The inter-Arab trade is experiencing customs and non-customs obstacles and constraints, of which are standards and country-of-origin regulations. Actually, acquaintance with the importance of specifications and regulations contributes to developing standards of Arab commodities and elevates their competitive advantage. In the Arab world, each country has its national standards and they, all, have European and American standards as their reference. Few years ago, the League of Arab States, through its organizations and bodies, embarked upon establishing Arab unified standards with a view to facilitate trade among Arab countries, of which are Arab unified standards for cement and other building materials. The Arab Union for Cement and Building Materials (AUCBM), being a principal member in the Arab Unified Standards Committee, sees the above as an important and necessary step, as the application of these unified standards does not conflict with national standards for each country. The persistence by AUCBM on the importance of this Arab unified standard comes in a time in which Arab cement industry has largely expanded and became an important commodity in the Arab trade. However, the growth and expansion of this industry have contributed, during the last few years, to raising production capacities, the matter that led to opening out to international markets in addition to the Arab circle. This requires harmony and conformity between the Arab unified standards and international standards, headed by unified European Standards for cement, and even fully adopting them as it is the case with some Arab countries. This would, in turn, relieve hurdles facing trade and would facilitate the introduction of the product to international markets. The dedication of this issue's foreword to standards came in light of experiences and problems that has blocked, and are still hindering, the movement of commerce in cement industry on Arab and international levels. Avoiding this as soon as possible is most important for the Arab cement industry which could, in near future, witness fierce competition due to its wide expansion and growth. This necessitates that it withstand competition in international, and even, Arab markets.
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The inter-Arab trade is experiencing customs and non-customs obstacles and constraints, of which are standards and country-of-origin regulations. Actually, acquaintance with the importance of specifications and regulations contributes to developing standards of Arab commodities and elevates their competitive advantage. In the Arab world, each country has its national standards and they, all, have European and American standards as their reference. Few years ago, the League of Arab States, through its organizations and bodies, embarked upon establishing Arab unified standards with a view to facilitate trade among Arab countries, of which are Arab unified standards for cement and other building materials.
The Arab Union for Cement and Building Materials (AUCBM), being a principal member in the Arab Unified Standards Committee, sees the above as an important and necessary step, as the application of these unified standards does not conflict with national standards for each country. The persistence by AUCBM on the importance of this Arab unified standard comes in a time in which Arab cement industry has largely expanded and became an important commodity in the Arab trade. However, the growth and expansion of this industry have contributed, during the last few years, to raising production capacities, the matter that led to opening out to international markets in addition to the Arab circle. This requires harmony and conformity between the Arab unified standards and international standards, headed by unified European Standards for cement, and even fully adopting them as it is the case with some Arab countries. This would, in turn, relieve hurdles facing trade and would facilitate the introduction of the product to international markets.
The dedication of this issue's foreword to standards came in light of experiences and problems that has blocked, and are still hindering, the movement of commerce in cement industry on Arab and international levels. Avoiding this as soon as possible is most important for the Arab cement industry which could, in near future, witness fierce competition due to its wide expansion and growth. This necessitates that it withstand competition in international, and even, Arab markets.
ForewordAUCBM Member Companies: Arab NewsInternational NewsNew Products and Media
Articles:
- Emissions Monitoring in the Cement Industry An important way of creating transparency and credibility
By: Martin Schneider, Ute Zunzer, VDZ (Verein Deutscher Zementwerke e.V.), Research Institute of the Cement Industry, Düsseldorf, Germany
- Removing dust from process gases in the cement pyroprocess with optimized A TEC cyclone systems
By: Dipl.-Ing Dr. Nat. Techn. Gerald Koglbauer Dipl.-Ing. Dr. Walter Gigacher – A TEC Production & Services GmbH/ Austria
- In Search of the Right Concept By: Dipl.-Ing Ralf Esser, Astrid Kögel, Dipl.-
Ing. Theo Schrooten, Klaus Hansper – Intensiv-Filter GmbH & Co. KG/ Germany
- Elecrtical Power System-with a Power Profile of a Cement Plant
By: Sanwar M. Mishra / India
- Kiln Doctor By: Phillips Kiln Services (India) Pvt. Ltd.,
India
- Evaluation Methods related to Waste Incineration
Mâchefer, a material that could be evaluated in the field of public buildings and facilities
By: Soussi Chokri and Rajaa Zmemla, Institut Supérieur Des Etudes Technologiques de Sfax, Tunisia
- Diary Dates
� Cement silos � Rawmeal blending silos � High capacity mixing plants � Power plants � Shiploaders/unloaders � Cement carriers
IBAU HAMBURG · Rödingsmarkt 35 · D-20459 HAMBURG · Phone +49 (0) 40 36 13 090 Fax +49 (0) 40 36 39 83 · Email: [email protected] · Internet: www.ibauhamburg.de
Amember of the HAVER & BOECKER Technology group
THE STATE OF THE ART for modern bulk material handling
IBAUHAMBURG
THE POWER FORSUCCESS
� Cement silos � Rawmeal blending silos � High capacity mixing plants � Power plants � Shiploaders/unloaders � Cement carriers
IBAU HAMBURG · Rödingsmarkt 35 · D-20459 HAMBURG · Phone +49 (0) 40 36 13 090 Fax +49 (0) 40 36 39 83 · Email: [email protected] · Internet: www.ibauhamburg.de
Amember of the HAVER & BOECKER Technology group
THE STATE OF THE ART for modern bulk material handling
IBAUHAMBURG
THE POWER FORSUCCESS
6
NORTHERN REGION CEMENT COMPANY
SAUDI ARABIA
Northern Region Cement Company's plant is located in the northern region, 190 Km from Arar and 50 Km from the city Turaif. The plant area is estimated to be 98,0000 m2.
The Company Capital: Northern Region Cement Company is a Saudi Joint Stock Company, founded with a capital amount of one billion two hundred million Saudi riyals.
Design and Production Capacity: Plant design capacity is 6,000 tpd of cement at an annual capacity of 2.199Mt of different types of cement. Actual production in 2009 reached 1.61Mt of clinker and 1.8Mt of cement.
Marketing: During 2009, NRC was able to achieve its marketing plan, with its local sales reaching 1.473Mt of cement; 223,000t of cement were exported.
New Projects: The Company established Northern Cement Co. in Jordan, and the project is now completed; trial production started in September 2009, and 148,000t of cement were produced.
The Plant Accessories: The factory was built with European specifications; there is a hi-tech station for electricity generation with capacity of 42Mw. There are also water treatment stations for use in plant and the housing for the city.
Address: Northern Region Cement CompanyP.O. Box 3100Arar, Kingdom of Saudi ArabiaTel.: (+966 4) 6633661Fax: (+966 4) 6611040Email: [email protected]: www.nrc.com.sa
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5593_Anzeigenkampagne_2009.indd 7 21.01.2009 11:40:08 Uhr
8
IRAQ
The General Company for Southern Cement concludes investment contracts for training and employment of Karbala Cement Plant production in a participatory manner
Southern Cement State Company entered on 27/4/ 2010 a contract with leading Iraqi and its strategic partner (Lafarge France) for the operation and rehabilitation of Karbala Cement Plant production in a participatory manner in accordance with the Companies Act No. General (22) for the year 1997.
The contract for the first party (General Company for Southern Cement) Director General, Engineer Nasser Idris Mahdi civil society and the tip second company pioneers, represented by Mr. Basil Mahdi Mohamed Jawad Rahim (Chairman) and the French company Lafarge, represented by Mr. Guillaume Rowe Executive Vice President. It is hoped that through the said contract which outlined a period of time (15 years) will work on the rehabilitation of the plant to reach design production capacity after three years of receipt by the second party that the company achieved a qualitative leap in the field of investment and operation of laboratories
Source: The Company website www.southern-cement.com
SAUDI ARABIADuring 2009, Saudi Cement Company produced 6.519Mt of clinker and 5.478Mt of cement from its Hufouf and Ain Dar plants.
JORDANLafarge Jordan Cement to pay $0.91 cash dividendLafarge Jordan Cement announced that the Company was able to maintain the same level of its profits during 2009 as compared to previous year.
The Company registered a profit of JD 46.3 million although its sales volume fell by 3% registering 3.557Mt in 2009 as compared to 4.885Mt in 2008. Lafarge Cement Jordan's sales have been hit by the entry of new Saudi competitors and weaker domestic consumption as the country reels under the impact of the global downturn, company officials say.
Shareholders in the Company approved a cash dividend for 2009 of 650 fils ($0.91) per share. The total dividend payout amounts to 39 million dinars from the firm's total 46.320 million dinars of net profits in 2009, comprising a 6 percent drop from the previous year.
9
SAUDI ARABIA
During 2009, Saudi Cement Company's sales in local market registered 4,824Mt of different kinds of cement. The Company exported 753,000t of cement.
JORDANLafarge Cement Jordan wins the Encouraging Excellence Award in Health & Safety for the third consecutive year
Lafarge Cement Jordan, and specifically Al-Rashadiyeh cement plant, has won 2009 Encouraging Excellence Award for installations in the area of safety and occupational health, presented by the Social Security Corporation.
This is the third consecutive year that the Company wins this award for its outstanding efforts in the field of safety applications and commitment to it throughout its laws and standards for safety and occupational health. Lafarge Cement Jordan seeks to provide a safest working environment for its employees, customers, suppliers, contractors and visitors, and Safety ranks at the top of its priorities.
The Company considers safety as a core value that must be included in all the Company’s works and activities, as well as its administrative systems. Lafarge focuses on the need to adopt safe behaviors in all its activities in a spontaneous and regular manner, as well as to work as one team to abide by safety regulations and fulfill the single acceptable goal of “Zero” Lost Time Injuries at all its sites.
It is worth mentioning that the Company has managed to lower the number of LTI’s from 55 in 2002 to 3 LTI’s in 2008 and down to one LTI in 2009. This means that the Company has achieved a record, which is considered the best in his long history in the area of safety.
Source: www.cafraj.net
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10
IRAQ
Lafarge Cement Jordan wins the Encouraging Excellence Award in Health & Safety for the third consecutive
That Al Sawari State Company y for Chemical Industries, related to the Ministry of Industry and Minerals completed the rehabilitation works of two production lines in rock wool plant after allocating 2 billion Iraqi Dinars. The plant produces rockwool in all its types, used in thermal insulation for buildings, burners and pipes in power stations, oil and industrial companies, in addition to sound insulation.
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12
FLSmidth to supply a complete cement plant in
Tunisia
FLSmidth has signed a contract worth 107m Euros (DKK 797m) with Tunisian-owned Carthage Cement to supply equipment and services for a 5,800 tonnes per day state-of-the-art cement plant. The plant will be located approximately 40 km southwest of the Tunisian capital Tunis.
The scope of supply includes a full pyro processing line, ATOX and UMS mills, silos, a complete automated ECS installation (Expert Control and Supervision) as well as a packing plant. To achieve the best environmental performance the plant also features a QCX quality control system, gas analysing equipment and air pollution control filters. The contract was signed in close cooperation with the Turkish building contractors EKON and PROKON who are responsible for all the construction work, buildings and structures as well as the installation of the equipment supplied by FLSmidth. The cement plant, which will be technologically the most advanced in Tunisia, is designed for possible future use of alternative fuels. "FLSmidth has a long history in Tunisia and other North African countries and we believe that the African cement market will continue to offer opportunities for growth. This project is therefore very important and will further strengthen our position in the region. The cement plant will be one of the largest in North Africa featuring the latest technology, the most energy efficient solutions and the highest environmental standards," Group CEO Jørgen Huno Rasmussen comments.
The order will contribute beneficially to FLSmidth's earnings until the plant is taken over by the customer in 2012.
FLSmidth receives operation and maintenance contract in
Tunisia
FLSmidth has been awarded a contract from Tunisian owned Carthage Cement for operation and maintenance of their new cement plant to be constructed approximately 40 km southwest of the Tunisian capital Tunis. The cement plant is being designed and supplied by FLSmidth and cooperation with the Turkish contracting companies EKON and PROKON. The scope of the supply includes complete staffing of the plant for operation and maintenance of the equipment, training of the staff as well as sourcing and inventory control of spare parts and lubricants. The objective of the operation and maintenance contract is to ensure a high production level of the plant as well as ensuring an ongoing knowledge transfer and training of the local staff. The value of the operation and maintenance contract will over a period of five years amount to more than 65m Euros (DKK 500m) for FLSmidth. "This is the sixth, large cement operation and maintenance contract awarded to FLSmidth and it clearly demonstrates how well our operation and maintenance services and One Source offering are received by the customers. The operation and maintenance activities reduce our sensitivity to cyclical developments in the sale of cement and minerals plants and provide us with valuable operational experience," Group CEO Jørgen Huno Rasmussen comments. The order will contribute beneficially to FLSmidth's earnings until 2017.
13
Material handling order to FLSmidth in Kuwait
FLSmidth has received an order worth approximately 34m Euros (DKK 250m) from Kuwait Cement Company for the supply of in-plant material handling equipment for the second production line at their cement plant located at Shuaiba Port in Kuwait. The first production line with a capacity of 5,500 tonnes per day was supplied by FLSmidth in 1998 and the second 5,500 tonnes per day line is currently being supplied by FLSmidth. The scope of the supply includes complete design, engineering, manufacture and supply of all mechanical and electrical equipment. The material handling system includes belt conveyors, belt/weigh feeders, stackers, reclaimers, crushers, screens, bucket elevators, deep pan conveyors, air pollution control filters and revamping of existing ship unloader as well as of the respective transportation. "This material handling order is a great example of the one source solutions we are able to provide to our customers in both the cement and minerals industries from our global material handling technology centre, headquartered out of Wadgassen, Germany. The contract is the first raw material handling facility for a cement plant in Kuwait and is therefore an important material handling order on this growing Middle Eastern market," Group CEO Jørgen Huno Rasmussen comments. The order will contribute beneficially to FLSmidth's earnings until late 2011.
Operation and maintenance contract in Egypt to FLSmidth
FLSmidth has been awarded a contract from Egyptian owned Wadi El Nile Cement Company for operation and maintenance of their 5,000 tonnes per day cement plant, being constructed approximately 120 km south of the Egyptian capital Cairo. The equipment for the cement plant's production line was designed and supplied by FLSmidth A/S (see Company Announcement no. 18- 2008). Wadi El Nile Cement Company chose to cooperate with FLSmidth due to its proven performance and state-of-the-art maintenance, using original spare parts, as well as for its experience in training of local workforce. The operation and maintenance contract covers a period of five years. The parties have agreed not to disclose the value of the contract. "Egypt is a very well-known market to FLSmidth as we have delivered several cement plants in the country which is undertaking large investments in the development of their infrastructure. FLSmidth already maintains and operates one cement plant in Egypt and this second contract for operation and maintenance in the country clearly demonstrates the value of our ability to serve as a one source provider to our customers," Group CEO Jørgen Huno Rasmussen comments. The order will contribute beneficially to FLSmidth's earnings until 2016.
14
Duravit Tunisia puts its trust in Sacmi
Flexible and high-performance with cost-
cutting consumption levels
Almost 190 years in the ceramic business: this is Duravit, founded in 1817 in Germany, now present in over 90 different countries and the owner of eight modern production plants. One of them, Duravit Tunisia, previously known as Manufacture Tunisienne des Ceramiques, was purchased by Duravit (as majority holding) in 2008.
A specialist sanitaryware producer, Duravit Tunisia, based in Bizerte, can now count on new cutting-edge Sacmi machine, installed between 2008 and early 2009. This is a shuttle kiln with a massive 95 cubic metre capacity, a HWS 13.5140/500/ with “Firelane” burners, with two lifting doors and ceramic fibre lining.
