems

GASloq 1200 multiscan system

Up to 6 silo measuring points
Continuous O2 at filter
ABB, Siemens or Emerson
analysers
Power

GASloq 600 single probe system

Used for silo or filter
ABB, Siemens or Emerson
analysers

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Upgrade of gas analysis to fulfil

emission requirements

Different solutions for measuring gas

depending on requirements
GASloq system

NEO LaserGas Monitor

CO, CO2, NOx, SO2, TOC, O2

CO, CO2, NO, NO2, SO2,

H2O, HCl, HF, NH3

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Different solutions for measuring dust

depending on requirements
Durag D-R 800

Durag D-R 300

Durag D-R 290

Durag D-R 800 Optical Dust Monitor

Forward scattered light reflection

principle
Designed for small and medium dust
concentrations
Easy one-side installation
Easy configuration without need for PC
Integrated purge air unit in the
electronics unit
Automatic function test with soiling
correction
TV 17. BImSchV approved
M-Certs approval pending
Purging Air

Pane
Fibre Optic

Receiver
Diode

Reference Light Beam

Transmitter
Diode

Measuring Light Beam

Shutter
Measuring
Volume
Light Trap

Beam
Splitter

Objective
Cleaning
Flange

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Emission Monitoring and Reporting

SO2
CO TOC
HCL
HF
NOx

Dust

Measurement

Environmental reporting systems type ReportLoq

Meets local legislation for environmental reporting
Integrated solution with emission monitoring equipment

PLC

Control
System

Real-time
Monitoring

History, Analysis
& Reporting

Analyser

Controller

ECS or none-ECS

ReportLoq

We cheated a little
you dont really need the wrench

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Easy maintenance

Human Machine Interface (HMI) display

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Human Machine Interface (HMI) display

Used for setup of the system
Used for information on status, failure and warnings

Human Machine Interface (HMI) display

System start/stop and manuel probe cleaning

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Human Machine Interface (HMI) display

Calibration

Human Machine Interface (HMI) display

Alarm list

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Human Machine Interface (HMI) display

Trend facilities

Spare parts

gas-service@flsmidth.com

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Service Contract
Remote service & trouble shooting by
internet
No open ports in Firewall!!

References in Pakistan

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FLSmidth Gas Analysis Technology

a Unique Supplier
More than 40 Years of experience in combining process
knowledge from the cement and minerals industry with
practical solutions of gas analysis
Patented technology offering unique selling proposition
to our customers
Focus on simplicity high run factor through ease of
maintenance
Specialized gas analysis organization with a huge
accumulated experience base
Trouble shooting by experts supported by fast spare
part deliveries
The credibility from belong to the FLSmidth One Source
Brand

Full Gas Analysis Product Range

EQUIPMENT FOR ALL CEMENT APPLICATIONS:

Kiln Inlet competitive kiln operation

Calciner maximised throughput

Preheater filter protection system

Coal Mill secure supply of combustibles

Stack emission monitoring and reporting

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Thank you for your attention

Friendships are like standing in wet cement The longer you stay, the harder it is to
leave, and you can never go.without
leaving your footprints behind !

Any questions

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