DK202300087A1 - Method for controlling chemical clinker quality in a cement factory using alternative fuels - Google Patents
Method for controlling chemical clinker quality in a cement factory using alternative fuels Download PDFInfo
- Publication number
- DK202300087A1 DK202300087A1 DKPA202300087A DKPA202300087A DK202300087A1 DK 202300087 A1 DK202300087 A1 DK 202300087A1 DK PA202300087 A DKPA202300087 A DK PA202300087A DK PA202300087 A DKPA202300087 A DK PA202300087A DK 202300087 A1 DK202300087 A1 DK 202300087A1
- Authority
- DK
- Denmark
- Prior art keywords
- fuel
- alternative fuel
- clinker
- chemical
- kiln
- Prior art date
Links
- 239000000446 fuel Substances 0.000 title claims abstract description 68
- 238000000034 method Methods 0.000 title claims abstract description 46
- 239000000126 substance Substances 0.000 title claims abstract description 45
- 239000004568 cement Substances 0.000 title claims abstract description 19
- 235000012054 meals Nutrition 0.000 claims abstract description 19
- 238000011545 laboratory measurement Methods 0.000 claims abstract description 4
- 238000004458 analytical method Methods 0.000 claims description 8
- 235000008733 Citrus aurantifolia Nutrition 0.000 claims description 7
- 235000011941 Tilia x europaea Nutrition 0.000 claims description 7
- 239000004571 lime Substances 0.000 claims description 7
- 239000000463 material Substances 0.000 claims description 7
- 229910052710 silicon Inorganic materials 0.000 claims description 4
- 239000010703 silicon Substances 0.000 claims description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 239000002994 raw material Substances 0.000 claims description 3
- 238000005070 sampling Methods 0.000 claims description 3
- 239000002956 ash Substances 0.000 description 16
- 230000001276 controlling effect Effects 0.000 description 6
- 239000000523 sample Substances 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 235000002918 Fraxinus excelsior Nutrition 0.000 description 2
- 238000009529 body temperature measurement Methods 0.000 description 2
- 239000012467 final product Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000004886 process control Methods 0.000 description 2
- 238000003908 quality control method Methods 0.000 description 2
- 230000002411 adverse Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 230000002596 correlated effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B7/00—Hydraulic cements
- C04B7/36—Manufacture of hydraulic cements in general
- C04B7/361—Condition or time responsive control in hydraulic cement manufacturing processes
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B7/00—Hydraulic cements
- C04B7/36—Manufacture of hydraulic cements in general
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/20—Measuring; Control or regulation
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B7/00—Hydraulic cements
- C04B7/36—Manufacture of hydraulic cements in general
- C04B7/43—Heat treatment, e.g. precalcining, burning, melting; Cooling
- C04B7/44—Burning; Melting
- C04B7/4407—Treatment or selection of the fuel therefor, e.g. use of hazardous waste as secondary fuel ; Use of particular energy sources, e.g. waste hot gases from other processes
- C04B7/4423—Waste or refuse used as fuel
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F1/00—Measuring the volume flow or mass flow of fluid or fluent solid material wherein the fluid passes through a meter in a continuous flow
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
- G01N33/38—Concrete; Lime; Mortar; Gypsum; Bricks; Ceramics; Glass
- G01N33/383—Concrete or cement
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F17/00—Digital computing or data processing equipment or methods, specially adapted for specific functions
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Physics & Mathematics (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- General Physics & Mathematics (AREA)
- Life Sciences & Earth Sciences (AREA)
- Health & Medical Sciences (AREA)
- General Engineering & Computer Science (AREA)
- Theoretical Computer Science (AREA)
- Mathematical Physics (AREA)
- Food Science & Technology (AREA)
- Data Mining & Analysis (AREA)
- Software Systems (AREA)
- Fluid Mechanics (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Databases & Information Systems (AREA)
- Medicinal Chemistry (AREA)
- Analytical Chemistry (AREA)
- Biochemistry (AREA)
- General Health & Medical Sciences (AREA)
- Immunology (AREA)
- Pathology (AREA)
- Thermal Sciences (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
The invention relates to a method for controlling a chemical clinker quality in a cement factory, said method comprises the steps of measuring a temperature in a calciner and preheating tower and kiln; measuring and recording flow rates of raw meal, primary fuel and alternative fuel in said preheating tower, calciner and kiln; utilizing said recorded flow rates of raw meal, primary fuel and alternative fuel to estimate an alternative fuel’s calorific value; utilizing said calorific value of alternative fuel to estimate chemical characteristics of said alternative fuel’s ash, said estimation of chemical characteristics being based on a priori laboratory measurements and a model describing a correlation between said alternative fuel’s calorific value and said alternatives fuel’s ash content and ash composition Calculating a new ratio between a raw meal feed and said primary and alternative fuel feeds such that a chemical clinker quality target is obtained while maintaining a calorie feed to said calciner and to said kiln.
