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    Kenny Ruiz
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    This document discusses measuring dusty air streams in cement manufacturing plants. It outlines some of the challenges in measuring these streams, including accessibility, safety issues, and fluctuating temperature, pressure, moisture and dust concentration. Specific areas of interest are identified, such as vertical roller mills and preheaters/precalciners. The document then focuses on using the Promecon instrument to accurately measure airflows at a Holcim cement plant, allowing operators to minimize airflow and save 0.5-1 kWh/t of raw meal production through automatic fan speed control calibrated to the Promecon measurements. Installation of the Promecon system at this plant in late 2004 proved it to be a reliable and accurate means of measuring the difficult

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    This document discusses measuring dusty air streams in cement manufacturing plants. It outlines some of the challenges in measuring these streams, including accessibility, safety issues, and fluctuating temperature, pressure, moisture and dust concentration. Specific areas of interest are identified, such as vertical roller mills and preheaters/precalciners. The document then focuses on using the Promecon instrument to accurately measure airflows at a Holcim cement plant, allowing operators to minimize airflow and save 0.5-1 kWh/t of raw meal production through automatic fan speed control calibrated to the Promecon measurements. Installation of the Promecon system at this plant in late 2004 proved it to be a reliable and accurate means of measuring the difficult

    Copyright:

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    Download as PDF, TXT or read online from Scribd
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    254 views11 pages

    White Paper - HolcimIEEE - Air

    Uploaded by

    Kenny Ruiz
    This document discusses measuring dusty air streams in cement manufacturing plants. It outlines some of the challenges in measuring these streams, including accessibility, safety issues, and fluctuating temperature, pressure, moisture and dust concentration. Specific areas of interest are identified, such as vertical roller mills and preheaters/precalciners. The document then focuses on using the Promecon instrument to accurately measure airflows at a Holcim cement plant, allowing operators to minimize airflow and save 0.5-1 kWh/t of raw meal production through automatic fan speed control calibrated to the Promecon measurements. Installation of the Promecon system at this plant in late 2004 proved it to be a reliable and accurate means of measuring the difficult

    Copyright:

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    of 11

    Measuring Dusty Air Streams

    in Cement Manufacturing

    Syed Suhail Akhtar Roland Bachmann

    Challenges to Measure Dusty Gas Streams


    List of challenges
    4 4 4 4 4

    Location of the duct (accessibility & safety) Temperature, Pressure and Moisture Fluctuation in flow rate Dust concentration of the stream Availability of appropriate equipment

    Holcim (US) Inc - CTS Group

    23.05.2005/Su .ppt

    Where in Cement Manufacturing


    Areas of interest
    4 4 4 4 4 4

    Vertical roller mill Tube mill Preheater / Precalciner kiln Long Wet/ Dry kilns Direct fired burning system Kiln gas bypass system

    Holcim (US) Inc - CTS Group

    23.05.2005/Su .ppt

    Where in Cement Manufacturing - VRM


    After Cyclones

    Holcim (US) Inc - CTS Group

    23.05.2005/Su .ppt

    Where in Cement Manufacturing Ball Mills


    Sep Sweep

    Mill Sweep
    5

    Holcim (US) Inc - CTS Group

    23.05.2005/Su .ppt

    Where in Cement Manufacturing - Preclaciner

    Tertiary Air

    Downcome

    By-pass Duct
    6

    Holcim (US) Inc - CTS Group

    23.05.2005/Su .ppt

    Where in Cement Manufacturing - Cooler


    Tertiary Air Primary Air Waste Air

    ~550C

    Holcim (US) Inc - CTS Group

    23.05.2005/Su .ppt

    Use at Midlothian Plant


    Installation Background
    - Two vertical roller (raw) mills (Loesche, Pfeiffer) - The high moisture of the raw material (13%) require more than normal gas flow quantities to be moved through the mill for drying power consumption of the mill ID fan is about 60% of the total power consumption of the grinding system. - Operators used to control the mill draft manually and tended to overdraft the mill to maintain a more stable operation without loading up the internal recirculation.

    Holcim (US) Inc - CTS Group

    23.05.2005/Su .ppt

    Use at Midlothian Plant


    A potential for savings by automatically controlling the fan

    speed was realized, based on a relative indication of the gas flow through the system.
    - The following indicators were used: - Differential pressure across the raw mill cyclones: poor and inconsistent correlation with actual air flow - Calculated airflow by using fan power and differential pressure across fan: a little better than cyclone dp but no satisfactory results were achieved. - Mill inlet pressure: Works quite well because our mills have no recirculation duct - December 2004, commissioned the Promecon instrument (2 sensor pairs per raw mill). Works very well.
    9

    Holcim (US) Inc - CTS Group

    23.05.2005/Su .ppt

    Results at Midlothian Plant


    4

    Excellent correlation between the two sensor pairs validate location


    Promecon 1 vs. Promecon 2 [000' m3/h]

    690 670 650 630 610 590 570 550 500

    Promecon 1

    520

    540

    560

    580

    600

    620

    640

    Promecon 2

    10

    Holcim (US) Inc - CTS Group

    23.05.2005/Su .ppt

    Conclusions
    On vertical roller mills power savings of 0.5-1 kWh/t raw meal can be achieved by minimizing and controlling the airflow through the mill This can only be done successfully with an accurate indication of the actual airflow The Promecon system (installed in December 04) has proven itself as reliable and accurate measurement

    11

    Holcim (US) Inc - CTS Group

    23.05.2005/Su .ppt

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