WO2022090599A1 - Outil pour gérer l'incorporation efficace de combustibles alternatifs dans des usines de ciment - Google Patents

Outil pour gérer l'incorporation efficace de combustibles alternatifs dans des usines de ciment Download PDF

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Publication number
WO2022090599A1
WO2022090599A1 PCT/ES2021/070773 ES2021070773W WO2022090599A1 WO 2022090599 A1 WO2022090599 A1 WO 2022090599A1 ES 2021070773 W ES2021070773 W ES 2021070773W WO 2022090599 A1 WO2022090599 A1 WO 2022090599A1
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WIPO (PCT)
Prior art keywords
amount
volatile elements
fuel
plant
volatile
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PCT/ES2021/070773
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English (en)
Spanish (es)
Inventor
Luz Marina GALLEGO FERNÁNDEZ
Rocío GONZÁLEZ FALCÓN
Benito Navarrete Rubia
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Universidad De Sevilla
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Publication of WO2022090599A1 publication Critical patent/WO2022090599A1/fr

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    • 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
    • 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
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06N—COMPUTING ARRANGEMENTS BASED ON SPECIFIC COMPUTATIONAL MODELS
    • G06N3/00—Computing arrangements based on biological models
    • G06N3/02—Neural networks
    • G06N3/08—Learning methods