Description
DK 2023 00087 A1 1
METHOD FOR CONTROLLING CHEMICAL CLINKER QUALITY IN A
CEMENT FACTORY USING ALTERNATIVE FUELS
This invention relates to an apparatus and method for controlling a chemical clinker quality in a cement factory.
Alternative fuels are being used in an increasing degree in most cement plants.
The ashes from the alternative fuels end up in the product - the clinker - and the ashes have an adverse effect on the constancy of the chemical composition of the clinker, and consequently also the cement's quality. Furthermore, the inconsistency of the clinker induces higher fuel consumption and could cause problems in the kiln operation. The inconsistency of the clinker increases the number of operations needed to obtain the desired quality. — State of the art standard quality control has a buffer of 2 hours’ delay between the mixing of the input materials and chemical quality results from the laboratory analysis. This is thus not a sustainable solution for the use of alternative fuel as the calorific value is too unstable. — In order to mitigate the above-mentioned problems, it is desired to stabilize the clinker's chemical composition, the chemical quality control, and the control of the feeding of fuels (feeding calories) must be integrated. So far, the two objectives have been separated.
DK 2023 00087 A1 2
It is an object of the present invention to overcome or at least alleviate one or more of the above problems of the prior art and/or provide the consumer with a useful or commercial choice. lt is an object of the present invention to provide a method for controlling a chemical clinker quality in a cement factory.
It is an object of the present invention to provide an apparatus for controlling a chemical clinker quality in a cement factory.
It is a further object of the present invention to provide an alternative to the prior art
In a first aspect, the invention relates to a method for controlling a chemical clinker quality in a cement factory, the method comprises the steps of - measuring a temperature in a calciner and preheating tower and kiln - Measuring and recording flow rates of raw meal, primary fuel and alternative fuel in said preheating tower, calciner and kiln - Utilizing said recorded flow rates of raw meal, primary fuel and alternative fuel to estimate an alternative fuel’s calorific value - Utilizing said calorific value of alternative fuel to estimate chemical characteristics of said alternative fuel's ash, said estimation of chemical characteristics being based on a priori laboratory measurements and a model describing a correlation between said alternative fuel’s calorific value and said alternatives fuel's ash content and ash composition
DK 2023 00087 A1 3 - Calculating a new ratio between a raw meal feed and said primary and alternative fuel feeds such that a chemical clinker quality target is obtained while maintaining a calorie feed to said calciner and to said
Kiln.
The advantage of this setup is that it will result in more consistent clinker properties, allowing for higher primary fuel substitution (use additional alternative fuels), reduce fuel consumption and optimized kiln processes. It also contributes to the extension of the lifetime of the kiln lining and increases the strength of the final product, reduces the effort needed to deliver a final product to the desired quality.
The method according to the present invention is easy to deploy on standard cement plants as the signal’s inputs are standard to the state of the art (commons sensors).
The method will also allow a low-quality alternative fuel (big variation in calorific value) to be used in larger portion. — The method may further comprise the step of measuring and recording flow rates of ash percentage in said clinker, Lime Saturation Factor of the clinker and the raw meal, calorific value of the primary fuel and alternative fuel of all inputted fuels and raw materials, temperatures at said calciner, pre-heating tower and kiln, ash content of other materials added in the process.
The chemical characteristics is Lime Saturation Factor and/or ash percentage and/or carbon content.
In another embodiment of the present invention, the chemical characteristics is silicon module.
DK 2023 00087 A1 4
In another embodiment of the present invention, the chemical characteristics is alumina module.
The method may further comprise the step of sampling hot clinker at the kiln outlet. This method will provide chemical clinker data with a shorter delay compared with the method in which clinker are being sampled after the clinker cooler. The shorter delay makes it possible to achieve a more precise control of the clinker chemical quality.
The result from the hot clinker will be used to get an earlier update of the parameters of the control algorithm.
In as second aspect, the invention relates to an apparatus utilizing the method according to any of the above-mentioned embodiments.
