Proposal for Relocation of Kiln Inlet Gas Sampling Point and Probe

8/16/2019 Proposal for Relocation of Kiln Inlet Gas Sampling Point and Probe

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BESTWAY CEMENT LIMITED CHAKWAL

Proposal For Relocation of Kiln Inlet Gas

sampling Point and Analyzer Probe

Production/Optimization Team 15-Mar-16


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Table of ContentsSummary ....................................................................................................................................................... 2

1-Gas analysis at Kiln Inlet for Process Optimization .................................................................................... 3

2- Selection of sample point for Gas Analyzer Probe ................................................................................... 3

3- Location of Gas Analyzer Probe at Kiln Inlet ............................................................................................. 3

3.1- Standard location of Gas sampling probe at Kiln Inlet ...................................................................... 3

3.2- Sampling Point Probe installation (By ITECA) .................................................................................... 4

4- Location of Gas sampling probe at Kiln Inlet of BCL Chakwal .................................................................. 5

5- New Proposed Installed position of Inlet Gas Analyzer ............................................................................ 5

6- Comparison with Technical Sister Plants .................................................................................................. 6

6.1 Inlet Gas Analyzer Probe location at Kohat Cement (Technically sister Plant) ................................... 6

6.2- Gharibwal Cement (Position of Kiln inlet Analyzer Probe) ................................................................ 7

7- Recommendation: .................................................................................................................................... 7

References .................................................................................................................................................... 7

Figure 1 : Standard location for Kiln inlet Analyzer ...................................................................................... 3

Figure 2 Sample point Probe Installation ...................................................................................................... 4

Figure: 3 Design for Optimum Probe Location ............................................................................................. 4

Figure 4 Location of Inlet Gas Analyzer Probe at BCL Chakwal .................................................................... 5

Figure 5 Proposed new location for Gas sampling ....................................................................................... 5

Figure 6 Comparison between KOHAT cement and BCL Chakwal ................................................................ 6

Figure 7 New Location and proposed shifting of Probe ............................................................................... 7

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Summary

Kiln inlet is the best spot for gas analysis for better process monitoring. An accurate

monitoring of process gasses at kiln inlet is of prime importance for optimized operation.

For better analysis of gas the probe of gas analyzer should be installed at correct location,

close to kiln seal on the side where the kiln wall is turning downwards (0-400mm in front

of the seal and up to 200 mm beyond the seal).

Chakwal Inlet analyzer position is not as per standard. The probe is located inside kiln

inlet chamber wall towards the side of kiln moving downwards.

Probe blockage is also a chronic issue being faced. This issue is because of installation of

probe inside kiln inlet Chamber. Dust content inside kiln inlet chamber is on higher side.

This was highlighted by Mr. Anis Haider (ITECA expert) and Mr. Sajjad Ullah (Team

Leader Optimization Pakcem).

World wide references are available for installation of Gas analyzer probe inside beyond

Kiln Inlet seal. (FLS +ITECA)

Comparison between technically sister plants KOHAT Cement and GHARIBWAL

cement have installation of gas analyzer probe inside kiln inlet.

At BCL Chakwal since feed enters from both side (A & B) feed pipes into Kiln inlet. Due

to this design the probe location as per standard becomes critical.

Relocation of Probe sampling point at Kiln inlet is possible. This provides an opportunity

for plant optimization listed as under

1.

Accurate analysis at kiln inlet.

2.

Reducing the false air effect from Kiln inlet Seal.

3.

Optimizing fuel consumption.

4.

Optimizing power consumption

5.

Reduce probe blockage.

6.

More availability of Inlet gas Analyzer.