Effective kiln width is 5 metres and there is double-deck loading. Note that the machine supplied to Duravit Tunisia is suitable for first- and re-firing application. With firing cycles lasting 12- 24 hours, the machine can manage some 675 pieces per cycle and can even fire different product types simultaneously (Vitreous China, Fine Fire Clay, Coarse Fire Clay).
Another key competitiveness factor on which Duravit Tunisia can count thanks to Sacmi is the extremely low energy consumption of the new kiln. Moreover, the machine was designed by Sacmi/Riedhammer to minimise in-atmosphere carbon dioxide emissions, in keeping with the Group’s strict energy efficiency and consumption reduction policies while increasing quality and production performance.
Flaminia: new application for internal glazing of the
water trap Automatic water trap glazing unit installed on
existing glazing line
After a positive experience with semiautomatic internal glazing of WCs, Ceramica Flaminia (Civita Castellana-VT), a Sacmi customer for several years now, has decided to switch to a new version of this application and so take advantage of a fully automatic system.
To achieve that goal an automatic glazing line with robot has been installed on the existing line, which is based on a mixed process: flow coating and spray.The main feature is the short WC internal glazing time, which results in an average cycle time of about 70 / 80, and the main advantage lies, without doubt, in the fact that every surface of the under-rim is covered completely.
For more information, please contact:Mr. Cristian Cassani, PR & Adv. Dept.SACMI IMOLA S.C.R.L.Via Selice Prov. Le 17/A40026 Imola (BD)ItalyTel.: (+39 0542) 607472Fax: (+39 0542) 642354Email: [email protected],Http:// www.sacmi.it
15
FLSmidth receives copper order in the Middle East
FLSmidth has been awarded a contract worth 49.5m Euros (approximately DKK 368m) from a company in the Middle East for engineering services and equipment for the expansion of a copper mine. The scope of the supply for the 7 million tonnes per year capacity copper concentrator includes stockpile feeders, a SAG mill, ball mills, pumps and cyclones, flotation cells, concentrate and tailings
thickeners and concentrate filters - comprising a full minerals processing line. "FLSmidth has a strong position in the global copper industry and this order for a complete process line further underlines the strength of our unique ability to provide a single source of products and service solutions to the copper industry," Group CEO Jørgen Huno Rasmussen comments. The order will contribute beneficially to FLSmidth's earnings until mid 2013.
FLSmidth to work for New Phosphate Rock Terminal in
Jordan
FLSmidth is being awarded a contract worth approximately 70m Euros (DKK 520m) from Afcons Infrastructure Limited, India who signed a contract worth approximately 200 Million USD with Jordan Phosphate Mines Co., Jordan, for a new Phosphate Rock Terminal. The terminal will be located approximately 25 km south of Aqaba .- Jordan The work comprises a land terminal where the phosphate rock is unloaded at the truck unloading facility, suitable for self-tipping or bottom-discharge trucks comprising also tippling platforms for fixed-trailer trucks from where the phosphate rock is conveyed by means of chain conveyors, trough belt conveyors and reversible shuttle belt conveyors with a capacity of 1,800 tonnes per hour into the covered bulk flat store with a storage capacity of 240,000 tonnes. From there it is discharged and transported by collecting
belt conveyors and overhead two parallel pipe conveyors 1,800 tonnes per hour each to a marine terminal with two rail mounted ship loaders having .a loading capacity of 2,200 tonnes per hour each The scope of supply will include design, engineering, manufacture, supply, transportation of mechanical and electrical equipments to the site, fabrication, erection, testing, commissioning as well as training of the terminal's personnel and .performance testing The international demand for phosphate is high" and this order highlights the fact that FLSmidth can offer our customers single source solutions, not only within metal mining but also in various other markets like steel, port facilities, the energy sector, industrial water treatment and in this case - phosphate for fertilizer products," Group CEO.Jorgen Huno Rasmussen comments The order will contribute beneficially to .FLSmidth's earnings until end 2012
16
11th NCB International Seminar on Cement and Building Materials was organized by NCB on 17- 20 November 2009, New Delhi. It was inaugurated by Hon’ble Minister of State for Commerce & Industry, Govt. of India, Shri Jyotiraditya Scindia.
The Seminar drew overwhelming participation of about 700 delegates including 67 overseas delegates from various countries. About 90 technical papers were presented in fifteen Technical Sessions including five Special Lectures, during the four day event. A Special Publication entitled Global Economic Scenario – Challenges and Outlook for Indian Cement and Construction Industries was brought out on the occasion of the Seminar, with contributions by domain experts. The Technical Exhibition organized concurrently with the Seminar provided valuable information about the latest machinery, related auxiliaries and instrumental & control techniques available to the industry.
The Seminar provided a comprehensive update on cement and construction technologies including related plant and machinery, projecting international endeavours and experiences in these areas with the underlying objective of sustainable development.
The deliberations focused on the latest developments in raw material, utilization of wastes, process optimization, advances in plant and machinery, project engineering, energy conservation, environmental protection, quality control systems, durability of concrete systems, and cement sustainability chain including global warming, carbon trading etc.
The focused approach for maximization of operational efficiency through retrofit of energy efficient equipment/system, integrated electrical and control systems, application of refractory products to withstand aggressive chemical agents in Waste Derived Fuels and adoption of best practices for operation and maintenance has helped the plants in achieving significant reduction in production costs as emphasized by a large number of case studies presented during the Seminar.
The adoption of new generation pollution control equipment has helped the cement industry to achieve very low levels of dust emissions,even below 20 mg/cum. Sustainable development through durable construction using efficient chemical admixtures, supplementary cementitious materials and stainless steel reinforcement was emphasized.
In the concluding session of the Seminar, the NCB National Awards for Energy Efficiency, Environmental Excellence and Quality Excellence in Indian Cement Industry for the years 2007- 08 and 2008- 09 were presented by Mrs Renu Sharma, Joint Secretary to the Government of India, Department of Industrial Policy and Promotion.
The deliberations in the Seminar gave an exhaustive coverage on the technical issues relating to cement and construction industries and the intense interactions, which took place, benefitted the professionals from these industries.
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18
من المعروف أن عملية تصنيع الكلنكر واإلسمنت ، كأي نشاط صناعي آخر ، تستهلك الكثير من الطاقة . كما أنها تصدر للبيئة انبعاثات غالبًا ما تكون على شكل غبار يحمله الهواء . وتساهم عملية قياس االنبعاثات ومراقبتها وإصدار تقارير عنها في فهم وتوثيق وتحسين األداء البيئي للصناعة . وقد أصبح نقص المعلومات المتعلقة باالنبعاثات مصدرًا للقلق بشأن تشغيل المصانع . وعليه فمن مصلحة كال الحكومات والمصنعين مراقبة االنبعاثات بشكل منتظم ووضع أسس المراقبة بشكل واضح . وينطبق ذلك بشكل خاص إذا كانت الوقودات
والمواد الخام البديلة هي التي تستخدم في عملية التصنيع .
وقد طور معهد األبحاث لصناعة اإلسمنت في Düsseldorf تجربة عميقة في تنفيذ أنواع مختلفة من القياسات في صناعة اإلسمنت والجير . ويتم تفسير النتائج مع األخذ بعين االعتبار حالة كل مصنع ، ويلعب ذلك دورًا هامًا في حال أردنا تقييم تأثير المواد الخام على
االنبعاثات . ويقوم المعهد حاليًا بتقديم خدمات المراقبة هذه لصناعة اإلسمنت في جميع أنحاء العالم .
The manufacture of clinker and cement is - like other industrial activities - a resource and energy intensive process. It produces
- apart from valuable products - releases to the environment, primarily as airborne emissions. Emissions measurement, monitoring and reporting contribute to understanding, documenting and improving the industry’s environmental performance. A lack of information concerning emissions can lead to local concerns about plant operations. It is therefore in the interest of both the regulators and the plant operators that emissions are monitored regularly and that the rules for such a monitoring are clearly laid down. This is especially the case if alternative fuels and raw materials are used in the manufacturing process. The Research Institute of the Cement Industry in Duesseldorf has developed over the last decades comprehensive expertise in carrying out different kinds of measurements in the cement and lime industry. Based upon a profound knowledge of the specific process characteristics, the results can thus be interpreted taking into consideration the peculiarities of the plants. This plays a role if e.g. the influence of the raw materials on the emission has to be assessed. These monitoring services of the Institute are now delivered to the industry on a worldwide basis.
General principles of emission monitoringMore or less every human activity is a potential source for emissions to the environment. This does not necessarily imply that these emissions are potentially harmful to the environment. But nevertheless rules have to be laid down in order to ensure an industrial production in accordance with the preservation of the environment and natural resources. Nowadays these rules consist mainly of international documents such as ISO or CEN standards that have to be applied for the execution of actual measurements as well as for the calibration and surveillance of continuous emission monitors (CEM). The application of these international standards and guidelines also facilitates the comparability of results that have been gained at different sites, perhaps even in different countries.
Apart from the standards or methods there are some guiding principles that have to be taken into consideration before an actual measurement operation is carried out. These considerations are relevant for permit writers and plant operators when establishing optimised monitoring conditions. These basic principles can be summarised as follows:
-“Why” monitoring?In principle, the monitoring can be carried out for compliance assessment and/or for the environmental reporting of emissions. However, monitoring data can
By: Martin Schneider, Ute ZunzerVDZ (Verein Deutscher Zementwerke e.V.), Research Institute of the Cement Industry, Düsseldorf, Germany
19
often be used for many other reasons and objectives and indeed, it is often more cost effective when monitoring data obtained for one purpose can serve other purposes as well. In all cases it is important that the objectives for undertaking the monitoring are clear for all the participants involved.
-“Who” carries out the monitoring?The responsibility for monitoring is generally divided between the competent authorities and the plant operators. Depending on the specific boundary conditions, the competent authorities can rely on self-monitoring by the operator and/or on measurements carried out by third party contractors (usually accredited, independent laboratories such as e.g. the Research Institute of the Cement Industry). It is important that the monitoring responsibilities are clearly assigned to all parties involved (operators, authorities, independent monitoring bodies).
-“What” and “how” to monitor?The parameters to be monitored depend on the production processes, raw materials and fuels used in the respective installation. It is advantageous if the parameters chosen to be monitored also serve the plant operation control needs. Additionally, a risk-based approach can be used to match various levels of potential risk of environmental damage with an appropriate monitoring regime. It should be pointed out that a properly maintained cement kiln which is operated according to the “Best Available Techniques” (BAT) [1] normally does not bear such risks of creating any actual damage to the environment.
-“How” to express monitoring results?The way in which emission limit values (ELVs) or equivalent parameters are expressed depends on the objective for monitoring the respective emissions. Depending on the purpose, different types of units can be applied such as:
- concentration units- specific units and- emission factors, etc.
In all cases, the units to be used for compliance monitoring purposes should be clearly stated, they should be preferably internationally recognized and they should match the relevant parameter, application and context.
-Monitoring timing considerations?Several timing considerations are relevant for setting monitoring requirements in permits, including the time when samples and/or measurements are taken, the averag¬ing time and the frequency. In
this context, for instance, the European Directive on the incineration of waste (2000 / 76 / EC) [2] distinguishes between continuous measurement and periodic measurements. Continuous measurement is mostly used for dust, SO2
, and NOx while other parameters are usually determined by periodic spot measurements.
-How to deal with uncertainties?It is quite important to be always aware of measurement uncertainties during the whole monitoring process. Uncertainties need to be estimated and reported together with the result so that compliance assessment can be carried out thoroughly.
Furthermore, it has to be pointed out that the determination of monitoring data follows several consecutive steps which all need to be performed according to either (international) standards or method-specific instructions to ensure good quality results and harmonisation between different laboratories and institutes. This “data production chain” consists of the following steps which have to be taken into consideration:
1. flow measurement2. sampling3. storage, transport, and preservation of the
samples4. sample treatment5. sample analysis 6. data processing7. reporting of data
The practical value of measurements and monitoring data depends on the degree of confi-dence, e. g. reliability that can be placed on the results, and their validity when compared to other results from other plants. Therefore, it is quite important to ensure the appropriate reliability and comparability of the data. In order to allow a proper comparison of the data it should be ensured that all relevant information is indicated together with the data in the respective report.
The Research Institute of the Cement Industry operates as an officially accredited monitoring body which has gained profound expertise especially in the cement and lime industry. Based upon this expertise and deep knowledge about the characteristics of the cement and lime manufacturing processes these specific requirements are taken into consideration from the very beginning of a project. By doing so the reports of the Institute not only deliver the plain measurement results to the customers. Moreover,
20
they also put the results into the proper context, e.g. if the influence of the raw materials on the overall emissions has to be assessed or the optional impact of alternative fuels has to be explained.
Emissions monitoring in the cement industryThe releases from cement kilns originate from the physical and chemical reactions of the raw materials and from the combustions of fuels. The main constituents of the stack gases are nitrogen from the combustion air, carbon dioxide from calcination and to a lesser extent from combustion, water from the combustion process and the raw material as well as excess oxygen. Figures 1 - 4 show typical sampling situations.
Simultaneously, the exhaust gases also contain minor quantities of dust, chlorides (HCl), fluorides (HF), sulphur dioxide (SO2), nitrogen oxides (NOx), carbon monoxide (CO) and small quantities of organic compounds and trace elements (heavy metals).
In order to accurately quantify the emissions, continuous measurements are recommended for the following parameters:
- temperature- dust
Figure 1: Installation of a probe in the stack
Figure 1: Installation of a probe in the stack
Figure 2: Computer controlled set-up forcontinuous monitoring
Figure 2: Computer controlled set-up for continuous monitoring
Figure 3: Sampling of heavy metals
Figure 3: Sampling of heavy metals
Figure 4: Preparation of a dioxinmeasurement
Figure 4: Preparation of a dioxin measurement
21
- oxygen- NOx- SO2
The exhaust gas volume and the humidity can be derived from periodic spot measurements. In this context it has to be pointed out that the different operation conditions of a cement kiln (mill on / mill off mode) require individual measurements. A continuous monitoring of these parameters is only necessary if the individual kiln exhibits larger fluctuations.
Furthermore, regular periodical monitoring can be appropriate for the following substances:
- metals (trace elements and their compounds)- organic constituents (TOC)- HCl- HF- dioxins and furans (PCDD/F)
A current legal example for the practical application of these general considerations is the European Directive on the incineration of waste ( 2000 / 76 / EC). It sets the general standards for the emission
monitoring for dedicated incinerators as well as for “co-incineration plants” such as cement kilns. Based upon this Directive the following monitoring requirements apply for cement kilns in the case of using alternative fuels:
- continuous monitoring of NOx, SO2, dust and TOC
- furthermore, two measurements per year for heavy metals (Hg, Cd, Tl, Sb, As, Pb, Cr, Co, Cu, Mn, Ni and V) and dioxins and furans (PCDD/F). Depending on the emissions level the frequency can be reduced to one measurement per year.
As the concentrations of HCl and HF are normally quite low in the stack gases of the clinker burning process, these components are normally also monitored via periodic measurements. In Annex III the European Directive declares the application of CEN standards as mandatory, as far as there are any. Table 1 gives a non-exhaustive overview of the current CEN standards for different individual measurements.Additionally, it is worth mentioning that the Directive 2000/ 76 / EC considers in its Annex II.1 specific
Table 1: Emission control - applied international standards
Table 1: Emission control - applied international standards
requirements for measurement sections and sites and for the measurement objective, plan and report.EN 15259
main standard for function and calibrationstationary source emissions quality assurance of automated measuring systems
EN 14181
determination of the mass concentration of PCDDs/PCDFs and dioxin-like PCBs (sampling, extraction and clean-up, identification and quantification)
EN 1948/1-3
NOX - stationary source emissions - determination of the mass concentration of nitrogen oxidesreference method - chemiluminescence
EN 14792
stationary source emissions - determination of low range mass concentration of dustpart 2: automated measuring system
EN 13284-2
stationary source emissions - determination of low range mass concentration of dustpart 1: manual gravimetric method
EN 13284-1
analyte - title of standard specificationssample preparation / measurement and testing technology
standard
22
aspects of the clinker burning process. To start
with this refers to the emission limits for organic
carbon (TOC) and SO2. The emissions of TOC
during the clinker burning process are almost
completely caused by small quantities of organic
constituents input via the natural raw materials
(remnants of organisms and plants incorporated
in the rock in the course of geological history).
