2017-TCMA 18th Technical Workshop and Exhibition

18tThechnical

Workshop
and

Exhibition

Thai Cement Manufacturers Association

The 18th TCMA Technical Workshop and Exhibition

Venue: The Greenery Resort, Khao Yai

CONTENTS Page
2
❖ Programme 3
❖ Floor Plan 4
❖ Appreciations
❖ Technical Workshop 5-99

Technical Paper Presentation 100-103
104-107
Innovative Design 108-110
➢ Technical Paper on PREPOL-SC: One Small Step for

Precalciners but a Giant Leap for Combustion
➢ Technical Paper on Energy Saving of Fan

Green Solutions
➢ Technical Paper on Think Green with AUMUND:

Environmental Friendly Solutions – Save Material and Energy

➢ Technical Paper on Automatic Energy Management for
Electrostatic Precipitator

➢ Technical Paper on Innovative Technology for NOx and
Co- Reduction in the Cement Industry

Grinding Technology
➢ Technical Paper on Ball Mill Optimization Using Smartest

Fill – Level Control

➢ Technical Paper on Energy Saving Grinding Systems with
Roller Press

➢ Technical Paper on MAAGTM CEM Drive – Vertical Roller Mill
Drive System

❖ Exhibition
➢ List of Exhibitors

❖ Lists of Participants
❖ About TCMA Technical Workshop and Exhibition

➢ TCMA and Members
➢ TCMA Technical Workshop and Exhibition
➢ Acknowledgement

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The 18th TCMA Technical Workshop and Exhibition

Venue: The Greenery Resort, Khao Yai

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The 18th TCMA Technical Workshop and Exhibition

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❖ Floor Plan

Registration will be on the 1st floor.
Workshop and Exhibition will be on the 2nd floor.

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The 18th TCMA Technical Workshop and Exhibition

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❖ Appreciations

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❖ Technical Workshop

Summary of Technical Paper Presentations Mr. Arumugam Thyssenkrupp Industrial
Vijayanarayanan Solutions
Innovative Design
PREPOL-SC: One Small Step for Precalciners Mr. Takaaki Nakamura Ebara Fan & Blower
but a Giant Leap for Combustion Co.,Ltd. (Japan)

Energy saving of fan

Green Solutions Mr. Dionisios Lappas AUMUND (H.K.) Ltd.

Think Green with AUMUND: Environmental
Friendly Solutions : Save Material and Energy

Automatic Energy Management for Mr. Supakint FLSmidth (Thailand)
Electrostatic Precipitator Suteepichatpunt Co.,Ltd.

Innovative technologies for NOx and co- Mr. Andreas Scheuch GmbH
reduction in the cement industry Renetzeder

Grinding Technology Mr. Dirk Schmidt KIMA Echtzeitsysteme
GmbH
Ball Mill Optimization Using Smartest Fill – Level
Control KHD Humboldt
Wedag GmbH
Energy Saving Grinding Systems with Roller Mr. Hans - Peter
Press Jeschinowski FLSmidth MAAGTM
Gear AG
MAAGTM CEM Drive – Vertical Roller Mill Drive Mr. Sujith Varghese

System George

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The 18th TCMA Technical Workshop and Exhibition

Venue: The Greenery Resort, Khao Yai

Technical Paper: PREPOL® - sc - One Small Step for
Precalciners but a Giant Leap for
Combustion

Mr. Arumugam Vijayanarayanan
Thyssenkrupp Industrial Solutions

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The PREPOL®-SC is an add-on for the PREPOL® precalciner. On this simple combustion grate,
waste can burn for more than 1,000 seconds at high temperatures. Compared to ordinary
calciner technology with only up to 7 seconds residence time the PREPOL®-SC opens a new
dimension in combustion. New sorts of wastes can be utilized resulting in a new level of fuel-cost
savings. The step-shaped grate can be connected to any kind of precalciner loop and is nothing
more than a tube-like extension: small in size but with huge potential in terms of combustion!

Especially for existing plants that face operation problems when burning waste-derived fuels due
to short calciner loops originally sized for the combustion of solid fuels, this huge extension of time
can be reached with minimum effort. Compared to an extension of the calciner loop, the SC
offers residence time in a significant smaller volume. This is possible as the fuel lies on the grate
instead of following the gas stream in the loop. The small volume and the resulting lower weight
of the combustion chamber mean that less civil-construction reinforcement is required.