Definitions

  • the present invention relates to a method and system for predicting the operational risk associated with the entry and accumulation of volatile elements in a given internal volatile circuit in a cement plant.
  • the technical invention is developed in the area of knowledge of Chemical Engineering. Specifically, this invention can be included in the sector of the use of biomass or waste, since it allows evaluating the operation of a cement plant, when the amount of volatile elements that are introduced into the process is modified together with the waste or biomass incorporated as alternative fuels to the traditional fossil fuels used in this type of plant.
  • An object of the invention is a method to predict the type of enrichment in volatile elements (chlorine enrichment, sulfur enrichment, alkali enrichment) to which a cement plant would tend, when the amount of these elements varies in the process, for incorporate new alternative fuels, so that the method allows deciding whether or not to incorporate a new waste or biomass as a substitute for traditional fossil fuel, thus ensuring the stability of the operation.
  • Another object of the invention refers to a system for predicting the operational risk present in the production process, derived from the amount of volatile elements that remain in the volatile elements circuit of the plant. This risk is associated with the possible appearance of scale or sticking inside the process equipment, and even blockage and shutdown of the plant.
  • waste in cement plants is a common practice to reduce the consumption of fossil fuel in the daily operation of the plant, and to provide an effective and safe response to society in the treatment of waste.
  • degree of thermal substitution in Spanish cement plants from alternative fuels reached 26.6%, and despite being a relevant percentage and continuously growing, it is far from the European average (41%) and even from the percentage of substitution achieved by countries such as Germany, Holland, Sweden, Switzerland, Norway or Austria, with values above 60%.
  • Integrated Environmental Authorization establishes the acceptance specifications for new materials or fuels that can be used in the production process, either as raw material or as alternative fuels.
  • Said specifications refer to different physical, chemical and/or energy parameters associated with the new materials or fuels (waste and biomass) that are to be recovered (PCI, Cl, F, S, etc.), and to the maximum quantity allowed to be introduced in the process. Compliance with these specifications guarantees the preservation of the environment after the use of waste in this type of facility.
  • This type of plant is of great interest in finding a solution to the problem derived from the accumulation of volatile elements inside the system, in order to reduce the number of plant stoppages caused by the presence of scale and sticking in the system. inside the equipment, and, therefore, minimize the economic losses derived from the drop in the efficiency of the process and its level of production.
  • the invention relates to a method for predicting the type of enrichment to which a cement plant would tend when waste or biomass are incorporated as new fuels, and the operational risk associated with said action, derived from the appearance of encrustations, sticking or blockages of the system due to the accumulation of volatile elements in the internal volatile circuit given in this type of installation.
  • the method of the invention thus makes it possible to solve, predictively, the operational problems that may arise from the incorporation of a new alternative fuel in cement plants.
  • the method of the invention allows to previously know the effect that the incorporation of a new fuel can cause on the equipment and on the daily operation of the plant, reducing the economic and environmental impact that this problem causes in this type of installation.
  • the method of the invention also makes it possible to estimate the risk posed to a specific cement plant, to incorporate said new fuel into its production system or to replace part of its fossil fuel with another of a biomass nature.
  • the method of the invention comprises a stage of obtaining the amount and composition of raw materials introduced and fuels used in the cement plant, since the entry of volatile elements (NaO 2 , KO 2 , Cl, S) to the The process can be carried out through the raw material fed or the fuels used in the kiln to provide sufficient thermal energy to produce the cement clinker.
  • a parameter is obtained that indicates a desired degree of thermal substitution, that is, the quantity of new fuel that it is desired to include.
  • a model is generated that relates the amount of volatile elements predicted in the new operating situation, with the amount of volatile elements that remains circulating in the circuit of volatile elements of the cement plant, indicating the type of enrichment (sulfur, chlorine and/or alkalis) that would prevail in the plant, given the new recovery scenario.
  • the generated model has the form of a decision tree, which marks the enrichment trend of the plant when the composition of volatile elements is modified with the incorporation of the new fuel.
  • the model is developed using the CRISP-DM methodology and data mining techniques from which the data is analyzed, the model is generated and validated.
  • This model is based on the estimated amount of volatile elements and data previously obtained regarding the order of affinity of the volatile elements in the system, such as the Alkali-Sulfate Ratio and the Residual Alkali parameter, thus determining whether there is an enrichment of volatile elements of the sulfur, alkali or chlorine type in the circuit of volatile elements of the cement plant.
  • This calculation is carried out because, once the volatile elements have been introduced into the system, depending on the compounds formed, respecting the order of affinity of the volatile elements and depending on the quantities introduced, they can leave the volatile elements circuit. together with process gases, clinker, clinker dust or CKD, or be trapped in it.
  • the method can also include the stages of:
  • the relationship between the amount of sulfur oxide (SO 3 ) and chlorine (Cl) in the crude meal and the risk of plant failure is expressed by a tolerance graph of Cl vs. SO 3 in the Hot Meal or raw meal, which indicates the risk level of the appearance of operational problems (sticking, encrustations or blocks) that the plant would most likely tend to (Low level, medium level, high level) according to the type of enrichment given when the new fuel is introduced into the furnace.
  • the combination of the described model and the analysis of the amount of sulfur oxide (SO 3 ) and chlorine (Cl) in the crude meal allows estimating the level of risk in the plant. of forming sticking, encrustations and/or blockages of the system, when the modification of the mix of fuels used in the clinker furnace is considered.
  • the method of the invention allows a production manager to decide before acting, whether or not it is convenient to incorporate a new fuel into the original fuel mix, or what type of alternative fuel may be the most recommended based on its use.
  • composition to replace part of the fossil fuel used until then in the plant, reducing or improving the technical and environmental impact that this fact causes on the operation.