They are converted during kiln feed preheating
and become oxidized to form mainly CO and
CO2. Furthermore, in this process small portions
of organic trace gases (total organic carbon)
are formed as well. The same principle also
applies for the emissions of SO2: The sulphur
oxides emissions of a cement kiln (if there are
any) are almost completely generated from
volatile sulphur compounds (e.g. pyrite) in the
raw materials. Therefore the Directive grants
exemptions for the emission limit values for
TOC and SO2 if the emissions do not arise
from the fuels. The distinction between the fuel
and the raw material related emissions requires
a profound knowledge of the clinker burning
process. If such questions are to be solved the co-
operation with an experienced monitoring body
is recommended.
In general it has to be pointed out that the proper
execution of environmental measurements is an
issue of growing concern for the cement and
lime industry. First of all these measurements
are important in order to prove that a certain
installation is operated according to the
conditions as they are laid down in the respective
permit. Apart from these legal aspects the
measurement results can also help the plant
operator to improve its process as well as
creating increased transparency towards external
stakeholders. This is a very pro-active way to
communicate the environmental performance
of an individual plant. In order to create such an
additional benefit it is an inevitable prerequisite
that the measurements are carried out according
to the current standards. Such a procedure also
safeguards the comparability of results that
have been gained in different periods and/or at
different stacks. The Research Institute of the
Cement Industry in Duesseldorf has focussed
its monitoring activities of the last decades on
the cement and lime industry. This expertise is
today the major basis upon which monitoring and
general environmental services are delivered to
the industry on a global scale.
Literature
[1] “Draft Reference Document on Best
Available Techniques in the Cement,
Lime and 1 Magnesium Oxide
Manufacturing Industries” European
Commission, May 2009
(Internet: http://:eippcb.jrc.es)
[2] “Directive 2000 /76/EC of the European
Parliament and of the Council of 4
December 2000 on the incineration
of waste” Official Journal of the European
Communities, December 2000
23
Summary: For over 10 years now, A TEC has focussed on the use of cyclones in the cement pyroprocess and the associated processes. One example of the latter is the preliminary removal of dust from drying and working gases for mill processes. Besides the traditional cyclone designs, A TEC supplies special, optimized designs or cyclone systems, which have crucial advantages compared to traditional cyclones. Individual technological features of these special systems, e.g. guide vanes, can be used to optimize existing cyclone installations, as described in the following paper.
1 IntroductionOn account of their simple design, limited space requirement, high operational reliability, as well as their low operating and investment costs, cyclones are used in almost all branches of industry. The cyclone’s main applications today are in hot gas and high-pressure dedusting, and as a preliminary separator for raw gases with high dust loads or as a final separator for easy-to-remove dusts.
In mineral processing, the removal of dust particles from air/gas mixtures by means of cyclones in combination with or without settling chambers is widely applied as a classical supplementary or auxiliary process on account of the high separation rate and the low pressure loss. Usually they are installed
1 IntroductionOn account of their simple design, limited space require-ment, high operational reliability, as well as their low operat-ing and investment costs, cyclones are used in almost all branches of industry. The cyclone’s main applications today are in hot gas and high-pressure dedusting, and as a prelimi-nary separator for raw gases with high dust loads or as a final separator for easy-to-remove dusts. In mineral processing, the removal of dust particles from air/gas mixtures by means of cyclones in combination with or without settling chambers is widely applied as a classical supplementary or auxiliary process on account of the high separation rate and the low pressure loss. Usually they are installed immediately downstream of the comminution processes for the purpose of preliminary dedusting so as to reduce the load on sizing or filtering equipment. Another not unimportant application is the removal of abrasive min-erals in order to protect pipelines, blower stations but also measurement and control equipment against wear. 2 A TEC cyclones with high separation efficiencyA TEC cyclones with high separation efficiency or High-Efficiency Cyclones (Fig. 1), A TEC-HEC for short, fre-quently differ from other cyclones on account of their com-paratively high cylinder body. Another feature is the form of the inlet cross-section. The tapered form prevents the settling or caking of material in the inlet channel and, as a result, guarantees defined flow conditions at the inlet over a longer period.
1 EinleitungWegen der einfachen Bauweise, dem geringen Platzbedarf, der hohen Betriebssicherheit sowie den daraus resultie-renden geringen Betriebs- und Investitionskosten wird der Zyklon in fast allen Industriezweigen eingesetzt. Der Haupt-einsatzbereich des Zyklons liegt heute überwiegend in der Heißgas- und Hochdruckentstaubung sowie als Vorab-scheider bei hohen Rohgasstaubgehalten oder als Endab-scheider für leicht abzuscheidende Stäube. Im Bereich der Mineralaufbereitung findet die Abscheidung von staubförmigem Gut aus Luft/Gas-Gemischen mittels Zyklonapparaten in Kombination mit oder ohne Absetz-kammern aufgrund hoher Abscheideleistung bei gleichzeitig geringem Druckverlust als klassisches Ergänzungs- oder Hilfsverfahren ebenfalls breite Anwendung. Meist wird die Einsatzwahl direkt nach Zerkleinerungsvorgängen aus dem Blickwinkel der Vorentstaubung zur Entlastung von Klassier- bzw. Filterapparaten getroffen. Ein weiterer nicht unerheb-licher Anwendungsfall stellt die Entfernung abrasiver Mine-rale hinsichtlich Verschleißschutz etwa von Rohrleitungen, Gebläsestationen oder auch von Mess- und Regeleinrichtun-gen dar. 2 A TEC Zyklone mit hoher Abscheide-EffizienzDie A TEC Zyklone mit hoher Abscheide-Effizienz, oder auch engl. High Efficiency Cyclone (Bild 1), kurz A TEC-HEC genannt, unterscheiden sich von anderen Zyklonen häufig durch ihren vergleichsweise hohen Zylinderkörper. Ein weiteres Merkmal ist die Form des Eintrittsquerschnittes. Durch die Abschrägung werden Ablagerungen im Eintrittskanal verhindert und dadurch längerfristig definierte Strömungszustände am Eintritt gewährleistet.
Lafarge Zement in Wössingen/Deutschland Lafarge Cement at Wössingen/Germany
Lafarge Cement atWössingen/Germany
. بها المتعلقة الحرارية لإلسمنت والعمليات المعالجة السيكلونات في A TEC على استخدام أكثر من عشر سنوات ركزت شركة منذ وأحد األمثلة على ذلك هو إزالة الغبار من غازات التجفيف والعمل في عمليات الطحن . وتتمتع هذه األنظمة بمزايا تكنولوجية فريدة يمكن
استخدامها لتطوير السيكلونات القائمة وهذا ما يقدمه المقال .
By : Dipl.-Ing Dr. Nat. Techn. Gerald Koglbauer, Dipl.-Ing. Dr. Walter Gigacher – A TEC Production & Services GmbH/ Austria
24
immediately downstream of the comminution processes for the purpose of preliminary dedusting so as to reduce the load on sizing or filtering equipment. Another not unimportant application is the removal of abrasive minerals in order to protect pipelines, blower stations but also measurement and control equipment against wear.
2 A TEC cyclones with high separation efficiencyA TEC cyclones with high separation efficiency or High- Efficiency Cyclones (Fig. 1), A TEC-HEC for short, frequently differ from other cyclones on account of their comparatively high cylinder body. Another feature is the form of the inlet cross-section. The tapered form prevents the settling or caking of material in the inlet channel and, as a result, guarantees defined flow conditions at the inlet over a longer period.
3 Guide vanes – HURRIVANE®
The function of the dip tube of a cyclone is best described by the term “vortex finder”. It takes the still rotating solidsladen gas and leads it out of the cyclone. This results in highly unfavourable fluidic conditions, which are reflected in the high proportional pressure loss of the dip tube. Depending on the loading degree, this can account for up to 90% of the total pressure loss.
Guide vanes are used to reduce the pressure loss at the dip tube. With their vanes, they “trap” the rotating clean gas flow. This is followed by the formation of a stabilized vortex tube in the centre of the cyclone, which precesses more or less. The flow conditions now generated result in an around 30% reduction in the pressure loss at the dip tube.
A TEC has translated these findings into a patented product, the HURRIVANE® (Fig. 2). It supplies HURRIVANE® worldwide to customers as cost- and time-efficient option for retrofitting to their cyclones. The customers immediately notice a change in the operating conditions, as a much reduced pressure loss is noticeably reflected in the power consumption of the gas conveying equipment. Classical applications for HURRIVANE® are the upper stages in the suspension heat exchangers. But also in mill circuits, energy savings can be achieved with these special dip tube guide vanes.
Naturally, the HURRIVANE® is particularly suitable for installation in A TEC-HEC, as a result of which, depending on the situation, separation and pressure loss are both positively influenced.
4 HURRICLON® – a special cycloneAs is widely known, a reduction in the pressure loss with a constant separation rate can only be
1 A TEC High-Efficiency Cyclone
3 Tauchrohrleitapparate – HURRIVANE®
Die Funktion des Tauchrohrs eines Zyklons wird am besten durch seine englische Bezeichnung „Vortex Finder“ („Wirbel-Sucher/Finder“) beschrieben. Es nimmt das sich noch in Rotation befindliche, an Feststoff abgereicherte Gas auf und führt es aus dem Zyklon ab. Dabei ergeben sich sehr ungünstige strömungsmechanische Zustände, wel-che sich im hohen anteilsmäßigen Druckverlust des Tauchrohres widerspiegeln. Dieser kann je nach Grad der Beladung bis zu 90 % des Gesamtdruckverlustes des Zyklons ausmachen. Tauchrohrleitapparate dienen zur Reduktion des Druck-verlustes am Tauchrohr. Durch ihre Leitschaufeln (engl. „vane“) „fangen“ sie die rotierende Reingas-Strömung ein. In weiterer Folge bildet sich eine stabilisierte Wirbelröhre im Zentrum des Zyklons aus, welche nur mehr wenig Präzession aufweist. Die nun vorherrschenden Strömungszustände bewirken eine Reduktion des Druckverlustes am Tauchrohr von ca. 30 %. Die Firma A TEC hat diese Erkenntnisse zu einem paten-tierten Produkt umgesetzt, dem HURRIVANE® (Bild 2). Sie bietet den HURRIVANE® weltweit Kunden als kosten- und zeiteffiziente Möglichkeit zur Nachrüstung ihrer Anlagen an. Für den Kunden ist eine Änderung der Betriebs-bedingungen sofort spürbar, da sich ein deutlich reduzierter Druckverlust in den Leistungsaufnahmen der Gasförder-aggregate spürbar widerspiegelt. Klassische Anwendungsfälle für HURRIVANE® sind die oberen Stufen bei Suspensions-
3 Guide vanes – HURRIVANE®
The function of the dip tube of a cyclone is best described by the term “vortex finder”. It takes the still rotating solids-laden gas and leads it out of the cyclone. This results in highly unfavourable fluidic conditions, which are reflected in the high proportional pressure loss of the dip tube. Depending on the loading degree, this can account for up to 90 % of the total pressure loss. Guide vanes are used to reduce the pressure loss at the dip tube. With their vanes, they “trap” the rotating clean gas flow. This is followed by the formation of a stabilized vortex tube in the centre of the cyclone, which precesses more or less. The flow conditions now generated result in an around 30-% reduction in the pressure loss at the dip tube. A TEC has translated these findings into a patented product, the HURRIVANE® (Fig. 2). It supplies HURRIVANE® worldwide to customers as cost- and time-efficient option for retrofitting to their cyclones. The customers immediately notice a change in the operating conditions, as a much reduced pressure loss is noticeably reflected in the power consumption of the gas conveying equipment. Classical applications for HURRIVANE® are the upper stages in the suspension heat exchangers. But also in mill circuits, energy savings can be achieved with these special dip tube guide vanes. Naturally, the HURRIVANE® is particularly suitable for installation in A TEC-HEC, as a result of which, depending
HURRIVANE® guide vane 2 Tauchrohrleitapparat HURRIVANE®
A TEC High-Efficiency Cyclone 1 A TEC-High Efficiency Cyclone
2 HURRIVANE® guide vane
3 Tauchrohrleitapparate – HURRIVANE®
Die Funktion des Tauchrohrs eines Zyklons wird am besten durch seine englische Bezeichnung „Vortex Finder“ („Wirbel-Sucher/Finder“) beschrieben. Es nimmt das sich noch in Rotation befindliche, an Feststoff abgereicherte Gas auf und führt es aus dem Zyklon ab. Dabei ergeben sich sehr ungünstige strömungsmechanische Zustände, wel-che sich im hohen anteilsmäßigen Druckverlust des Tauchrohres widerspiegeln. Dieser kann je nach Grad der Beladung bis zu 90 % des Gesamtdruckverlustes des Zyklons ausmachen. Tauchrohrleitapparate dienen zur Reduktion des Druck-verlustes am Tauchrohr. Durch ihre Leitschaufeln (engl. „vane“) „fangen“ sie die rotierende Reingas-Strömung ein. In weiterer Folge bildet sich eine stabilisierte Wirbelröhre im Zentrum des Zyklons aus, welche nur mehr wenig Präzession aufweist. Die nun vorherrschenden Strömungszustände bewirken eine Reduktion des Druckverlustes am Tauchrohr von ca. 30 %. Die Firma A TEC hat diese Erkenntnisse zu einem paten-tierten Produkt umgesetzt, dem HURRIVANE® (Bild 2). Sie bietet den HURRIVANE® weltweit Kunden als kosten- und zeiteffiziente Möglichkeit zur Nachrüstung ihrer Anlagen an. Für den Kunden ist eine Änderung der Betriebs-bedingungen sofort spürbar, da sich ein deutlich reduzierter Druckverlust in den Leistungsaufnahmen der Gasförder-aggregate spürbar widerspiegelt. Klassische Anwendungsfälle für HURRIVANE® sind die oberen Stufen bei Suspensions-
3 Guide vanes – HURRIVANE®
The function of the dip tube of a cyclone is best described by the term “vortex finder”. It takes the still rotating solids-laden gas and leads it out of the cyclone. This results in highly unfavourable fluidic conditions, which are reflected in the high proportional pressure loss of the dip tube. Depending on the loading degree, this can account for up to 90 % of the total pressure loss. Guide vanes are used to reduce the pressure loss at the dip tube. With their vanes, they “trap” the rotating clean gas flow. This is followed by the formation of a stabilized vortex tube in the centre of the cyclone, which precesses more or less. The flow conditions now generated result in an around 30-% reduction in the pressure loss at the dip tube. A TEC has translated these findings into a patented product, the HURRIVANE® (Fig. 2). It supplies HURRIVANE® worldwide to customers as cost- and time-efficient option for retrofitting to their cyclones. The customers immediately notice a change in the operating conditions, as a much reduced pressure loss is noticeably reflected in the power consumption of the gas conveying equipment. Classical applications for HURRIVANE® are the upper stages in the suspension heat exchangers. But also in mill circuits, energy savings can be achieved with these special dip tube guide vanes. Naturally, the HURRIVANE® is particularly suitable for installation in A TEC-HEC, as a result of which, depending
HURRIVANE® guide vane 2 Tauchrohrleitapparat HURRIVANE®
A TEC High-Efficiency Cyclone 1 A TEC-High Efficiency Cyclone
25
realized with the parallel connection of more than one cyclone. A special design based on the principle of parallel connection of two cyclones is represented by the HURRICLON® (Fig. 3). In the HURRICLON®, A TEC has succeeded in combining the particular advantages of parallel connection with
the compactness of a single cyclone.