The apparatus preferably comprises a number of temperature measurements probes, mass flow measurements and dosing of alternative and primary fuels to the kiln and calciner. All above-mentioned devices are connected to a computer — with a control software.
The apparatus is preferably a computing device. The computing device is preferably configured for receiving inputting digital signals from sensors and analysis, configured for making mathematical operations with the signals and for outputting digital signals that adjust raw meal and fuel feeds to the plant process.
The apparatus may be used to control a chemical clinker quality in cement material. — Ina third aspect, the invention relates to a cement factory, comprising the apparatus according to the second aspect of the invention.
DK 2023 00087 A1
The first, second and third aspects of the present invention may be combined.
In the present context, a number of terms are used in a manner being ordinary to the skilled person. Some of these terms are detailed below:
Lime Saturation Factor (LSF), Silicon module (SIM) and Alumina module (ALM) 5 are preferably used to mean/denote the chemical composition of clinker.
SIM = Si/ (Al + Fe) are preferably used to mean/denote oxides. Typical targets for SIM: SIM = 2.4
ALM = (Al / Fe) (short for oxides). Typical targets for ALM: ALM = 1.4
LSF = 100% Ca/ (2.8 "Si + 1.18 " Al + 0.65 * Fe). Typical target for LSF being = 97
Chemical clinker quality is preferably used to mean/denote the chemical composition in regard to the target defined according to the standard defined in the industry.
The figure shows one way of implementing the present invention and is not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set.
Embodiments of the invention, by way of example only, will be described with reference to the accompanying figure in which:
Figure 1 schematically illustrates the method according to the present invention.
DK 2023 00087 A1 6
In a first aspect, the invention relates to a method for controlling a chemical clinker quality in a cement factory. The method comprises the steps of - measuring a temperature in a calciner and preheating tower and kiln - Measuring and recording flow rates of raw meal, primary fuel and alternative fuel in the preheating tower, calciner and kiln - Utilizing the recorded flow rates of raw meal, primary fuel, alternative fuel and data from the laboratory analysis to estimate an alternative fuel's calorific value - Utilizing the calorific value of alternative fuel to estimate chemical characteristics of the alternative fuel's ash, the estimation of chemical characteristics being based on a priori laboratory measurements and a model describing a correlation between the alternative fuel's calorific value and the alternatives fuel's ash content and ash composition - Calculating a new ratio between a raw meal feed and the primary and alternative fuel feeds such that a chemical clinker quality target is obtained while maintaining a calorie feed to the calciner and to said
Kiln.
The data is received from laboratory analysis.
The update is performed by the algorithm on a set frequency correlated by the frequency update of all the external inputs from the process. Once the new calculation is available, it is transferred to the user who can choose to manually update the process with this data or let the algorithm automatically feed the updated values to the master software which automatically adjusts the — parameters of the process.
DK 2023 00087 A1 7
The algorithm returns an estimation of the calorific values of the fuels and their ash percentage, it also returns adjustment recommendation to the process parameters (fuel's feed, raw meal feed) to meet the target chosen. The primary target of the method according to the present invention, is to use as much alternative fuel as possible in respect of the chemical clinker quality, but it can also be used to reduce the standard deviation in the chemical clinker quality around a set value.
The algorithm is a retroactive loop and adjusts the parameters.
Figure 1 schematically illustrates the method according to the present invention.
The steps according to the method are schematically illustrated with segments (1-5) in figure 1: e 1. Collect data from the sensors (cement production plant) e 2. Quality sample analysis (system to collect and prepare sample of clinker) e 3. Collect data from the quality measures (laboratory analysis of clinker) e 4. Calculate the estimated outputs: processing/computing device o calorific value, o ash percentage, o LSF, SIM, ALM, e 5. Outputs are sent to the plant process control system or operator. e 6. The operator manually, or the plant process control system automatically, adjusts the parameters of the process.
In a preferred embodiment of the present invention, the method further comprises the step of measuring and recording flow rates of ash percentage in the process,
Lime Saturation Factor (or other modules) of the clinker and the raw meal, calorific value of the primary fuel and alternative fuel of all inputted fuels and raw materials, temperatures at the calciner, pre-heating tower and kiln, ash content of other materials added in the process.
DK 2023 00087 A1 8
The chemical characteristics is Lime Saturation Factor and/or ash percentage and/or carbon content.
In another embodiment of the present invention, the chemical characteristics is — silicon module.