  • the invention also relates to a system for predicting the amount of volatile elements in a cement plant, comprising: a database, comprising data about the affinity order of the volatile elements; a processing unit, which calculates the amount of volatile elements present in the raw material and fuel, based on data on the amount and composition of the raw material and fuel, which can be obtained through a set of sensors placed in the plant of cement; a prediction unit, connected to the processing unit, which predicts the amount of volatile elements that would be in the raw material, the fuel and in the raw meal or Hot Meal, based on a parameter of the desired degree of thermal substitution and the composition and amount of new fuel introduced; and a unit for calculating volatile elements, connected to the database and to the prediction unit, and which obtains a measure of enrichment in volatile elements such as sulphur, alkalis or chlorine, by means of a model, preferably based on algorithms generated by means of the methodology CRISP-DM, which relates the number of volatile elements predicted by the prediction unit to the number of volatile elements remaining in a loop of
  • the system may also comprise a risk prediction unit, connected to the volatile elements calculation unit, and which obtains an estimate of the risk of plant malfunction based on the amount of sulfur oxide (SO 3 ) and chlorine (Cl) present in the raw meal (Hot Meal) and the amount of volatile elements that circulate through the volatile elements circuit of the plant.
  • a risk prediction unit connected to the volatile elements calculation unit, and which obtains an estimate of the risk of plant malfunction based on the amount of sulfur oxide (SO 3 ) and chlorine (Cl) present in the raw meal (Hot Meal) and the amount of volatile elements that circulate through the volatile elements circuit of the plant.
  • the system reflects the current situation of the plant in terms of the presence of volatile elements, through the processing unit; indicates how the operation would evolve when you want to incorporate a fuel or waste with a certain content of volatile elements in its matrix, through the prediction unit; and, depending on whether the addition of biomass or residue as fuel produces an increase or a decrease in the total volatile elements that would enter the system, it indicates the tendency that the installation would present to evolve towards enrichment in chlorine, enrichment in alkalis or an enrichment in sulfur, through the calculation unit of volatile elements.
  • the predictive analysis carried out by the system allows the decision to be made whether or not to incorporate a new fuel into the clinker kiln by increasing or not the degree of thermal substitution in this equipment, or knowing the quality that the fuel to be introduced in the kiln must have. process and, therefore, the conditioning needs of this new fuel. In this way, the operation would be prevented from moving to areas where the operational risk becomes evident, thus reducing unexpected plant stoppages, the reduction in production capacity or the drop in the quality of the manufactured product.
  • Figure 1 shows a preferred embodiment of the system for predicting the amount of volatile elements that circulate through a circuit of volatile elements of a cement plant of the invention.
  • Figure 2.- shows a preferred embodiment of the method for predicting the amount of volatile elements that circulate through a circuit of volatile elements of a cement plant of the invention.
  • Figure 3.- shows a decision tree model for predicting the type of enrichment in volatile elements in a cement plant according to a preferred embodiment of the invention.
  • Figure 4.- Shows an example of a graph of tolerance chlorine - sulfur oxide in raw flour or Hot Meal, according to a preferred embodiment of the invention.
  • Figure 5.- shows the evolution of the operation of the plant with the incorporation of a certain quantity of a new fuel to the clinker furnace, on the chlorine - sulfur oxide tolerance graph according to an example of implementation of the invention.
  • the present invention refers to a method and a system for predicting the type of enrichment in volatile elements given in a cement plant, when incorporating biomass or waste as fuel in the clinker oven, and the risk associated with said action in terms of the appearance of inefficiencies in the operation derived from the appearance of incrustations, sticking and blockages of the system.
  • the method of the invention makes use of a database (1) that contains the operating data history of a cement plant, recommended for at least 1 year, which includes the composition parameters in volatile elements (SO 3 , Cl, Na 2 O and K 2 O) of the raw material and the fuel used. These parameters are estimated (9) by the processing unit (2), previously obtaining (7) an amount and composition of raw materials introduced and fuels used in the cement plant, preferably by means of a set of sensors (6).
  • a decision tree model is generated (1 1), by means of a volatile element calculation unit (4), based on the definition of the following indicators: A/S ratio, residual alkalis, sulfur oxide, chlorine, alkalis, sulfur oxide in crude meal, chlorine in crude meal and alkalis in crude meal.
  • the CRISP-DM methodology is applied using data analysis software, and the decision tree model is obtained with an adjustment close to 90%.
  • Figure 3 shows an example of the decision tree model generated in a particular embodiment of the method of the invention, comprising 18 nodes, and node 0.
  • the input data is the amount of volatile elements that enter the system, sulfur oxide, chlorine, alkalis, represented in the lines that join the nodes, and the output data is the type of enrichment given in the plant in question.
  • function of the amount of volatile elements present that is, enrichment in sulfur; alkali enrichment; chlorine enrichment or normal operation, given at each node of the tree which in turn gives way to the nodes located below.
  • a low risk zone with a low percentage of chlorine and a low percentage of sulfur oxide, delimited by a continuous line
  • a medium risk zone with a medium percentage of chlorine and a medium percentage of sulfur oxide, delimited by the continuous line and a dashed line
  • a high risk zone with a high percentage of chlorine and a high percentage of sulfur oxide, delimited by the dashed line.
  • the amount of total volatiles present in the system and in the raw meal (Hot Meal, HM), both expressed based on clinker, in the current operating situation of the plant are shown in Table one .
  • Clinker 112000 1.10 0.01 0.74 0.07 1235.4 7.8 828.8 82.9 911.7
  • Figure 5 graphically shows the evolution of the plant operation in view of the addition of the new fuel, decreasing the amount of coke fed, which in this case would be recommended, by improving not only the environmental conditions (reduction of emissions) but also by improving the operational problems (scaling) that the plant has been suffering in its current mode of operation, since the displacement of the base case to the recovery scenario supposes a high reduction in the amount of sulfur oxide and a slight reduction in the amount of chlorine.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
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Abstract