Like a classical cyclone, the H U R R I C L O N ® has a spiral inlet, a cylindrical top section and a conical bottom section down to the material discharge. But in contrast to a classical cyclone, the HURRICLON® has two dip tubes with openings lying opposite. The “upper dip tube” leaves the H U R R I C L O N ® as in a classical cyclone, whereas the “lower dip tube”
is led down and exits the conical section from the side. Only outside the cyclone are the two dip tubes brought together again. To additionally stabilize the flow conditions within the HURRICLON®, there are two chiral HURRIVANES® are fitted at the openings of the dip tubes.
The splitting of the volume flow inside the HURRICLON® between two dip tubes reduces the diameter by a factor of around 1.4. As a result, providing the usual diameter ratio of dip tube to cylinder casing, e.g. of 1:2, is maintained, a much slimmer design is obtained. The smaller cylinder casing diameter has an indirectly proportional effect on the generated centrifugal forces, i.e. these increase with decreasing cylindrical casing diameter. Besides this crucial advantage in respect of the separation rate, thanks to the stabilized flow achieved with the HURRIVANE®, the HURRIVANE® exhibits a comparatively low pressure loss, which, depending on the specific model and application, can be up to 50 % lower than in a classical cyclone with the same capacity.
5 Removing dust from process gas in the cement pyroprocessOn account of the known weaknesses of the cyclones in respect of the removal of very fine dusts, cyclones are practically no longer used as the last dedusting unit prior to the release of the gases into the environment. But in contrast to this, thanks to its ruggedness and cost efficiency, the cyclone is now indispensable a separating unit in gas circulation processes. One of these processes or its sub-processes is the cement pyroprocess, which is explained in detail in the following.
5.1 Phase separation in the suspension heat exchanger State of the art for pre-heating the raw meal in the cement pyroprocess is the application of a suspension heat exchanger (Fig. 4). The suspension heat exchanger is based on a discontinuous counterflow principle. For the process flow, this means that after every gas-solids heat exchange in the suspension, this is re-separated. Both the now cooler gas and the warmer solids go in to the next stage opposite.
In this cascade of 4, 5 or 6 cyclone stages (Fig. 5), the cyclones of the lower stages are mostly designed for a minimum pressure loss. Only the cyclone or
Wärmetauschern. Aber auch bei Mühlenkreisläufen können durch diese speziellen Tauchrohrleitapparate energetische Einsparungen erzielt werden. Der HURRIVANE® eignet sich natürlich besonders für den Einbau in A TEC-HEC, wodurch situationsbedingt Abschei-dung und Druckverlust gleichermaßen positiv beeinflusst werden können.
4 HURRICLON® – ein besonderer ZyklonEs ist bekannt, dass man eine Druckverlustabsenkung bei gleichbleibender Abscheideleistung nur durch die parallele Verschaltung mehrerer Zyklone bewerkstelligen kann. Eine besondere Ausgestaltung des Prinzips der Parallelschaltung zweier Zyklone ist die Bauweise des HURRICLON® (Bild 3). Beim HURRICLON® ist es gelungen, die beson-deren Vorteile der Parallelschaltung mit jenen der Kompakt-heit eines Einzelzyklons zu vereinen. Der HURRICLON® verfügt wie ein klassischer Zyklon über einen Spiraleintritt, einen zylindrisches Oberteil und ein konisches Unterteil hin zum Materialaustrag. Aber der HURRICLON® verfügt im Gegensatz zu einem klassischen Zyklon über zwei Tauchrohre mit gegenüber liegenden Mündungen. Das „obere Tauchrohr“ verlässt den HURRICLON® wie bei einem klassischen Zyklon, wohin-gegen das „untere Tauchrohr“ nach unten geführt seitlich aus dem Konus heraustritt. Erst außerhalb werden die beiden Tauchrohre wieder zusammengeführt. Um die Strömungs-verhältnisse innerhalb des HURRICLON® noch zusätzlich zu stabilisieren, befinden sich an den Tauchrohrmündungen zwei chirale HURRIVANE®. Die Aufteilung des Volumenstromes innerhalb des HURRICLON® auf zwei Tauchrohre verringert den Durchmesser ca. um den Faktor 1,4. Dadurch ergibt sich bei Einhaltung eines üblichen Durchmesserverhältnis von Tauchrohr zu Zylindermantel z. B. von 1 : 2 eine deutlich schlankere Bauform. Der kleinere Zylindermanteldurchmes-ser wirkt sich indirekt proportional auf die auftretenden Zentrifugalkräfte aus; das heißt sie erhöhen sich bei sinken-dem Zylindermanteldurchmesser. Neben diesem entschei-denden Vorteil in Bezug auf die Abscheideleistung verfügt der HURRICLON® aufgrund der mittels HURRIVANE® stabilisierten Strömung über einen vergleichsweise geringen Druckverlust, welcher je nach Bauform und Anwendungsfall um bis zu 50 % geringer ausfallen kann als bei einem klas-sischen Zyklon gleicher Leistung. 5 Prozessgasentstaubung im Zement-PyroprozessAufgrund der bekannten Schwächen der Zyklone in Bezug auf die Abscheidung von Feinststäuben, wird der Einsatz von Zyklonen als letztes Entstaubungsorgan vor der Freisetzung der Gase in die Umwelt praktisch nicht mehr angewendet. Aber gegensätzlich dazu ist der Zyklon aufgrund seiner Robustheit und Kosteneffizienz als Trennapparat innerhalb von Gas-(Kreis-)Prozessen nicht wegzudenken. Einer dieser Prozesse bzw. dessen Teilprozesse, in welche nachfolgend eingegangen wird ist der Zement-Pyroprozess.
on the situation, separation and pressure loss are both posi-tively influenced. 4 HURRICLON® – a special cycloneAs is widely known, a reduction in the pressure loss with a constant separation rate can only be realized with the parallel connection of more than one cyclone. A special design based on the principle of parallel connection of two cyclones is represented by the HURRICLON® (Fig. 3). In the HURRICLON®, A TEC has succeeded in combining the particular advantages of parallel connection with the com-pactness of a single cyclone. Like a classical cyclone, the HURRICLON® has a spiral inlet, a cylindrical top section and a conical bottom section down to the material discharge. But in contrast to a classical cyclone, the HURRICLON® has two dip tubes with open-ings lying opposite. The “upper dip tube” leaves the HURRICLON® as in a classical cyclone, whereas the “lower dip tube” is led down and exits the conical section from the side. Only outside the cyclone are the two dip tubes brought together again. To additionally stabilize the flow conditions within the HURRICLON®, there are two chiral HURRIVANES® are fitted at the openings of the dip tubes. The splitting of the volume flow inside the HURRICLON® between two dip tubes reduces the diameter by a factor of around 1.4. As a result, providing the usual diameter ratio of
Schematic showing a HURRICLON® 3 Schema eines HURRICLON®
3 Schematic showing a HURRICLON®
5.1 Phasentrennung im Suspensions-Wärmetauscher
Stand der Technik für die Rohmehlvorwärmung im Zement-Pyroprozess ist die Anwendung eines Suspensions-Wärmetauschers (Bild 4). Dem Suspensions-Wärmetauscher liegt ein diskontinuierliches Gegenstromprinzip zu Grunde. Das bedeutet für die Prozessführung, dass nach jedem Gas-Feststoff-Wärmeaustausch in der Suspension, diese wieder getrennt wird. Sowohl das nun kühlere Gas und der nun wärmere Feststoffe gehen in die entgegengesetzte nächste Stufe. In dieser Kaskade von 4, 5 oder 6 Zyklonstufen (Bild 5) wer-den die Zyklone der unteren Stufen überwiegend auf einen minimalen Druckverlust ausgelegt. Nur der Zyklon bzw. die Zyklone der obersten Stufe sind in Richtung Abscheidung optimiert. Der daraus resultierende Druckverlust dieser Stufe, kann bis zu 30 % des Gesamtdruckverlustes des Wärme-tauscherturmes betragen. Das stellt natürlich eine besondere Herausforderung dar, da sich die Korngrößenverteilung durch die endliche Abscheidung der unteren Stufen signifi-kant in Richtung des Feinstmaterialanteils verschiebt. Daher ist in der obersten Stufe bei einem moderaten Druckverlust trotz A TEC-HEC mit Abscheideleistungen von „nur“ 93 % zu rechnen. Für die Zyklone der unteren Stufen liegen die Abscheideleistungen zwischen 80 % und 90 %. Zur Optimierung des Druckverlustes bei gleicher Abscheideleistung wird der Einbau von HURRIVANE® empfohlen. Weiters ist auch der Einsatz von HURRICLON®
dip tube to cylinder casing, e.g. of 1:2, is maintained, a much slimmer design is obtained. The smaller cylinder casing diameter has an indirectly proportional effect on the gener-ated centrifugal forces, i.e. these increase with decreasing cylindrical casing diameter. Besides this crucial advantage in respect of the separation rate, thanks to the stabilized flow achieved with the HURRIVANE®, the HURRICLON® exhibits a comparatively low pressure loss, which, depending on the specific model and application, can be up to 50 % lower than in a classical cyclone with the same capacity. 5 Removing dust from process gas
in the cement pyroprocessOn account of the known weaknesses of the cyclones in respect of the removal of very fine dusts, cyclones are practi-cally no longer used as the last dedusting unit prior to the release of the gases into the environment. But in contrast to this, thanks to its ruggedness and cost efficiency, the cyclone is now indispensable a separating unit in gas circulation proc-esses. One of these processes or its sub-processes is the cement pyroprocess, which is explained in detail in the fol-lowing. 5.1 Phase separation in the suspension heat exchanger
State of the art for pre-heating the raw meal in the cement pyroprocess is the application of a suspension heat exchanger (Fig. 4). The suspension heat exchanger is based on a discon-tinuous counterflow principle. For the process flow, this
A TEC suspension heat exchanger at Lafarge Cement
4 A TEC Suspensions-Wärmetauscher bei Lafarge Zement Schematic showing a cyclone cascade of a suspension heat
exchanger
5 Schema der Zyklonkaskade eines Suspensions-Wärmetauschers
26
cyclones of the upper stage are optimized for separation. The resulting pressure loss of this stage can account for up to 30 % of the total pressure loss of the heat exchanger tower. Naturally, this is a particular challenge, as the particle size distribution is shifted significantly in the direction of the ultrafine material sizes by the separation at the end of the lower stages. For that reason, in the top stage with a moderate pressure loss, despite A TEC-HEC, separation rates of “only” 93 % can be expected. For the cyclones of the lower stages, the separation rates lie between 80 % and 90 %.
For optimization of the pressure loss with the same separation rate, the installation of the HURRIVANE® is recommended. Further, the installation of a HURRIVANE® as the final cyclone in the cascade is one possibility for reducing the overall pressure loss.
5.2 Clinker cooler waste gas dedustingThe application of grate coolers for the controlled cooling of cement clinker after the kiln brings with it a hot current of flue gas, which cannot be recirculated
into the pyroprocess, e.g. in the form of secondary and tertiary air. The temperature of the this waste gas flow ranges between 150° and 400°C, i.e. at temperatures which are ideally suitable for drying and/or milling processes. Naturally, the waste gas is laden with clinker dust when it exits the cooler. The removal of this dust serves two purposes, first recovery of the product and secondly the cleaning of the waste air. The latter is intended to minimize wear caused by clinker dust and contamination of the product to be dried with clinker dust.
Depending on the type of waste air filter, preliminary dedusting e.g. with a HURRIVANE® has various effects on the downstream filters. If electrostatic filter is used, then thanks to preliminary dust removal, the specific electrical resistance of the suspension and the filter rate increases or the power input per filter surface area unit decreases. With a cloth filter, it is particularly important to ensure the temperature does not exceed 230°C for long periods. Particles entrained in the gas flow can, however, have a much higher temperature. If these reach the cloth in the filters, they damage it on account of the sustained punctiform thermal load. In both cases, the upstream HURRIVANE® removes these particles, without burdening the air filter compressor with any significantly higher pressure loss.
5.3 More complex cyclone/HURRIVANE® separation systemsIt is known that the separation rate of a cyclone depends essentially on the centrifugal and inertia forces acting in it. These depend in turn on geometrical and fludic factors. This explains why a cyclone can only be optimally dimensioned for one single operating state. Any deviating operating states show an immediate effect on the pressure loss and the separation rate. For example, a reduction of the volume flow leads to the reduction of all velocity vectors and therefore to a reduction of the pressure loss but also a fall in the separation rate. But also the change in the gas temperature has certain effects as the density and viscosity of the gas and consequently the particle suspension change.
Now, to remain permanently within the optimal operating state for a given cyclone or HURRIVANE® geometry, A TEC uses a special circulation system. In principle, a subflow of the clean gas is recirculated to the cyclone or HURRIVANE® inlet when required.
5.1 Phasentrennung im Suspensions-Wärmetauscher
Stand der Technik für die Rohmehlvorwärmung im Zement-Pyroprozess ist die Anwendung eines Suspensions-Wärmetauschers (Bild 4). Dem Suspensions-Wärmetauscher liegt ein diskontinuierliches Gegenstromprinzip zu Grunde. Das bedeutet für die Prozessführung, dass nach jedem Gas-Feststoff-Wärmeaustausch in der Suspension, diese wieder getrennt wird. Sowohl das nun kühlere Gas und der nun wärmere Feststoffe gehen in die entgegengesetzte nächste Stufe. In dieser Kaskade von 4, 5 oder 6 Zyklonstufen (Bild 5) wer-den die Zyklone der unteren Stufen überwiegend auf einen minimalen Druckverlust ausgelegt. Nur der Zyklon bzw. die Zyklone der obersten Stufe sind in Richtung Abscheidung optimiert. Der daraus resultierende Druckverlust dieser Stufe, kann bis zu 30 % des Gesamtdruckverlustes des Wärme-tauscherturmes betragen. Das stellt natürlich eine besondere Herausforderung dar, da sich die Korngrößenverteilung durch die endliche Abscheidung der unteren Stufen signifi-kant in Richtung des Feinstmaterialanteils verschiebt. Daher ist in der obersten Stufe bei einem moderaten Druckverlust trotz A TEC-HEC mit Abscheideleistungen von „nur“ 93 % zu rechnen. Für die Zyklone der unteren Stufen liegen die Abscheideleistungen zwischen 80 % und 90 %. Zur Optimierung des Druckverlustes bei gleicher Abscheideleistung wird der Einbau von HURRIVANE® empfohlen. Weiters ist auch der Einsatz von HURRICLON®
dip tube to cylinder casing, e.g. of 1:2, is maintained, a much slimmer design is obtained. The smaller cylinder casing diameter has an indirectly proportional effect on the gener-ated centrifugal forces, i.e. these increase with decreasing cylindrical casing diameter. Besides this crucial advantage in respect of the separation rate, thanks to the stabilized flow achieved with the HURRIVANE®, the HURRICLON® exhibits a comparatively low pressure loss, which, depending on the specific model and application, can be up to 50 % lower than in a classical cyclone with the same capacity. 5 Removing dust from process gas
in the cement pyroprocessOn account of the known weaknesses of the cyclones in respect of the removal of very fine dusts, cyclones are practi-cally no longer used as the last dedusting unit prior to the release of the gases into the environment. But in contrast to this, thanks to its ruggedness and cost efficiency, the cyclone is now indispensable a separating unit in gas circulation proc-esses. One of these processes or its sub-processes is the cement pyroprocess, which is explained in detail in the fol-lowing. 5.1 Phase separation in the suspension heat exchanger
State of the art for pre-heating the raw meal in the cement pyroprocess is the application of a suspension heat exchanger (Fig. 4). The suspension heat exchanger is based on a discon-tinuous counterflow principle. For the process flow, this
A TEC suspension heat exchanger at Lafarge Cement
4 A TEC Suspensions-Wärmetauscher bei Lafarge Zement Schematic showing a cyclone cascade of a suspension heat
exchanger
5 Schema der Zyklonkaskade eines Suspensions-Wärmetauschers
2727
For controlled conveying of the volume of gas and to overcome the pressure difference, another blower is used. The almost constant volume flow generated at the inlet guarantees acceptable flow conditions in the cyclone and therefore a uniform pressure loss and above all a uniform separation rate. Such systems are used mainly in the dedusting of gases with low loads, where separation is performed mainly in the cyclone vortex by means of centrifugal forces. For this reason, it is important to maintain the velocity vectors. Especially since their directed contributions go to the second power into the centrifugal forces, which has an effect on the accelerated particles.