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1-Gas analysis at Kiln Inlet for Process OptimizationKiln inlet is the best spot for gas analysis for better process monitoring. An accurate monitoring of

process gasses at kiln inlet will have following Key benefits

Optimized fuel consumption

Optimize quality

Stable and safe kiln operation

Kiln stop prevention

Emission reduction

2- Selection of sample point for Gas Analyzer Probe

The sampling point for gas has to be taken in respect to following points

Representative air

No influence of false air

Mechanical impact of material fall through

Risk of material build up

Dust impact

Condensation from volatiles

(FLSmidth, 2014) (Drawing Office Manual, 2008)

3- Location of Gas Analyzer Probe at Kiln Inlet

3.1- Standard location of Gas sampling probe at Kiln Inlet

The probe of gas analyzer should be installed at correct location, close to kiln seal on the side where the

kiln wall is turning downwards (0-400mm in front of the seal and up to 200 mm beyond the seal). The

probe head should be 200~400mm away from brick layer of rotary kiln. Sketch shows standard location

of gas Analyzer

Figure 1 : Standard location for Kiln inlet Analyzer


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3.2- Sampling Point Probe installation (By ITECA)

The probe is installed so that its tip is beyond kiln inlet seal to avoid influence of inlet seal false air.

(Anis Haider ITECA)

Figure 2 Sample point Probe Installation

3.3- Design for Optimum probe location (Anis Haider ITECA)

Figure: 3 Design for Optimum Probe Location


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4- Location of Gas sampling probe at Kiln Inlet of BCL Chakwal

Chakwal Inlet analyzer position is not as per standard. The probe is located inside kiln inletchamber wall towards the side of kiln moving downwards. (Pictures attached of position of gas

sampling probe at Kiln line # 2)

Ideally analyzer should take sample from inside the kiln to avoid false air impact of Kiln Inlet

seal. Moreover probe blockage is also a chronic issue being faced at due to high dust load inside

kiln inlet.

This was highlighted by Mr. Anis Haider (ITECA expert) and Mr. Sajjad Ullah (Team Leader

Optimization Pakcem).

5- New Proposed Installed position of Inlet Gas Analyzer

Figure 5 Proposed new location for Gas sampling

Figure 4 Location of Inlet Gas Analyzer Probe at BCL Chakwal


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6- Comparison with Technical Sister Plants

At BCL Farooqia and Pakcem the angle of installed Gas analyzer probe is similar. At both plantsfeed is entering at kiln inlet from one side.

At BCL Chakwal since feed enters from both side (A & B) feed pipes into Kiln inlet. Due to thisdesign the probe location as per standard becomes critical. To understand the possibilities

comparison is drawn from position of inlet Gas analyzer at technically sister plants.

6.1 Inlet Gas Analyzer Probe location at Kohat Cement (Technically sister Plant)

Figure 6 Comparison between KOHAT cement and BCL Chakwal

Kohat Cement is technically sister plant with same design of Kiln inlet and feed pipes. Figure

compares the analyzer position and design of KOHAT Cement and BCL Chakwal.

Inlet Gas Analyzer Probe at KOHAT CEMENT Inlet design at BCL Chakwal (Similar to KOHAT

Cement)

nlet Gas Analyzer Position


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6.2- Gharibwal Cement (Position of Kiln inlet

Analyzer Probe)

Figure shows installation of probe at Gharibwal cement.

7- Recommendation:Relocation of Probe sampling point at Kiln inlet is possible. This

provides an opportunity for plant optimization. Relocation of gas

analyzer will have following key benefits.

1.

Accurate analysis at kiln inlet.

2.

Reducing the false air effect from Kiln inlet Seal.

3.

Optimizing fuel consumption.

4.

Optimizing power consumption

5.

Reduce probe blockage. (As at present probe blockage is due to its installation at high dust zone)

6.

More available of Inlet gas Analyzer.

Figure 8 New Location and proposed shifting of Probe

References

Anis Haider ITECA. (n.d.). Presentation on Inlet Gas Analyzer.

FLSmidth. (2014). Kiln Inlet Analyzer Presentation .

Office, G. A. (2008). Kohat and Gharibwal Cement

Plate form has to be shifted down

for relocation of Inlet analyzer

Probe

roposed New Location

Figure 7 Kiln Inlet sampling point and

probe location

Proposal for Relocation of Kiln Inlet Gas Sampling Point and Probe

Documents

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