CALSINER CONTROL

Chekka Plant (Lebanon)

 Polysius
Prepol
 2 strings

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- Production
El Soukhna Plant (Egypt)

Ekstraksi udara tersier pada kiln hood

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- Production
Ramos Arizpe Plant (Mexico)

 F.L.Smidth
 ILC kalsiner
dengan
dikontrol hot
spot
 Line 2 (depan)
Line 1
(belakang)

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- Production
Komponen – komponen Kalsiner

Unit 1 dari 5
 Reaktor Tipe Vessel

Pola aliran pada reaktor tipe vessel

menunjukan zona pencampuran dan
zona resirkulasi (Kobe DDF kalsiner)

Kalsiner dengan orifice kalsiner tanpa orifice

menciptakan
pencampuran tambahan
dan resirkulasi

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 Reaktor Tipe Tube

Reaktor Kalsiner Tipe Tube

(KHD Pyroclon alternatives)

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 Burner Prekalsiner

Burner kalsiner dibawah penambahan

meal splash box (Sumber : Polysius)

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 Burner Prekalsiner

Burner Prekalsiner untuk batu bara

dan gas dengan udara axial dan radial

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 Tertiary Air (udara tersier) Intake

Udara atas
(untuk Nox rendah)

Dampak
frontal oleh
inlet dua
udara tersier

Inlet tangential
satu

F.L.Smidth Polysius

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Tertiary Air (udara tersier) Intake

KHD Design

Pencampuran
lambat dari
udara tersier
dan aliran gas
pada kiln.

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 Penambahan Meal
Tipe cakram
pembagi
saluran mill

Penambahan
Meal bagian
atas ke
kalsiner (untuk
mengontrol
temperatur
pada bagian
bawah
kalsiner)
FLS ILC dengan dikontrol hot
spot
Penambahan
Meal ke
kalsiner

Penambahan
Meal ke riser

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 Generator Turbulensi
(misalnya PYROTOP)

PYROTOP
compact
(KHD)

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 Generator Turbulensi
(misalnya Polysius)

Defleksi di
chamber
(Polysius)

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 Generator Turbulensi
(misalnya Orifice)

kalsiner
orifice

kalsiner
orifice

ILC DDF
F.L.Smidth Kobe Steel

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 Chamber Pembakaran

kalsiner
Burner loop

Keluaran
Chamber gas
pembakaran

Keluaran
Meal

Polysius Prepol CC
(El Soukhna, Egypt)

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 Chamber Pembakaran

Burner

Keluaran Gas Penambahan Meal

dan meal untuk proteksi meal

RSP kalsiner
(FCB Ciments)

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 Chamber Pembakaran

RSP kalsiner
(FCB Ciments)

RSP
vessel

kalsiner Keluaran
loop Gas
dan meal

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Sistem Udara Tersier

Unit 2 dari 5
Pengendalian Udara Tersier dan Udara Sekunder

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 Lokasi keluaran udara tersier

Ekstraksi udara tersier dari kiln

Ekstraksi udara tersierdari cooler
hood
roof
Temperatur udara tersier =
Udara sekunder panas
Temperatur udara sekunder
Udara tersier dingin

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Keluaran udara tersier dari Cooler Roof

Udara
tersier
Udara
tengah

Udara
buang

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Keluaran udara tersier dari Kiln Hood

Ekstraksi udara tersier dari kiln hood

(Cerro Blanco Kiln 1)

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 Keluaran udara tersier dari Kiln Hood

Hon Chong plant (Kobe Steel)

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 D opout Ch a ber
Tipe Cyclon
dropout
chamber

Penambahan
debu pada
cooler

Design KHD

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Extracksi Debu dari “Elbow” Udara tersier

Macuspana plant, Mexico,

FLS ILC kalsiner
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 Duct Udara tersier

Tertiary air duct dengan debu klinker Hon Chong

Guillotine damper, Midlothian, KHD

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Damper Udara tersier
Tipe (Guillotine)
Hanya bagian
dari damper
yang terkena
Udara tersier

Honeycomb diisi
dengan konkret Damper setelahr 10 bulan operasi
System Polysius
dipasang di Lägerdorf (dua positions)

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 Damper Udara tersier (Throttle Disc)

duct Udara tersier vertikal menuju Diinstalasi di : Lägerdorf, Chekka,

chamber Pembakaran Gladstone, El Soukhna, Ulco
El Soukhna (ECC)

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Damper Udara tersier
(Desain Technip)

Sistem Technip
Untuk alasan kenyamanan, damper udara tersier
dipasang di bagian vertikal dari saluran udara tersier.
Bagian damper dilindungi oleh beton refraktori. Flaps
dalam baja cor tahan api dengan pengaku dan dilindungi
oleh lapisan baja cor tahan api.
As roda dari flaps yang berlubang dan didinginkan terus
menerus selama operasi oleh Blowing Fan.