A TEC supplies such a system for the re-dedusting of suspension heat exchanger flue gas of cement pyrolines, which is used for drying and as a working gas in fuel mills. This is system is supplied under the name Opti-Coal®. Heat exchanger waste gas is often used for fuel mills as it only contains low quantities of oxygen and consists mainly of nitrogen and carbon dioxide. But on account of the separation at the end of the cyclones or /HURRIVANE®, this gas is still loaded with fine particles that have passed through the top cyclone stage of the suspension heat exchanger. Removal by means of a filter system would ensure effective dedusting, but besides the immense investment costs, this would also result in a comparatively high pressure loss. For this reason, here the economically efficient Opti-Coal® system is used. Core of the Opti-Coal® technology is the HURRIVANE®, which thanks to its especially slim shape enables high centrifugal forces in centrifugal separation. In addition it exhibits a comparatively low pressure loss, which as a positive effect on the power consumption of the circulating air blower on the one hand and the conveying blower on the other. The separation rate averages 60 %, depending on the load, sometimes even more than this. That is independent on the actual volume flow as the speed at the inlet to the HURRICLO is kept almost constant by the circulation system (Fig. 6).
6 Design criteria6.1 General design criteriaDepending on whether the design is drawn up for a cyclone, e.g. A TEC-HEC, or a HURRIVANE®, key operating data are necessary such as:
• Gas volume flow
• Entry load of the gas-solid suspension
• Particle size distribution of the solids
• Mean particle density of the solids
6Simplified flowsheet showing an Opti-Coal® system application
6.2 Special features in the design of the HURRIVANE®
The special feature of the HURRIVANE® with its two dip tubes has an effect on its design. On account of the smaller cylinder diameter, the outer (spiral inlet) and the inner circumferential speed are higher by a factor of 1.1 to 1.25 than in a traditional cyclone with the same volume rate.
It has been repeatedly proven (G.Staudinger, J. Keuschnigg, and M. Klupak, TU Graz & VA-Krems, 1991) that for a cyclone with a central cylinder, which corresponds to the geometry of a HURRIVANE®, the usual calculation methods for ui, Δpi and d* are not applicable. For this reason, the design of the HURRIVANE® is only roughly based on the common cyclone design methods (e.g. VDI). With protracted
tests, the individual values for pressure loss and the fraction separation efficiencies were determined empirically, from which semi-empirical correction terms were derived. Without these correction terms, it is not possible to calculate the pressure loss and separation rate of a HURRIVANE®.
und vor allem Abscheideleistung. Der Einsatz eines solchen Systems erfolgt zumeist bei der Entstaubung niedrig bela-dener Gase, wo vorwiegend die Abscheidung im Zyklonwirbel mittels Fliehkräfte erfolgt. Daher ist hier die Erhaltung der Geschwindigkeitsvektoren ganz wesentlich. Zumal gehen deren gerichtete Beiträge zur 2. Potenz in die Zentrifugalkräfte ein, welche auf die beschleunigten Teilchen wirken. A TEC bietet ein derartiges System für die Nachentstaubung von Suspensions-Wärmetauscherabgas von Zementpyrolinien an, welches für die Trocknung und als Arbeitsgas bei Brennstoffmühlen verwendet wird. Dieses System wird unter dem Namen Opti-Coal® vertrieben. Man verwendet Wärmetauscherabgas gerne für Brennstoffmühlen, da es nur geringe Mengen an Sauerstoff enthält und sonst überwie-gend aus Stickstoff und Kohlendioxid besteht. Aber dieses Gas ist aufgrund der endlichen Abscheidung der Zyklone bzw. HURRICLON® immer noch mit Feinpartikel beladen, welche die oberste Zyklonstufe des Suspensionswärmetauscher passiert haben. Die Entfernung mittels Filtersystemen bräch-te zwar eine gute Entstaubung, aber neben immensen Investitionskosten einen vergleichsweise hohen Druckverlust mit sich. Daher wird hier üblicherweise das wirtschaftlich arbeitende Opti-Coal®-System eingesetzt. Kern der Opti-Coal® Technologie ist der HURRICLON®, welcher auf-grund seiner besonders schlanken Geometrie hohe Zentrifugalkräfte in der Fliehkraftabscheidung ermöglicht. Zudem verfügt er über einen vergleichsweise geringen Druckverlust, was sich günstig auf die Leistungsaufnahme einerseits des Umluftgebläses und andererseits auf des Fördergebläses auswirkt. Die Abscheideleistung beträgt im Schnitt 60 %, abhängig von der Beladung auch darüber. Das ist unabhängig vom tatsächlichen Volumenstrom, da die Geschwindigkeit am Eintritt des HURRICLON® durch das Kreislaufsystem nahezu konstant gehalten wird (Bild 6). 6 Auslegungskriterien6.1 Allgemeine Auslegungskriterien
Unabhängig davon, ob eine Auslegung für einen Zyklon, z.B. A TEC-HEC, oder einen HURRICLON® erfolgt, sind die wesentlichen Betriebsdaten erforderlich wie: • Gasvolumenstrom• Eintrittsbeladung der Gas-Feststoff-Suspension• Korngrößenverteilung des Feststoffes• Mittlere Partikeldichte des Feststoffes
leads to the reduction of all velocity vectors and therefore to a reduction of the pressure loss but also a fall in the separa-tion rate. But also the change in the gas temperature has certain effects as the density and viscosity of the gas and consequently the particle suspension change. Now, to remain permanently within the optimal operating state for a given cyclone or HURRICLON ® geometry, A TEC uses a special circulation system. In principle, a sub-flow of the clean gas is recirculated to the cyclone or HURRICLON® inlet when required. For controlled con-veying of the volume of gas and to overcome the pressure difference, another blower is used. The almost constant vol-ume flow generated at the inlet guarantees acceptable flow conditions in the cyclone and therefore a uniform pressure loss and above all a uniform separation rate. Such systems are used mainly in the dedusting of gases with low loads, where separation is performed mainly in the cyclone vortex by means of centrifugal forces. For this reason, it is impor-tant to maintain the velocity vectors. Especially since their directed contributions go to the second power into the centrifugal forces, which has an effect on the accelerated particles. A TEC supplies such a system for the re-dedusting of sus-pension heat exchanger flue gas of cement pyrolines, which is used for drying and as a working gas in fuel mills. This is system is supplied under the name Opti-Coal®. Heat exchanger waste gas is often used for fuel mills as it only contains low quantities of oxygen and consists mainly of nitrogen and carbon dioxide. But on account of the separa-tion at the end of the cyclones or /HURRICLON®, this gas is still loaded with fine particles that have passed through the top cyclone stage of the suspension heat exchanger. Removal by means of a filter system would ensure effective dedusting, but besides the immense investment costs, this would also result in a comparatively high pressure loss. For this reason, here the economically efficient Opti-Coal® system is used. Core of the Opti-Coal® technology is the HURRICLON®, which thanks to its especially slim shape enables high cen-trifugal forces in centrifugal separation. In addition it exhib-its a comparatively low pressure loss, which as a positive effect on the power consumption of the circulating air blower on the one hand and the conveying blower on the other. The separation rate averages 60 %, depending on the load, sometimes even more than this. That is independent on the actual volume flow as the speed at the inlet to the HURRICLON® is kept almost constant by the circulation system (Fig. 6). 6 Design criteria6.1 General design criteria
Depending on whether the design is drawn up for a cyclone, e.g. A TEC-HEC, or a HURRICLON®, key operating data are necessary such as: • Gas volume flow• Entry load of the gas-solid suspension• Particle size distribution of the solids• Mean particle density of the solids
Simplified flowsheet showing an Opti-Coal® system application6 Vereinfachtes Fließbild einer Opti-Coal®-System-Anwendung
28 28
The transition from modernisation of an existing dust removal installation to a new installation is fluent. A modernisation can be so extensive that, apart from essential basic components - such as the filter housing - all components are new and the operator of the cement plant essentially disposes of a completely new installation. The fact that the costs for modernising a plant is usually much lower than those for investing in a new one, indicates that there are greater opportunities for modernisation in the current climate of austerity programs.
When it comes to determining the most suitable modernisation concept for dust removal processes in the cement manufacturing industry, it is necessary to take into account all the boundary conditions and choose the variant which will best fulfil all the different aims. Each concept is primarily developed based on a thorough evaluation of the situation. In this process, the cooperation between plant operator, plant engineer and filter specialist is essential. Which of the dust removal supplier's solutions best fulfil the aims of the plant operator is determined together.
Decision-making for modernisation projectsFor both new installations and modernisations, cement plant operators tend to opt for modern bag filter technology. A higher precipitation level and insensitivity to fluctuations in the gas volume, dust load and dust particle size constitute the triumphant success of high-performance bag filters. Where alternative fuels are used and strict regulations by authorities are in place, electrostatic precipitators are not able to adhere to emissions values. Especially with regard to residual dust content, the superior technology of bag filters has long since cancelled out the benefits of electrostatic precipitators.
Intensiv-Filter has proven, with a series of successful modernisation concepts, that conversions to bag filters meet the expectations of cement plant operators. With the Intensiv-Filter concept virtually any electrostatic precipitator can be converted to a bag filter. The typical conversion is carried out in several steps:
* Removal of the high voltage power supply as well as the interior equipment of the electrostatic precipitator until just the
By: Dipl.-Ing Ralf Esser, Astrid Kögel, Dipl.-Ing. Theo Schrooten, Klaus Hansper – Intensiv-Filter GmbH & Co. KG/ Germany
يتطلب تنفيذ مشاريع التحديث فهمًا لعملية التصنيع ومستوًى عاٍل من التجربة في مجال إزالة الغبار . لذلك فمن الضروري أن يتعامل مهندس المصنع مع جميع تفاصيل األمور والتحديات الناتجة عنها وأن يجد الحلول لها . يقدم المقال دراسات حالة حول مشاريع التحويل والتحديث
. Intensiv-Filter الجديدة لشركة
29
exterior walls remain* Installation of the baffle plates, filter head
modules, partitions and clean gas channels* Installation of a weather-proof casing
(penthouse) if necessary* If necessary modification work on the ducts
as well as on the dust transport system* Installation of the maintenance doors,
gangways and ladders * Installation of the filter elements * Installation of the cleaning system
With conversion concepts, the question often arises as to whether the new clean gas area should be placed in the interior of the existing electrostatic precipitator housing or on top of it. This decision is tied to the amount of gas to be filtered, the size of the existing electrostatic precipitator installation and the maximum length of the filter bags.
The installation downtime is of particular significance for modernisation projects. The time requirement depends, like the whole conversion project, on each individual situation. To experience no surprises during and after the changeover phase, nothing must be left to chance. Detailed plans which are supported by CFD simulations in advance are standard procedure at Intensiv-Filter. With such planning, the conversion can take place during the regular downtimes; unscheduled downtime is not necessary. Intensiv-Filter has successfully performed numerous conversions in the regular winter downtime.
Fig. 1: Pre-assembled filter head modules inside ESP housing and upper housing used as penthouse
Fig. 2: Pre-assembled filter head modules (incl. new penthouse) on top of ESP housing
Fig. 3: Pre-assembled casing on top of existing ESP hoppers
Realized modernisation conceptsEach conversion has its own prerequisites and requires a tailor-made concept. From the variety of modernizations that have been carried out by Intensiv-Filter, three examples with different requirements and design solutions are presented.
Project IA typical case is the upgrading to a bag filter for the kiln / raw mill dedusting at Deuna Zement GmbH, Germany. Besides the continuing use of the existing electrostatic precipitator housing to a large extend, the aim of the upgrade was to realise a filter surface load of 1.0 m³/m²/h. Unlike conventional electrostatic precipitator conversions, the raw gas chamber was fitted entirely with bags. Due to the spatial restrictions, both the raw gas inlet and the bag inflow had to be optimized. To achieve this, a lamella system specially developed by Intensiv-Filter was used. Besides reducing inflow speed, this solution made it possible to achieve uniform distribution of the volume flow to the bag packages.
30
The measures were validated using extensive flow simulations for the different optimisation variants. The high-efficient Intensiv-Filter cleaning system is supported by the consequential reduction of the upward flow between the bags. Further advantages of the flow optimisation include a significant reduction of the filter resistance and the operating costs associated with this. In addition to this, the dust loss was promoted due to uniformly velocity distribution throughout the raw gas chamber.
The roof was removed from the existing electrostatic precipitator housing and Intensiv-Filter head modules known as compartments were welded on. The compartments were then insulated on the clean-gas-side and equipped with pneumatic shut-off valves which are activated automatically as well as being externally accessible for maintenance purposes. The clean gas side of the filter was connected at each side to the existing clean gas duct work and the filter fan. Access is via the remaining, upper section of the electrostatic precipitator housing - a penthouse design with a weatherproof roof. The existing electrostatic precipitator outlet was removed and then sealed with a new insulated housing wall. There was no need to convert the dust
discharge system.
As part of the regular winter downtime, approx. 130 t of electrostatic precipitator materials were dismantled and scrapped after which the prefabricated bag filter components were fitted - an operation which caused quite a stir. After a total of six weeks of assembly and commissioning work, the new filter was put into operation.
Fig. 4: Deuna modernisation project
Table 1: Design data Deuna Zement
Dust removal kiln / raw mill
Original ESP Elex
Needed time for conversion 6 weeks
Gas volume 550.000 m³/h a.c.
Temperature 110 - 240 °C
Raw gas dust content 60-80 g/m³
Residual dust content < 8 mg/m³ n.c.
Cleaning mode semi-offline
Cleaning pressure 0.15-0.35 MPa
Compressed air consumption 122 m3/h n.c.
Filter surface area ca. 9,300 m2
Length filter bags 8,000 mm
Filter material PTFE glass fibre
Pressure loss 12 hPa Table 1: Design data Deuna Zement Project II At the Dyckerhoff Group's cement plant in Nowiny, Poland, the electrostatic
precipitators for kiln/raw mill lines 1 and 2 were replaced with efficient Intensiv-Filter
bag filters. The reasons for the modernisation were the high emission values of the
electrostatic precipitator technology which was in use and the desire to profit from the
advantages of bag filter installations. With emission values of 50 mg/m³ n.c. and more
in peak for the dedusting of the kiln exhaust gases of two raw mills, the performance
threshold of the electrostatic precipitators had been reached. Further increase in
volume flow were inevitable impossible with the existing technology, making an
upgrade imperative. Intensiv-Filter was given the task of coming up with suitable
solutions. In 2003 Dyckerhoff Polska – at that point still known as Cementownia
Nowiny – commissioned Intensiv-Filter with the conversion. In a first step the
electrostatic precipitator for raw mill line 2 had to be retrofitted. The commissioning
already was in 2004. When the contract was awarded for converting line 2, the
operator and Intensiv-Filter already agreed on the upgrade for kiln line 1. The switch-
over to the new bag filter for line 1 took place a few months ago.