L'invention concerne un procédé et un système pour la prédiction du type d'enrichissement d'éléments volatiles dans une usine de ciment à cause de la variation de la quantité d'éléments volatiles qui circulent dans un circuit d'éléments volatiles de l'installation, après l'ajout de biomasse ou de résidu comme combustible. Ledit procédé comprend les étapes consistant à : obtenir une quantité et la composition des matières premières et des combustibles utilisés ; établir un degré de substitution thermique souhaité ; estimer une mesure de la quantité d'éléments volatiles présents dans les matières premières et les combustibles ; prédire une mesure de la quantité d'éléments volatiles dans la matière première et le combustible lors de l'ajout de la biomasse ou du résidu ; et générer un modèle associant la quantité d'éléments volatiles prédite avec celle qui reste ; estimer la quantité d'oxyde de soufre et de chlore dans la farine crue et l'associer avec la quantité d'éléments volatiles restante, obtenant une estimation du risque de défaillance.
PCT/ES2021/070773 2020-10-26 2021-10-25 Outil pour gérer l'incorporation efficace de combustibles alternatifs dans des usines de ciment WO2022090599A1 (fr)

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ES202031069A ES2908114B2 (es) 2020-10-26 2020-10-26 Herramienta para gestionar la incorporacion eficiente de combustibles alternativos en plantas de cemento
ESP202031069 2020-10-26

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5707444A (en) * 1994-04-21 1998-01-13 F. L. Smidth & Co. A/S Method for controlling the temperature in a kiln
US6790034B1 (en) * 1999-11-04 2004-09-14 Pretoria Portland Cement Company Limited Kiln plant control system
EP1760418A1 (fr) * 2005-09-02 2007-03-07 ABB Research Ltd Method de modelisation pour un four a cement
WO2013179702A1 (fr) * 2012-05-30 2013-12-05 太平洋セメント株式会社 Méthode permettant de prédire la qualité ou la condition de fabrication du ciment
JP2017178651A (ja) * 2016-03-29 2017-10-05 太平洋セメント株式会社 セメントクリンカーの製造条件の予測方法

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012086754A1 (fr) * 2010-12-24 2012-06-28 太平洋セメント株式会社 Procédé de mesure de l'état de la qualité/de la fabrication du ciment

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5707444A (en) * 1994-04-21 1998-01-13 F. L. Smidth & Co. A/S Method for controlling the temperature in a kiln
US6790034B1 (en) * 1999-11-04 2004-09-14 Pretoria Portland Cement Company Limited Kiln plant control system
EP1760418A1 (fr) * 2005-09-02 2007-03-07 ABB Research Ltd Method de modelisation pour un four a cement
WO2013179702A1 (fr) * 2012-05-30 2013-12-05 太平洋セメント株式会社 Méthode permettant de prédire la qualité ou la condition de fabrication du ciment
JP2017178651A (ja) * 2016-03-29 2017-10-05 太平洋セメント株式会社 セメントクリンカーの製造条件の予測方法

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
GABRIEL DULCE; MATIAS TIAGO; PEREIRA J. COSTA; ARAUJO RUI: "Predicting gas emissions in a cement kiln plant using hard and soft modeling strategies", 2013 IEEE 18TH CONFERENCE ON EMERGING TECHNOLOGIES & FACTORY AUTOMATION (ETFA), IEEE, 10 September 2013 (2013-09-10), pages 1 - 8, XP032517051, ISSN: 1946-0740, DOI: 10.1109/ETFA.2013.6648036 *
KADDATZ K.T.; RASUL M.G.; RAHMAN AZAD: "Alternative Fuels for use in Cement Kilns: Process Impact Modelling", PROCEDIA ENGINEERING, ELSEVIER BV, NL, vol. 56, 7 May 2013 (2013-05-07), NL , pages 413 - 420, XP028534671, ISSN: 1877-7058, DOI: 10.1016/j.proeng.2013.03.141 *

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ES2908114B2 (es) 2022-12-02

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