In another embodiment of the present invention, the chemical characteristics is alumina module.
Ina preferred embodiment of the present invention, the method further comprises the step of sampling hot clinker at the kiln outlet. This method will provide chemical clinker data with a shorter delay compared with the method in which clinker are being sampled after the clinker cooler. The shorter delay makes it possible to achieve a more precise control of the clinker chemical quality.
The method according to any of the above-mentioned embodiments may be utilized by an apparatus. The apparatus comprises a number of temperature measurement probes attached to the calciner, mass flow measurements and dosing of alternative and primary fuels and kiln feed dosing and meter — equipment. All above-mentioned devices are connected to a computer with control software.
The apparatus according to the present invention, is a computing device configured for receiving inputting digital signals from sensors and analysis and configured for making mathematical operations with the signals and for outputting digital signals that adjust raw meal and fuel feeds to the plant process.
The apparatus is used to control a chemical clinker quality in cement material.
The apparatus may be installed as a part of a cement factory.
Although the present invention has been described in connection with the specified embodiments, it should not be construed as being in any way limited to the presented examples. It should also be understood that the form of this
DK 2023 00087 A1 9 invention as shown is merely a preferred embodiment.
Various changes may be made in the function and arrangement of parts; equivalent means may be substituted for those illustrated and described; and certain features may be used independently from others without departing from the spirit and scope of the invention as defined in the following claims.
Claims (1)
- DK 2023 00087 A1 10 CLAIMS 1: A method for controlling a chemical clinker quality in a cement factory, said method comprises the steps of - measuring a temperature in a calciner and preheating tower and kiln - Measuring and recording flow rates of raw meal, primary fuel and alternative fuel in said preheating tower, calciner and kiln - Utilizing said recorded flow rates of raw meal, primary fuel and alternative fuel to estimate an alternative fuel’s calorific value - Utilizing said calorific value of alternative fuel to estimate chemical characteristics of said alternative fuel’s ash, said estimation of chemical characteristics being based on a priori laboratory measurements and a model describing a correlation between said alternative fuel’s calorific value and said alternatives fuel's ash content and ash composition - Calculating a new ratio between a raw meal feed and said primary and alternative fuel feeds such that a chemical clinker quality target is obtained while maintaining a calorie feed to said calciner and to said Kiln.2: A method according to claim 1, further comprising the step of measuring and recording flow rates of ash percentage in said clinker, Lime Saturation Factor of the clinker and the raw meal, calorific value of the primary fuel and alternative fuel of all inputted fuels and raw materials, temperatures at said calciner, pre- heating tower and kiln, ash content of other materials added in the process. 3: A method according to claim 1 or 2, wherein said chemical characteristics is Lime Saturation Factor and/or ash percentage and/or carbon content.DK 2023 00087 A1 11 4: A method according to any of the preceding claims, wherein said chemical characteristics is silicon module. 5: A method according to any of the preceding claims, further comprising the step of sampling hot clinker at the kiln outlet.6: An apparatus utilizing the method according to any of the claims 1-5, said apparatus comprises a computing device, said computing device configured for receiving inputting digital signals from sensors and analysis, configured for making mathematical operations with said signals and for outputting digital signals that adjust raw meal and fuel feeds to a plant process. 7: An apparatus according to claim 6, for use to controlling a chemical clinker quality in cement material.8: A cement factory, comprising the apparatus according to claim 6 or 7.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DKPA202300087A DK181553B1 (en) | 2023-02-01 | 2023-02-01 | Method for controlling chemical clinker quality in a cement factory using alternative fuels |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DKPA202300087A DK181553B1 (en) | 2023-02-01 | 2023-02-01 | Method for controlling chemical clinker quality in a cement factory using alternative fuels |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| DK202300087A1 true DK202300087A1 (en) | 2024-05-14 |
| DK181553B1 DK181553B1 (en) | 2024-05-14 |
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ID=89845272
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| DKPA202300087A DK181553B1 (en) | 2023-02-01 | 2023-02-01 | Method for controlling chemical clinker quality in a cement factory using alternative fuels |
Country Status (1)
| Country | Link |
|---|---|
| DK (1) | DK181553B1 (en) |
-
2023
- 2023-02-01 DK DKPA202300087A patent/DK181553B1/en active IP Right Grant
Also Published As
| Publication number | Publication date |
|---|---|
| DK181553B1 (en) | 2024-05-14 |
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