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Project IIAt the Dyckerhoff Group's cement plant in Nowiny, Poland, the electrostatic precipitators for kiln/raw mill lines 1 and 2 were replaced with efficient Intensiv-Filter bag filters. The reasons for the modernisation were the high emission values of the electrostatic precipitator technology which was in use and the desire to profit from the advantages of bag filter installations. With emission values of 50 mg/m³ n.c. and more in peak for the dedusting of the kiln exhaust gases of two raw mills, the performance threshold of the electrostatic precipitators had been reached. Further increase in volume flow were inevitable impossible with the existing technology, making an upgrade imperative. Intensiv-Filter was given the task of coming up with suitable solutions. In 2003 Dyckerhoff Polska – at that point still known as Cementownia Nowiny – commissioned Intensiv-Filter with the conversion. In a first step the electrostatic precipitator for raw mill line 2 had to be retrofitted. The commissioning already was in 2004. When the contract was awarded for converting line 2, the operator and Intensiv-Filter already agreed on the upgrade for kiln line 1. The switch-over to the new bag filter for line 1 took place a few months ago.
When designing the new bag filter for dust removal of kiln line 2, a cost-effective option with the further use of the old electrostatic precipitator housing, the dust collection hopper and the dust discharge system was chosen. The roof of the electrostatic precipitator
housing and the interior were removed. In order to mount the filter heads, a new frame construction was welded into the interior of the housing shell.
Since the existing gas conditioning tower could maintain an operating temperature of 120°C, high-temperature-resistant filter materials were not necessary and a tried and tested polyacrylnitrile material was chosen. To protect the filter material from possible damage due to temperatures resulting from operating malfunctions prior to the bag filter, a decision was made to use additional air dilution dampers. This ensured a safe temperature within the filtering installation. Further important details related to the design are shown in Table 2.
The down-time for the modernisation of kiln line 1 was 10 weeks - just under 2 weeks for the removal of the internal components and 8 weeks for the actual conversion. The technical requirements of line 2 formed the basis for the second filtering installation. However, the bag length was increased to 8 m. Consequently the cleaning for line 1 could be even further increased. As with line 2, the design was laid out for an operating temperature of 120 °C, which was likewise achieved by the existing gas conditioning towers. In this case too, there was no need for high-temperature resistant filter media. In addition to this change compared to the first implemented retrofit, the duct work was enlarged, fresh air cooling expanded and the capacity of the ventilator increased. For this installation too, the bag
filter, the dust transport system and bunker were integrated into the housing of the former electrostatic precipitator. Therefore considerable savings on conversion costs could be achieved once more.
Fig. 5: Nowiny modernisation project
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Table 2: Design data Geseke
Project IIIIn 2007, the electrostatic precipitator in the Dyckerhoff Group's Geseke plant was replaced with a high-performing, energy-efficient bag filter. The existing electrostatic precipitator located after the rotary kiln was not surely able to comply with the legally specified limits. In addition to the optimised procedure for reducing dust emissions, Intensiv-Filter also implemented a cost-effective option. In the place where the old electrostatic precipitator was located, a completely new housing was attached to the existing dust collection hopper. All the existing dust transportation systems could be further used. The conversion time was kept to a minimum using prefabricated modules and a pre-assembled filter housing. Within the space of five weeks during downtime that had already been scheduled, the equipment was installed, connected and commissioned.
The characteristics of the bag filter used are distinguished by the following key figures:
* Cleaning at low pressure and in a semi-offline procedure * Glass bags with PTFE membrane measuring 7 m in length* Cleaning control system with the JetBus Controller®
The filter bags are cleaned by a periodic compressed air pulse at pressures of 0.15 to 3.5 MPa, depending on the filter differential pressure. In the Dyckerhoff cement plant at Geseke, a customized nozzle system from Intensiv-Filter was used. This significantly improved the cleaning effectiveness. The Intensiv-Filter nozzle system cleans the filter bags ideally and economically, thereby protecting the filter media.
Due to the high efficiency of the nozzle injector and by adjusting the cycle time or the cleaning pre-pressure using the JetBus Controller®, the compressed air consumption could be significantly reduced and major savings were achieved.
Fig. 5: Nowiny modernisation project
Dust removal kiln- / raw mill line 2
Dust removal kiln- / raw mill line 1
Original ESP Elwo (licensed construction of Lurgi, BS 672)
Elwo (licensed construction of Lurgi, BS 672)
Intensiv-Filter bag filter IFJEN 85/18-6000 DKS IFJCN 85/18-8000 DKS
Needed time for conversion 7 weeks 10 weeks
Gas volume 270,000 m3/h 430,000 m3/h
Temperature 120 °C 120 °C
Raw gas dust content 40 g/m3 40 g/m3
Guaranteed residual dust content 10 mg/m3 n.c. 10 mg/m3 n.c.
cleaning mode offline offline
Cleaning pressure ~ 0.3 Ma ~ 0.3 Ma
Compressed air consumption 54 m3/h n.c. 72 m3/h n.c.
Filter surface area ~4,800 m2 ~ 6,400 m2
Length filter bags 6,000 mm 8,000 mm
Filter material PAN PAN
Pressure loss 13 hPa < 10 hPa Table 2: Design data Geseke
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Fig. 6: Geseke modernisation project
Dust removal kiln- / raw mill
Original ESP KHD, Deutschland
Intensiv-Filter bag filter IF JCN 85/13 7000 Eco
Needed time for conversion 5 weeks
Gas volume < 240,000 m³/h
Temperature < 230 °C
Raw gas dust content 100 g/m3
Guaranteed residual dust content < 10 mg/m³ n.c.
cleaning mode semi-offline
Cleaning pressure ~ 0.25 MPa
Compressed air consumption < 45 m³/h n.c.
Filter surface area 4,010 m²
Length filter bags 7,000 mm
Filter material PTFE glass fibre
Pressure loss < 10 -11 hPA Table 3: Design data Geseke
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Fig. 6: Geseke modernisation project
Table 3: Design data Geseke
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Conclusion
The realisation of modernisation projects requires both an understanding of the manufacturing process and a high level of experience in the field of dust removal. Thus it is necessary that the plant engineer deals – also regarding small projects – with all the detailed questions and the challenges they bring, finds a solution and ensures a dialogue between all points of contact. This is in addition to a high degree of expertise and experience, a great interest in the individual project and a high level of motivation with regard to the customer. Such a commitment reflects therefore a particular service readiness, which is necessary to the successful outcome of modernisation projects.
The modern design variants described for the cement plants in Deuna, Nowiny and Geseke are prime examples of conversion and modernisation projects of Intensiv-Filter. On the basis of the specific customer conditions, each filtering installation represents a complex waste gas cleaning installation in which process engineering solutions are required and implemented. In order to design the gas cleaning installations and to realise the optimum solution, it is essential to be familiar with the details of each procedure and to specify the parameters in consultation with the operator. The planning of a gas cleaning installation for a specific requirement is only possible when all the facts are known that are relevant to the measurements, operating methods and selected materials. When implementing the set tasks, Intensiv-Filter combines the expertise with the will to provide the optimum solution to the customer and therefore could successfully implement so many modernisation projects.
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By : Sanwar M. Mishra / India
إن صناعة اإلسمنت هي صناعة ذات استهالك كبير للطاقة وتبلغ نسبة تكاليف الطاقة 40 % من إجمالي التكلفة . وتطبيق عملية الفحص والتدقيق للطاقة له فوائد كبيرة ويمكن استخدام االستهالك النوعي للطاقة الكهربائية للكيلو واط للطن المعتمد لدى اليونيدو لإلسمنت نوع
42.5 كمعيار لتقييم األداء . يقدم المقال نصائح عملية لكيفية المحافظة على الطاقة الكهربائية وتوفير الكلفة .
Introduction:Energy conservation and energy efficiency have become the essential requirement of the electrical power system. Today, the power system is viewed as a unit adding CO2 to the atmosphere, causing pollution to the global environment. Working on the thumb rule of “ power saved is power produced”, the importance of energy conservation and energy efficiency is enhanced. With a purpose to reinforce the institutional development in this field, the government of the country should enact the energy conservation regulation with a charter of demand for the consumer. It should aim at promoting energy-governance, so that the major users of electricity should step up measures to control and conserve power.
The concept of power conservation implies that the magnitude of avoidable energy loss in the power application areas is equivalent to extra generation of power. Action on elimination of this power loss means adding extra generation capacity to the system or saving this extra investment. It is with this spirit of commitment that an energy conservation drive is programmed. The area of conservation relates to the major users of electricity. With the expansion of power generation capacity the avoidable power leakage and losses should not be allowed to rise proportionately.
Main divisions of the power system are generation, transmission, distribution and utilization of electrical
energy. An analysis of the power system indicates that among others, distribution and utilization account for about 75% of the total cases of failure. At each of these divisions energy leakage/loss occurs. Reduction and control of this loss in itself adds to the generation capacity. The aim of an efficient and effective system is to control the avoidable losses and optimize the load conditions of power demand. Hence, power generation should conform to the demand load and to the specifications laid down for the supply system. A departure from these parameters can cause energy losses.
Power Quality:At the power generation stage, it is important to focus on the quality of power. It is described by the following parameters under the international IEC standard.
* Voltage* Power factor* Frequency* Harmonic distortion
Voltage:Under the situation, the prevailing voltage variations in the power supply system are caused by the transmission and distribution of power; whereas, within a network, these variations are produced by the connected load characteristics i.e. reactance. Voltage drop means more current flowing and consequently higher copper losses of the network.
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For example, a 20 % voltage drop amounts to 56 % losses. Hence the supply voltage variation should not exceed 4- 5%. It should be closely maintained in accordance to the recommended voltage marked on the nameplate of the motor. Voltage variation within phases should be controlled to 1%. Phase imbalances must be regulated within tolerance limits; otherwise, it gives rise to winding temperature.
Power factor:It is the ratio of active energy to apparent energy. Ideal power factor is unity. Lower power factor means higher energy consumption and is followed by a voltage drop indicating the nature of connected load. Power factor should be maintained as high as possible. Use of capacitor bank is advisable for improving the same. Capacitor should have low losses, long life, high over-current capability and improved heat dissipation feature.
Frequency:It is caused by the fluctuations in the load level of the supply system. A heavily loaded system will reduce the frequency of the power supply. It adversely affects the system parameters. It calls for a control on the power supply system.
Harmonic Distortion:Non-linear load causes harmonic currents. It is like polluting the network or pollution of the grid produced by an unscrupulous consumer. Harmonic distortion impacts higher energy consumption of the connected load. Electrical equipment like, transformers, motors etc. record higher iron and copper losses in proportion to the power of the frequency i.e. 5th, 7th harmonic and so on. Higher temperature in the core promotes fast aging of the protective insulation ending in premature failure of the equipment. Harmonic distortions can cause rise in motor temperature.
Electric Motors:Electric motors, in a way are the largest consumers of electricity. Power to the motor is made up of two components; one is the effective and useful net power that is available for the process and the other component of power accounts for the losses (iron and copper) as a result of conversion from electrical input to mechanical output.
It is observed that single-phase fractional horsepower and 3-phase induction motors are widely used in industry, which are designed to run at constant speed. They constitute a substantial part of the connected load to the power supply system. The 3-phase AC induction motor is designed to perform optimally in the range of 60 to 100 % efficiency,
which is linked to the rated capacity and the nature of the connected load. The load can be a resistance, capacitance and inductance or a combination of the same. For example a motor running at less than 50% of the rated capacity will unduly downplay the power factor, which in turn will increase the load on the supply system. Motor efficiency accounts for 15 to 20% of the total savings on electrical energy; whereas the remaining 80% relate to the process load conditions.
Unlike 3-phase, single-phase induction motors generally run at 20 – 30% efficiency. They are employed for household use, e.g. motors for ceiling, table, exhaust fans etc. More efficient motors of pump and blower run at 60 to 70 % efficiency. The number of such motors is very large. A small improvement in efficiency can yield large savings in energy. These motors are constant speed drive; they cannot be energy efficient unless adjustable speed drive (ASD) is used; as it is not easy to vary the supply voltage and the frequency so easily. But the use of ASD-motors introduces harmonics in the power system and thus pollutes the power quality. Besides the AC-variable frequency drive (VFD), DC brush less Drive (BLDC) motors are fast replacing the constant speed induction motors in the single-phase category.
All 3-phase AC induction motors run at constant speed. To meet the changing load demand, some mechanical resistance is applied. For example, motor driving a centrifugal fan and a pump use a damper and a throttle valve respectively to control the flow of air and fluid for the changing process requirements. The action of the damper and the throttle valve resists the flow. It does not reduce the speed of the motor. The resistive action wastes the power, thereby reducing the energy efficiency of the power system. Instead, a Variable Frequency Drive (VFD) motor will reduce the motor speed to suit the process load requirement, eliminating the use of any damper or throttle valve. In this way, the VFD does not resist the flow; it achieves the desired condition by simply reducing the speed, thus it saves power and enhances the energy efficiency of the system. Power saving approximates to 25 – 40 %, which is a substantial saving.
The relationship between the speed and the power is that power is proportional to the cube of the speed (P oc cube of N). For example, at full flow of air/fluid, the motor speed is 100 % and it consumes 100 % power. At 90 % flow, the motor speed is reduced to 90 %, but the energy consumed is 73 % only. It means that a small reduction in speed makes a large reduction in power consumption.
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For speed reduction low voltage e.g. 415 V/690V and medium voltage - 2.3KV, 3.3KV, 6.6KV AC VFD motors are available. Current trends are for the application of power transistors for motor speed reduction. For example, HV – IGBT (Insulated Gate Bipolar Transistor) feeds the motor with Pulse Width Modulated, which is harmonic-free current and makes it an energy-efficient solution.
Some tips for improving motor efficiency:
* If the motor is running at a small load, then convert the supply to Star from Delta connection. This will improve the motor efficiency
* Examine and if found necessary, change the existing motor winding to more energy efficient motor.
* If the motor is required to run at a variable load, which is higher for the normal operation of the motor, then change over to Variable Frequency Drive (VFD). It will save on energy. VFD is a microprocessor based electronic drive; it is specially programmed to regulate the speed.
Advantages:The aforesaid suggested solutions help achieve the following.
* Promotes energy conservation-* Reduces iron and copper losses* Prevents harmonic distortions* Improves motor efficiency and energy
efficiency* Enhances motor life
Protective System:A reliable electrical distribution and utilization network depends on an effective protection system. The protection system should be such that it safeguards the equipment against an overload current to pass through the network by disconnecting it from the disruptive situations. For this purpose, relays, circuit breakers etc are employed.
Various types of protective relays are used for automatic protection in response to load changes. The purpose of operating a relay is to trip the circuit breaker; it isolates the network and saves from the risk of damage. One relay can not protect against all
types of hazards.
Some of the equipment protected against the risk of damage is described as follows
Motor protection against the following risks:
* Thermal overload, short-circuit current, earth fault etc.
* Single phasing/unbalancing* Starting problem/ locked rotor
Transformer protection against following risks:
* Differential protection for multi-phase faults
* Restricted earth fault* Over-fluxing protection* Over-current and earth leakage
Circuit Breakers:The oldest device was a manually operated knife-switch, which isolates the circuit. Then, came the switch fuse unit. It blows off upon the incidence of a fault, but requires replacement. Now, various types of circuit breakers are in use to meet the requirements of a particular situation., given as follows.
Low Voltage (LV) Circuit Breakers:* Miniature Circuit Breaker - MCB* Earth Leakage Circuit Breaker – ELCB* Molded Case Circuit Breaker – MCCB* Air Circuit Breaker – ACB
Medium and High Voltage Circuit Breaker:* Oil Circuit Breaker – OCB* Air Blast Circuit Breaker – ABCB* Vacuum Circuit Breaker – VCB* Gas Circuit Breaker – GCB
Currently, modern microprocessor based relays are available for providing total protection against generators, motors, transformers etc.