The refractory steps of the grate are equipped with air nozzles. These are connected to air-pulse
cannons. The air pulses swirl the fuel up and progressively convey it along the grate. Moreover,
the swirling-up constantly turns over the fuel and assists the combustion process, ensuring that a
very high throughput rate is achieved per unit area of grate. A further advantage is that the light,
already-converted char of the fuel particles is quickly blown out of the combustor and entrained
in the suspension gas stream of the calciner, while the heavier particles remain on the grate for
further thermal processing. The fuel transformation is thus positively assisted by the active fuel
conveyance system throughout the entire fuel retention time.

With standard precalciner equipment, processed refuse-derived secondary fuels can only be
used successfully if the waste has passed through a multistage mechanical processing plant. The
secondary fuel has to be in such small pieces that it can be entrained in the gas stream and
totally burns out within a retention time of approx. 5 seconds in the calciner. This demands an
edge length of about 50 –100 mm. In order to meet this requirement, multistage mechanical
processing is needed.

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The 18th TCMA Technical Workshop and Exhibition

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Using the advanced PREPOL®-SC technology, heavy waste fuels can be used that are non-
flyable and that have an edge length of up to 300 mm. Waste preparation is only needed in
order to adjust the heating value and to control contaminations, inert constituants and harmful
substances. Instead of multiple shredding and sorting steps in fuel preparation, the fuel is treated
on the multiple steps of the combustion grate.

In order to ensure the best combustion performance, the step combustor is equipped with a
sophisticated feeding system. The material is fed in by two screw conveyors which push the fuel
onto the first step of the grate without projecting into the combustion chamber themselves. The
cold fuel protects the conveyors from direct contact with the fire. The first step of the combustion
grate is the platform-like ignition table, on which the incoming fuel piles up. The heap of fuel acts
as a seal against false air prevents hot gas from flowing back into the screw conveyors and
protects the feeding screws against overheating. The fuel remains on the ignition table for a few
minutes and is slowly dried, pyrolysed and ignited by contact with the tertiary air. The heap of
fuel buffers variations in feed rate and chemical properties.

If space in the preheater is limited, it is worth thinking about the short version of the step
combustor, the so-called PREPOL®-SC-S. In this version, the combustor only consists of the first
three steps of the grate together with the screw feeding system. The retention time is small
compared to the PREPOL®-SC but big compared to ordinary calciner loops, about 150-300
seconds can be achieved; enough time to dry and devolatize the fuel. The grate becomes so
short that the fuel enters close to the calciner duct. Hence it is not necessary to connect tertiary
air and hot meal – the flow turbulence alone delivers the required air-meal mixture to the grate.
This makes retrofitting of the system even easier.

SAFE:
The thermal process always takes place in an air excess of at least 30 %. It is therefore impossible
for dangerous carbonization gases such as CO, H2 and CxH0 to form.
Forced feeding of the fuel seals the system off from the environment. In an overpressure situation
(e.g. failure of the system fans), ignition of the fuel in the conveyors can be prevented. During a
stoppage, the combustor is completely isolated from the conveyors by pneumatically-operated
airlock slide valves.

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The 18th TCMA Technical Workshop and Exhibition

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EFFECTIVE:
The use of air cannons ensures that the fuel actively transported and turned over. Every air blast
brings the fuel into contact with fresh oxygen, and every agitation separates the smaller
particles, so that only the large fuel particle fraction remains on the step grate.
The PREPOL-SC thus operates extremely effectively, as the fuel is only processed as far as
necessary until it can enter the calciner as gas-stream-entrainable char. Related to the low space
requirement of the combustor, very large quantities of fuel can thus be processed effectively.

SIMPLE & RELIABLE:
The combustor consists entirely of mechanical components that have already thoroughly
proven their reliability in the cement industry. Moreover, both the screw conveyors and the air
cannons have been specially optimised for the rough conditions of the fuel-handling
applications. The astonishing thing is, although both systems actively assist fuel conversion
through agitation of the fuel, they are not subjected to the thermal and chemical stresses in the
combustion space. The mechanically-moved components are located completely outside the
combustor.

A further advantage: The simple geometry of the system makes it very easy to add it on to any
kind of existing precalciner system, yet the installation time is very short.