Hon Chong

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 Variabel - variabel Kiln Orifice

Design FLSmidth

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Variabel Kiln Orifice

Desain FLSmidth

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Pembakaran dan Kalsinasi

Unit 3 dari 5
 Kalsinasi

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True and Apparent Calcination

PC PC

PH
PH

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Kehalusan Fuel yang disarankan
(Coal dan Petcoke)

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 Waktu tinggal (resident time) gas
yang disarankan untuk Burnout

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 “Hot Spot "untuk penyalaan Bahan
Bakar Reaktif Rendah

Pemisah meal

Lokasi
pengukuran
Temperature

pengontrolan
area
“Hot Spot“

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Pembentukan dan
Penguraian NOx

Unit 4 dari 5
Thermal NOx dan Fuel NOx

Operating
conditions and
nitrogen content in

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Lokasi pembentukan NOx pada PC Kiln

Fuel
NOx
Thermal
NOx

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 Volatilitas bahan bakar dan Reduksi
NOx pada kalsiner

Only reactive fuels

(e.g. lignite) react
so intensely at
start of
e.g. plastics, combustion that
brown coal, local reducing
e.g. petcoke, lignite
conditions occur
anthracite

Source: Menzel (Polysius), Bertschinger (JCF):

International Cement Review, June 1997, p.65ff

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Penambahan Bahan Bakar Bertahap
(Contoh Kobe DDF)

kalsiner
Burner

de NOx
Burner de NOx
Burner

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 Penambahan Bahan Bakar Bertahap
(Contoh KHD LowNOx)

Meal
DeNOx Zone
(Reduction Zone)

Main
Burner

Low NOx
Burner

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 Penambahan Udara Bertahap

Memperpendek
zona di kalsiner

Memperpendek
zona di kalsiner

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 Titik Injeksi untuk SNCR
(Contoh Lägerdorf)

Injection
levels

Tertiar
y Air

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Utilitasi AFR pada kalsiner

Unit 5 of 5
 Titik umpan AFR pada kalsiner

Hanya AFR cair dan halus

(TAD blockage)

Titik umpan

B1 AFR Burner
kalsiner
AFR cair dan padat
Titik umpan Meal
B2

Lump fuel,
ban utuh
(max 10%)
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Sistem Umpan ban (tire) secara umum
untuk Prekalsiner

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Penanganan keping ban (tire chip )
dan Ferrocarbon di LD

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 Suspensi Finger untuk ban (Devil’s
Slide)

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Suspensi Finger untuk ban (Devil’s Slide)

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Mendukung Tire Finger
(Cadence Environmental)

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 Hotdisc (F.L.Smidth)
Tertiary air
Inline Lump fuel
Scraper feed
kalsiner
removes ash
Inline
kalsiner

Controlled
meal inlet

Controlled
meal inlet
Exit of hot
gas and ash

Lump fuel and

tertiary air feed Kiln orifice

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Hotdisc (F.L.Smidth)

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 Instalasi Hotdisc di Kjopsvik, Norway

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 Fixed Bed Gasifier
(Polysius, Wildegg Plant )

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 Fixed Bed Gasifier (Polysius,
Wildegg plant)

Gas panas ke
kalsiner

Konsumsi
udara tersier

Reaktor
vessel

Ekstraksi
abu ke risser

Movable
bottom

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 CFB Gasifier
(Lurgi, Rüdersdorf Plant)

 Spesifikasi Gasifier
 Ø 3.5 x 23.5 m
2
 Luas area bawah : 2.3 m

 Kapasitas panas: 100 MW

 Temperatur operasi.: 950 - 1000 °C

 Tekanan Operasi : +120 mbar

 Nilai panas untuk gas panas: 3.7

MJ/Nm3
 Kecepatan umpan dengan MSW: 15 -
18 t/h
 Konsumsi energi El. : 1.6 kWh/t cli
3
 Input udara total : 34’000 Nm /h

 Biaya proyek : 35 Mio DEM

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 Tipe Gasifier Polysius
(Wildegg plant)

Sistem Kiln
 2’000 t/d kiln, 4 stage preheater dengan MSC prekalsiner

 Bahan bakae : batu bara , s: coal, whole tires, granulated plastics

Gasifier Polysius
 Bahan bakar : hanya ban utuh y

 Fixed bed gasifikasi

 3 t/h kecepatan umpan ,

40% thermal subst. (75% of PC

bahan bakar)
 Valve umpan rotari

 Vessel: Ø 2.7 x 3.5 m

 produk: 7’500 Nm3/h gas

1.5 t/h abu (coke & wire)
 Iinvestasi : 4 Mio USD incl.

Sistem penanganan bahan bakar

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 TERIMA KASIH

PT. Sarana Agra Gemilang People & Organization Development