Power System Activity Diagram: Following exhibit marks the route of energy flow, starting from power generationto the point of energy utilization. At each of these stages, measures are suggested for improving the conservation of power and achievement of energy efficiency.
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Review of the Electrical System Losses:
• Losses related to power generation, transmission and distribution• Mechanical losses of the rotating equipment• Losses caused by the failure of the protective relays and switchgear• Corona losses in EHV voltage levels• Miscellaneous other losses e.g. poor earthing, overloading etc.
Steps to Reduce Losses:
• Use of photoelectric or light dependent resistors (LDR) for indoor and outdoor lighting controls.• Providing line post sensors in HT (High Tension) and LT (Low Tension) lines for fault detection• Installation of load flow controllers with static transfer switches.• By using computer aided software e.g. SCADA (Supervisory Control and Data Acquisition System),
energy management software etc.
Power Consumption Profile of A Cement Plant:Cement manufacturing is a power-intensive process, where about 40 % of the cost is spent on energy. It offers a great potential for conservation by introducing energy audit. The specific power consumption in kwh/ton (metric) available from UNIDO for 42.5-grade cement can be used as a norm for benchmarking.
Description of Activity Activity Flow Improvement
Power Generation - Maintain power quality & - Reduce transmission loss Transmission
Phases of power delivery Distribution -Provide protective & switch-gear Utilization - Reduce distribution loss
Application Large Consumers -Improve motor efficiency of -Reduce energy loss
Electricity -Improve motor life
Constant speed 3-phase AC Induction motor Single-phase drive AC FHP motors Speed Reduction Variable Frequency Drive(VFD) Adjustable Speed
Drive (ASD)/VFD
Current trends MV and HV- IGBT BLDC–inverter-drive in speed reduction (Brush less DC) Review of the Electrical System Losses:
Losses related to power generation, transmission and distribution Mechanical losses of the rotating equipment Losses caused by the failure of the protective relays and switchgear Corona losses in EHV voltage levels Miscellaneous other losses e.g. poor earthing, overloading etc.
Steps to Reduce Losses:
Use of photoelectric or light dependent resistors (LDR) for indoor and outdoor lighting controls.
Providing line post sensors in HT (High Tension) and LT (Low Tension) lines for fault detection
Installation of load flow controllers with static transfer switches. By using computer aided software e.g. SCADA (Supervisory Control and Data
Acquisition System), energy management software etc.
5
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In order to meet these figures of specific power consumption and to make efforts for the energy conservation program, the suggested areas of action are summarized as follows.
* To interlock the crusher auxiliaries to minimize idle running
* To introduce closed circuit grinding, using high efficiency separators in grinding mills
* To use variable speed drive motor e.g. VFDs (variable fan drive) for fans in pre-heater, ESP, Cooler
etc. and to eliminate the use of damper control, where possible.
* To replace compressed air by mechanical conveying for transport of cement to silo.
* To use elevator for kiln feed transport in place of air-lift
* To use blowers for packing department in place of compressors
* To use roll- press prior to cement grinding mill. It saves 10- 15 % power.
* A vertical roller mill consumes about 30 % less power than the ball mill; it can be employed for coal
grinding, limestone grinding and recently introduced for cement grinding also.
* To use electronic chokes in place of conventional ones.
* To use timer controllers where possible.
* To use 36W slim tubes for lighting.
* To explore the use of BLDC and VFD motors for power conservation
* To consider providing a single stack or a common exhaust on a building, where more than one fan
or one machine units are installed and each having a exhaust fan.
References:* Energy Conservation in Induction Motors by Technology Trends Nov. 2001* Determining Electric Motor Load and Efficiency by Dept. of Energy, USA
Mr. Sanwar Mal Mishra, Ex-UNIDO Consultant Dadhichi Nagar, Sheetla Marg P.O. SIKAR-332001 Rajasthan, INDIA
Power Consumption Profile of A Cement Plant: Cement manufacturing is a power-intensive process, where about 40 % of the cost is spent on energy. It offers a great potential for conservation by introducing energy audit. The specific power consumption in kwh/ton (metric) available from UNIDO for 42.5-grade cement can be used as a norm for benchmarking.
Operating Areas kwh/ton (Source – UNIDO) Crushing and stacking 1.5 Reclaiming, transport, grinding 18.0 Kiln feed, kiln, cooler 22.0 Coal mill 5.0 Cement- grinding, transport 23. Packing plant 1.5 Lighting, services, pumps etc 4.0
Total 75.0 In order to meet these figures of specific power consumption and to make efforts for the energy conservation program, the suggested areas of action are summarized as follows.
To interlock the crusher auxiliaries to minimize idle running To introduce closed circuit grinding, using high efficiency separators in grinding mills To use variable speed drive motor e.g. VFDs (variable fan drive) for fans in pre-heater, ESP,
Cooler etc. and to eliminate the use of damper control, where possible. To replace compressed air by mechanical conveying for transport of cement to silo. To use elevator for kiln feed transport in place of air-lift To use blowers for packing department in place of compressors To use roll- press prior to cement grinding mill. It saves 10-15 % power. A vertical roller mill consumes about 30 % less power than the ball mill; it can be employed
for coal grinding, limestone grinding and recently introduced for cement grinding also. To use electronic chokes in place of conventional ones. To use timer controllers where possible. To use 36W slim tubes for lighting. To explore the use of BLDC and VFD motors for power conservation To consider providing a single stack or a common exhaust on a building, where more than
one fan or one machine units are installed and each having a exhaust fan. References:
Energy Conservation in Induction Motors by Technology Trends Nov. 2001 Determining Electric Motor Load and Efficiency by Dept. of Energy, USA
- Mr. Sanwar Mal Mishra, Ex-UNIDO Consultant - Dadhichi Nagar, Sheetla Marg - P.O. SIKAR-332001 - Rajasthan, INDIA
6
40
KILN DOCTORWhat is Shell Flexing & can it be evaluated by tyre creep measurement? What is the importance of this measurement? Mohammed - KSA
Shell Flexing (earlier known as Shell Ovality) is change of curvature of the kiln shell during one rotation of the kiln. It is the difference between the smallest & largest diameters (a-b) during one rotation of the kiln, which result in change of curvature of shell during rotation. Kiln refractory brick linings depend on the principle of continuous arch to stay in place. Any forces acting on that arch, such as a kiln shell flexing, will deteriorate the mechanical stability of that arch. Refractory failure occurs if excessive flexing of the kiln shell exists. Hence, it needs to be monitored to enhance the refractory life.
Factors contributing to shell flexing are:-
1. Tyre thickness & width (cross section). 2. Air gap between the chairpad OD & Tyre ID 3. Shell thickness under tyre 4. Kiln Alignment. 5. Runout / Bend in kiln shell near the tyre. 6. Type of refractory. Calculating shell flex by Tyre Creep :-One can not calculate shell ovality from tyre creep alone to any level of accuracy. Some of the OEMs use empirical formulae to estimate shell flexing based on tyre ovality which is estimated depending on size and MOC of tyre, shell thickness & other assumed load factors like brick load, product load etc., at the time of engineering design. Once the kiln is in operation, all these factors change considerably.
Most of the kilns give wide range of results by this method, since shell thickness, type of refractory, coating, wear off and distortion of tyre & shell affect the results. The shell flex values are also influenced by misalignment, bend in kiln and several other aspects.
Therefore by creep measurement the calculated results will be inaccurate since the same depends on several assumptions and if any of the parameters are deviating form the designed one, this will affect shell flex values very largely. As such the creep can not be considered alone for shell ovality or shell flex measurement.
Correct way of measuring Shell Flex (the only alternative) :-Shell flexing can be measured directly without any assumption and takes into account all the above factors with a High Resolution Shell Flex Beam. This will take around 600 readings per tyre electronically. This will average out the shell flex values on real time basis with out any manual error. In addition these electronic readings developed into a linear / polar graphs gives other important information like uneven load on piers, crack in shell, alignment condition, bend in the shell etc. Infact, this analysis helps as a ‘second opinion’ for the alignment analysis.
Hence when ever shell Flexing Analysis is carried out make sure that all the above factors are answered by the analysis, which is fairly impossible by using tyre creep method but only possible by using a Shell flex Beam. Shell Flex Beam
b
a
By : Phillips Kiln Services (India) Pvt. Ltd. / India
أبعاد تغير قياس خالل من تقييمه وإمكانية الفرن غطاء انثناء الربع هذا مقال يناقش إطار الفرن . ويركز المقال على أهمية هذا القياس والحاجة لذلك كجزء أساسي لتصحيح
alignment الفرن الحار .
By : Phillips Kiln Services (India) Pvt. Ltd. / India
www.cemweek.com | [email protected] | t: +1-702-430-1748
global cement industry knowledge platform | global cement industry knowledge platform | global cement industry knowledge platform
Daily news: The cement industry’s leading news service, offering detailed and insightful articles put together by our global team of writers covering more markets and more news than any other industry source.
Proprietary intelligence: Interviews with cement industry thought-leaders and experts, including CEOs, executives, analysts and consultants through the CemExec feature series.
Market research: High-quality research reports, including detailed market studies, competitive assessments, cement trade flows, and export opportunity assessments, among many others. Custom research available upon request.
Data services: Statistical and data research tools offering industry practitioners a wealth of cement supply and demand data.
cement industry knowledge: news, interviews, data & research
You need to know what is happening in the global cement industry. Right now. Your competitive advantage demands it.
CemWeek must be your information and market intelligence source. CemWeek.com – knowledge delivered.CemWeek’s online news and knowledge platform for the global cement industry identifies and researches key industry events and uncover hard-to-find news from around the world. CemWeek regularly speaks to cement sector experts to provide a continuous flow of insights and analysis.
42
Thermo Fisher Scientific Inc., the world leader in serving science, announced a new and powerful addition to its range of automated optical emission and X-ray fluorescence spectrometers. As an alternative to single spectrometer automation, the new Thermo Scientific ARL SMS-3500 integrates multiple standalone laboratory instruments, including sample preparation, in a fully automated cell to optimize the entire analytical workflow and enhance process control efficiencies in the mining and metals industries.
Thermo Scientific robotized spectrometers have established a high standard of excellence in the most demanding environments, and the new ARL SMS-3500 represents a step forward for users requiring more comprehensive and integrated workflow automation solutions. At the heart of the system is a FANUC industrial robot, driven by intelligent Thermo Scientific SMS software, which allows for the preparation and analysis of samples using two sample preparation machines and two optical emission and/or X-ray fluorescence spectrometers.
The Thermo Scientific ARL SMS-3500 uses highly reliable components to ensure higher instrument uptime. The FANUC robot is designed to handle heavy loads of up to 7kg in industrial environments with great precision. The large floor-standing robot has six axes of movement to optimize sample handling speed, eliminate unnecessary hardware and increase overall system reliability. All system components operate simultaneously for greater efficiency, while sample priority management, temporary sample storage and rapid transfer between system components allows for high sample throughput that cannot be matched by traditional manual systems.
Complex procedures such as instrument control and standardization are scheduled and executed systematically to avoid delaying production sample
analysis. Optimizing sample handling and laboratory response times allows for real-time production decision-making that maximizes yield and grows the bottom line.
The system provides easy and direct access to the various components for maintenance purposes or manual work. Each instrument can be quickly disconnected without interruption of the automatic operation and the spectrometers can be easily moved to a separate park position for servicing.
The integration of separate sample preparation and analysis systems in one or more compact ARL SMS-3500 cells streamlines large laboratory automation. Samples received via automated air tubes can be immediately processed, avoiding a separate sample preparation stage and leading to significant cost and response time savings.
For more information on the Thermo Scientific ARL SMS 3500, please call +1 800 -532 -4752, email [email protected] or visit www.thermo.com/oes.
Scheuch GmbHWeierfi ng 68 I A-4971 Aurolzmünster
Phone: +43/7752/905-0 I Fax:-370 I offi [email protected]
The patented EMC technology is the only system to offer a constant and
low differential pressure, which makes it possible to exclude negative effects
that impact upstream processes. This creates the conditions necessary for
continuous plant operation and high operating availability.
In addition to the technical aspects, EMC technology is also persuasive in terms
of its economic and commercial viability. Reduced investment costs, a 30%
reduction in fan power requirements, a doubling of fi lter bag service lifetimes
and an 80% reduction in compressed air energy can be achieved.
THE BENCHMARK FOR THE CEMENT
INDUSTRY
LOWEST OPERATING COSTS
HIGH AVAILABILITY
REDUCED INVESTMENT COSTS
44
PANalytical launched CubiX3, the 3rd generation of its successful CubiX X-ray powder diffractometers range. Building on the company’s reputation for speed, reliability and reproducible analysis, the CubiX3 introduces new features such as high-intensity data collection as well as extra flexibility in sample handling for automated environments. X-ray diffraction has already reached significant importance as a process and production control method for powdered materials in many industries. Its initial investment is rapidly earned back because of the ease of operation, the independency of operators and the safety for the users, when compared to traditional methods like wet-chemical process control or microscopy methods. The CubiX3 range includes dedicated versions, tailored to the needs of those working in cement, minerals, pharmaceuticals or aluminium production.
Dr. Uwe König, Applications Specialist, XRD, highlighted the advantages of XRD analysis with the new CubiX3 range: “X-ray diffraction is recognized as the most efficient method of obtaining direct phase information for many types of materials. Results enable manufacturers to maintain consistency in the quality of their product while optimizing production speeds. CubiX3 is the fastest, most flexible and most accurate diffractometer available for production control. It yields a complete diffraction pattern up to 150 times faster than conventional detection technology”.
PANalytical was the first X-ray solutions provider to bring ‘walk-up’ functionality to its line of XRPD systems. The Walk-Up software available for CubiX3 enables a user with no knowledge of XRD to enter urgent samples at any time, even if the diffractometer is already processing a routine batch; and automatically receive a More
speed, more applications power, more automation potential report of results with no user input to the analysis. The Walk-Up / CubiX3 combination provides the perfect analysis tool for multi-user environments.
The CubiX3 supports the full analytical X-ray powder analysis methodology from classical data analysis up to full pattern cluster analysis for statistical data interpretation and pass/fail determination.
For more information about CubiX3 contact your local representative or visitwww.panalytical.com/CubiX3
CubiX3 – Industrial XRD system
More speed, more applications power, more automation potential…/2
Page 2 of 2
report of results with no user input to the analysis. The Walk-Up / CubiX3
combination provides the perfect analysis tool for multi-user environments.
The CubiX3 supports the full analytical X-ray powder analysis methodology from
classical data analysis up to full pattern cluster analysis for statistical data
interpretation and pass/fail determination.
For more information about CubiX3 contact your local representative or visit
www.panalytical.com/CubiX3
CubiX3 – Industrial XRD system Visit our website at www.panalytical.com for more information about our activities. PANalytical is part of Spectris plc.
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The Most Flexible Ultrasonic Data Logging Thickness Gauge
Cygnus is proud to introduce the NEW Cygnus 3 Data Logger multiple echo thickness gauge developed toaccommodate the need for a simple yet versatile method of logging thickness measurements through coatings.
The New Cygnus 3 Data Logger isengineered with a flexible data loggingfacility. The gauge offers three data loggingmodes: Simple Linear Data Logging with acapacity of up to 5000 points each record;Grid Based Data Logging using simple XYgrids for up to 5000 points; Template BasedData Logging featuring definablemeasurement points, minimum andreference thickness values and up to 40configurable user fields to collect additionalinformation.
The equipment also benefits from a facilityto add Additional Radial Measurements around any chosen point; alphanumeric data entry via phone stylekeys; data stored on internal SD memory card for data security; a bright multi colour LED giving visualfeedback when logging data; USB connection to computer without driver installation. While in one handoperation, the auto log function enables stable measurements to be recorded automatically without the needto press any keys.