FLEXIBLE:
The PREPOL-SC is made for all kind of fuels, but it is flexible in size. According to given boundary
conditions, the width and length of the unit can be adjusted. For complex retrofits, the grate can
be shortened: This PREPOL-SC-S still offers more than 50 times more combustion time compared to
existing calciner loops but needs a minimum of space.

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The 18th TCMA Technical Workshop and Exhibition

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Technical Paper: Energy Saving of Fan

Mr. Takaaki Nakamura
Ebara Fan & Blower Co., Ltd. (Japan)

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The 18th TCMA Technical Workshop and Exhibition

Venue: The Greenery Resort, Khao Yai
Many fans are running in all cement plant, they are one of the most important equipment in
cement manufacturing process. Especially, main fans, such as Preheater (Kiln) IDF, Raw mill IDF,
and Cooler EP fans are one of the biggest machine which need big electrical motors. The motor
KW is app. 2,000-3,000KW, which energy saving even 10% makes big benefit to plant operation
itself and fewer loads to environment.

In most of cases, total plant process is designed by engineering company. When one
engineering company designs the plant, it is required to guarantee total production amount per
day. To ensure to achieve this target, engineering company always design all equipment based
one the calculation and specification that include some “ margin” . After that the specification
was hand over to each fan manufacture, fan manufacturer design the fan as per the
specification. As fan manufacture also guarantee the required specification, fan manufacture
also put some “margin” to the specification. Finally supplied fan can satisfy plant operation, but in
some cases, the fan ability is too big for actual required flow volume & differential pressure, they
are being operated under damper closed condition. This “ damper closed condition” means
“waste of energy” , that’s chance of energy saving! Once actual operating point was checked
through site performance test, new fan ( or only new rotor <impeller + shaft>) can achieve big
energy saving.

Even fan original design specification and actual fan operating point is same or close, no need
give up. With changing fan blade design change, we can achieve fan efficiency improvement,
i. e. energy saving. Airfoil type fan can achieve max. 85-88% , the difference of fan efficiency
between new fan and existing fan may make big energy saving.

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The 18th TCMA Technical Workshop and Exhibition

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Background

Many fans are running in all cement plant, they are one of the most important equipment in
cement manufacturing process. Especially, main fans, such as Preheater (Kiln) IDF, Raw mill IDF,
and Cooler EP fans are one of the biggest machine which need big electrical motors. The motor
KW is app. 2,000-3,000KW, which energy saving even 10% makes big benefit to plant operation
itself and fewer loads to environment.

Ex) Big energy saving (250Kw)

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The 18th TCMA Technical Workshop and Exhibition

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FAN design specification and actual fan operation point
In most of cases, total plant process is designed by engineering company. When one
engineering company designs the plant, it is required to guarantee total production amount per
day. To ensure to achieve this target, engineering company always design all equipment based
one the calculation and specification that include some “ margin” . After that the specification
was hand over to each fan manufacture, fan manufacturer design the fan as per the
specification. As fan manufacture also guarantee the required specification, fan manufacture
also put some “margin” to the specification. Finally supplied fan can satisfy plant operation, but in
some cases, the fan ability is too big for actual required flow volume & differential pressure, they
are being operated under damper closed condition (fig.1).

(fig.1)
This “damper closed condition” means “waste of energy”, that’s chance of energy saving! Once
actual operating point was checked through site performance test, new fan (or only new rotor
<impeller + shaft>) can achieve big energy saving.

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Other method (Fan blade design change)
Even fan original design specification and actual fan operating point is same or close, no need
gives up. With changing fan blade design change ( fig. 2) , we can achieve fan efficiency
improvement, i.e. energy saving. Airfoil type fan can achieve max. 85-88 %( fig.3), the difference of
fan efficiency between new fan and existing fan may make big energy saving.

(fig.2)

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(fig.3)

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Technical Paper: Think Green with AUMUND:
Environmental Friendly Solutions –
Save Material and Energy

Mr. Dionisios Lappas
AUMUND ASIA (H.K.) LTD.

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Technical Paper: Automatic Energy Management
for Electrostatic Precipitator

Mr. Supakint Suteepichatpunt
FLSmidth (Thailand) Co., Ltd.

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This regulating principle is illustrated in figure 2.

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2.2 System lay-out
The block diagram for the hardware of the EMCS is shown below in figure 4.

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Technical Paper: Innovative Technologies for NOx- and
CO-reduction in the Cement Industry

Mr. Andreas Renetzeder
Scheuch GmbH

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