The New Cygnus 3 Data Logger is housed in a rugged, IP65 rated aluminium enclosure. The kit includes aMicrosoft Excel Add In for easy data import into blank worksheets or Excel templates. In addition, Data LoggerManager Software is supplied for generating reports and transferring data between the gauge and computer.
As with all Cygnus thickness gauges, the new Cygnus 3 Data Logger carries a 3 year warranty and employs theCygnus Pioneered Multiple Echo Technique to give accurate, error checked measurements through coatings.
Cygnus Instruments Ltd. www.cygnus instruments.comTel: +44 (0) 1305 265533 sales@cygnus instruments.com
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FLSmidth released a new version of its kiln shell infrared scanner solution. This new version of the ECS/CemScanner is optimized for newly developed hardware and is the first of a new generation of software products.
The new generation ECS® process control solutions are based on the latest Microsoft .NET technology and the Microsoft Windows 7 operating system. "This new technology enables more flexible and rapid product development to the benefit of our customers", Global Product Manager Joju Jacob comments. "The short distance between the industry and our development teams has always been essential to remain close to the customer and thereby stay competitive." Being a Microsoft Gold Certified partner and having the highest level of competence and expertise enables FLSmidth to always offer software solutions that are based on the latest Microsoft technology and platform.
For more information about ECS/CemScanner®, or our process and quality control solutions, please visit www.flsmidth.com/automation
The SCL Compression Loadcell, now available from Celsum Technologies Ltd, can be supplied with full scale ranges between 1 tonne and 100 tonnes, or 10kN and 1,000kN (or 1MN). Fabricated from stainless steel, these precision force transducers are sealed to IP67 to the BS60529 standard, and use a 700 ohm strain gauge bridge with a sensitivity of 1.5mV/V. Designed with long term resistance to fatigue, the SCL loadcells have a high cycle life, a safe overload capacity of 150% of full scale, and an ultimate overload limit of 300% of full scale. The maximum error is 0.05% of full scale, and they have a compensated temperature range of 0 to 50°C. Excitation voltages of 5 to 15 volts AC or DC may be used, and traceable calibration certificates may be supplied for just the loadcell or for the loadcell with instrumentation. For systems using multiple load cells, the outputs of the sensors can be standardised.
Says Celsum's Roy Carter, "The SCL load cell is a welcome addition to the range that we offer, with applications from materials testing through to weighing, and from on-line process control to R & D and quality control. As well as this and other load cells, we offer a wide range of instrumentation, too, from simple analogue amplifiers to digital electronics with computer interfaces and precision digital displays and controllers, to state-of-the-art wireless telemetry."
For more information, please contact:
Roy E Carter MSc CEng FIM3Managing DirectorCelsum Technologies LtdThe Innovation CentreDe Montfort University49 Oxford StreetLeicester LE1 5XY United Kingdom Tel: +44-(0)116 207 8807Fax: +44-(0)870 120 9370Email: [email protected]: www.celsum.com
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Wirelessly configuring and monitoring scales from "a safe distance"
Weighing and feeding can be a very elaborate, time-consuming and costly process. Configuration, monitoring and maintenance work are significant factors depending on the raw materials to be processed and the system properties. In some cases, scale controls used in tough environments incur high maintenance and repair costs.
Ten years ago Schenck Process took its first major step towards improving cost/benefit ratios with specially designed mechatronic weighfeeders. These feature mechanics and electronics in a shared sturdy unit which makes them particularly robust, durable, easy to maintain and highly interoperable as various interfaces allow them to be linked to virtually any automation system.
When coupled with the innovative EasyServe service program, the result is an unbeatable system that can now also be configured wirelessly from a distance.
EasyServe. The name says it allThe EasyServe service program can be used to conveniently install, configure and monitor the weighfeeders using a laptop. And thanks to new Bluetooth wireless modules, this process went wireless two years ago.
A process requiring no cables offers much more than simply high convenience. When weighfeeders are difficult to access, Bluetooth provides impressive selling points as these are now free for wireless communication and the full range of opportunities that offers.
The operator can also work at a clean and really comfortable workplace at a safe distance from all the action, which conserves the operating unit and is better for maintenance staff at the service site. Other selling points include the fact that cumbersome cables are no longer needed and can be consigned to history.
But let's stick to the present where wireless methods can be used over considerable distances, saving both time and money. Depending on the variant used, weighfeeders can be wirelessly configured from distances of 30 or 100 metres. Existing scales and feeders, fitted with DISOCONT®, INTECONT® PLUS or DISOMAT®, can also be equipped for modern networks. Both Ethernet and WLAN can be used for communication and data processing with the customer's network.
Great communication services includedThe breadth of services offered by the new wireless module is also impressive. Its main job is optimum configuration via EasyServe for commissioning and ongoing service work, including parameterisation, monitoring and maintenance. Settings for trends such as feed rate and weight in the weighfeeders' time line can also be easily recorded and graphically depicted within the service program.
Perfectly equipped for every scenarioEasyServe can be used for DISOCONT®, INTECONT® PLUS, INTECONT® Satus and INTECONT® Opus.
DISOPLAN is the service tool for DISOMAT® Tersus, DISOMAT® Satus, DISOMAT® Opus and DISOBOX®. When using several DISOCONT® feeding electronics in one system, Bluetooth wireless technology can take the place of the service bus.
Depending on specific requirements, Schenck Process offers two different module range classes: Bluetooth class 1 for up to 100 metres and Bluetooth class 2 for up to 30 metres. A two metre connection cable allows the transmission path to be aligned perfectly.
As they are simply attached using two external clips, it's just as easy to affix the two modules as it is to operate them. Smooth data operation is indicated on the integrated LEDs and both modules offer IP65 protection.
For more information, please contact:Schenck Process GmbHMarketing CommunicationPallaswiesenstraße 10064293 DarmstadtGermanyT +49 61 5187 29 31 15-F +49 61 5154 27 31 [email protected]
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The volumetric version of the gravimetric ProFlex® C feeder is a low-cost alternative to a proven Schenck Process product. It is also used to feed additives and fillers in powder, granulate or fibre form. One particularly appealing feature of the volumetric feeder is that it requires no maintenance. Its well thought-out design also makes flexible installation possible. Available in two feeder sizes and a total of three container sizes, the system fits in any available space. Up to eight feeders can be installed in a very compact space to form one complete feeder station as the augers are positioned off-centre. The position of the drive and auger can be changed at any time and they can easily be modified later on.
Vertical container walls mean that optimum use is made of the space available and this also impacts positively on how the bulk material flows.
The ProFlex® C feeder system is available in two discharge lengths for feed rates of up to 9500 dm3/hr. Maintenance-free operation, easy cleaning, the external agitation drive using connecting rods and the robust auger mounting make the ProFlex® C very easy to care for.
Both models of the ProFlex® C can be completed with various feed hoppers, augers and spirals. Various control concepts, ranging from the simple version with constant speed to Profibus-based control, are also available.
For more information, please contact:Schenck Process GmbHMarketing CommunicationPallaswiesenstraße 10064293 DarmstadtGermanyT +49 61 5187 29 31 15-F +49 61 5154 27 31 [email protected]
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the leading power and automation technology group, announced today the successful installation of its SpectraFlow and Raw Mix Preparation (RMP) solutions at CEMMAC’s plant in Slovakia.
CEMMAC was founded in 1883 with the acquisition of its limestone quarry. Today CEMMAC employs 247 people and manufactures Portland cement and Portland slag cement.
The material at CEMMAC’s quarry comes from three different zones, yielding a mixture of medium and low quality marl and high quality limestone. Moisture changes have a big effect of the marl, which makes it difficult to measure the concentration with a conventional sampling station. Consequently it was frequently the case that the lime saturation factor (LSF) of the raw material arriving at the raw mill exceeded the upper process limit. Therefore CEMMAC was seeking a solution, which would establish a target LSF and significantly reduce the LSF variations in its mixing bed. The solution was a combination of the ABB online analyzer SpectraFlow plus the ABB Expert Optimizer module Raw Mix Preparation.
SpectraFlow uses SOLBAS™ technology which uses Near Infra-Red Spectroscopy (NIRS) to provide the chemical composition data. The SpectraFlow analyzer solution can be used on any conveyor belt, regardless of width or belt composition and does not require dedicated safety personnel or special operating licenses. The SpectraFlow analyzer does not require any physical contact with the sample material in order to provide data. This immediately brought improvements for CEMMAC, since previous problems caused by a sample based analyzer coming into contact with moist marl no longer existed. ABB installed its SpectraFlow online analyzer at CEMMAC in February 2008. Moisture, however, impacts composition readings and so in February 2009 a new analyzer strategy model was installed to take moisture levels into better account in the data and analysis.
A further benefit is that the SpectraFlow online
analyzer is able to provide a sample value every minute. The frequency of sample data means that truck by truck sampling is possible by CEMMAC.
ABB’s RMP solution, in combination with SpectraFlow, is now achieving an LSF of 80 +/- 5 for each 180 tonnes segment of a round mixing bed. Mr Kebisek, Quarry Manager at CEMMAC, said “Pressure on the quarry staff has been reduced since they can now refer to the RMP solution for clear guidance on how best to handle material”.
For more information please contact:ABB Switzerland LtdMax BernerMarketing Services Business Unit Minerals(Baden/Switzerland)Tel: +41 58 586 88 32Fax: +41 58 586 73 33e-mail: [email protected]
Cemmac is a subsidiary of Austrian
Group Asamer & Hufnagel
Baustoffholding GmbH and has a single integrated works at Hornee Srnie, Slovakia
The ABB SpectraFlow
analyzer at work
Press Release
Cemmac is a subsidiary of Austrian Group Asamer & Hufnagel Baustoffholding GmbH and has a single integrated works at Hornee Srnie, Slovakia
The ABB SpectraFlow analyzer at work
Press Release
Cemmac is a subsidiary of Austrian Group Asamer & Hufnagel Baustoffholding GmbH and has a single integrated works at Hornee Srnie, Slovakia
The ABB SpectraFlow analyzer at work
Installation achieves stable LSF and improves use of quarry material for CEMMAC
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CEMENT
35th CORAL Conference on Our World in Concrete & Structures Date : 26- 27 August 2010Venue: Adelaide, AustraliaFor more information please contact:CI-PREMIER PTE LTD150 Orchard Road #0714-, Orchard PlazaSingapore 238841Tel.: +65 67332922Fax.: +65 62353530Email: [email protected]
Trends in Secondary Abatement TechnologiesDate : 22 -23 September 2010Venue: SCHWENK, Mergelstetten, GermanyFor more information please contact:European Cement Research Academy GmbHTannenstrasse 2 • 40476 Düsseldorf GermanyP.O. Box 30 03 32 • 40403 Düsseldorf GermanyTel.: + 49 211 23 98 38 -0Fax: + 49 211 23 98 38 -500Email: [email protected]: www.ecra-online.org
Reducing Energy Consumption and CO2 Emissions in the Cement Industry of Fast Developing Economies – CemEnergy Date : 26 October 2010Venue: ExpoCentr, Moscow, RussiaFor more information please contact:Ms. Tatyana Nesterova, Manager ASTC “ALIT”197022 Russia, Saint-Petersburg,Instrumentalnaya st., 3 B, office 218Tel./fax: +7 (812) 380 - 65 - 72 335 - 09 - 92E-mail: [email protected]: www.alitinform.ru
Hydration of Blended Cements Date : 5 October 2010Venue: ECRA, Düsseldorf, Germany
For more information please contact:European Cement Research Academy GmbHTannenstrasse 2 • 40476 Düsseldorf GermanyP.O. Box 30 03 32 • 40403 Düsseldorf GermanyTel.: + 49 211 23 98 38- 0Fax: + 49 211 23 98 38- 500Email: [email protected]: www.ecra-online.org
6th European Slag Conference, EUROSLAGDate : 20- 22 October 2010Venue: Madrid, SpainFor more information please visit: www.euroslag2010.eu
Influence of Alternative Fuels and Raw Materials on the Properties of Clinker and CementDate : 9- 10 November 2010Venue: CEMEX Plant, Beckum, GermanyFor more information please contact:European Cement Research Academy GmbHTannenstrasse 2 • 40476 Düsseldorf GermanyP.O. Box 30 03 32 • 40403 Düsseldorf GermanyTel.: + 49 211 23 98 38 -0Fax: + 49 211 23 98 38- 500Email: [email protected]: www.ecra-online.org
6th Global Slag Conference Date : 22 -23 November 2010Venue: Sydney, Australia For more information please visit: www.propubs.com/gsc
55th BetonTage Date : 8 -10 February 2011Venue: Neu Ulm, Germany For more information please visit: www.betontage.de
13th International Congress on the Chemistry of CementDate : 3- 8 July 2011
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Venue: Madrid, SpainFor more information please visit: www.icccmadrid2011.org
CERAMIC
The 16th China International Ceramics and Sanitary-ware Fair FOSHANDate : 18 -22 October 2010Venue: Center Huaxia Ceramic Expo City, Foshan, ChinaFor more information please contact:Foshan International Conference & Exhibition Center – Huaxia Ceramic Expo CityTel.: +86 - 757 - 8532 / 8833 - 6777 / 8531 - 3888Fax: +86 - 757 - 8833- 6383Email: [email protected] http:// www. foshanfair.com
GENERAL
Master Class on Business Costs ReductionStrategies and best approaches to bring down & streamline business costDate : 2 -3 August 2010Venue: Berjaya Times Square Hotel & Convention Centre, Kuala Lumpur, MalaysiaFor more information please contact: Mr. Mohammed Atif, Senior Sales & Marketing Manager – Middle East & AfricaBridge KnowleTel.: +92 - 346 - 3303727Fax: +603 - 42703059Email: [email protected]:\\ www.bridgeknowle.com
XXIst World Energy Congress Date : 1216- September 2010Venue: Montreal, CanadaFor more information please visit:www.wecmontreal2010.ca
2nd Global Landfill Mining ConferenceDate : 13 September 2010
Venue: London, UKFor more information please visit :www.propubs.com/glm
IFAT 2010 Date : 13- 17 September 2010Venue: Munich, GermanyFor more information please visit: www.ifat.de
10th International Conference on Steel, Space and Composite Structures Date : 21 -23 September 2010Venue: Macau, SAR ChinaFor more information please contact:CI-PREMIER PTE LTD150 Orchard Road #0714-, Orchard PlazaSingapore 238841Tel.: +65 67332922Fax: +65 62353530Email: [email protected]
5th Global Insulation ConferenceDate : 4 -5 October 2010Venue: London, UKFor more information please visit: www.propubs.com/gic
The 12th International Mineral Processing Symposium Date : 6 - 8 October 2010Venue: Hotel Dedeman Cappadocia, Nevşehir, TurkeyFor more information please visit: www.imps2010.org
Contact Information for Registration, Accommodation, Transfer, Tour, Sponsorship and Exhibition:Soykan GÜLEREsentepe Yıldız Posta Cad. Akın Sitesi 1. Blok No:6 Kat:1 D:3 Şişli 34394Istanbul, Turkey Tel.:+90 212 347 63 00
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Fax: +90 212 347 63 63 Email: [email protected] Web: www.dekon.com.tr
10th Global Gypsum Conference and ExhibitionDate : 25 -26 October 2010Venue: Paris, FranceFor more information please visit:www.propubs.com/ggc
FILTEC 2011Date : 22- 24 March 2011Venue: Wiesbaden, Germany For more information please visit: www.filtec.de
Interpack Date : 12- 15 May 2011Venue: Düsseldorf, Germany For more information please visit: www.interpack.de
ICCC Date : 3 -8 July 2011Venue: Madrid, Spain For more information please visit: www.iccmadrid2011.org