SKAMOL A/S Skamol is in business to reduce energy

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SKAMOL A/S
Skamol is in business to reduce energy consumption and pollution from energy intensive processes, to
improve indoor climate, and to secure lives and values in case of fire
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+
Skamol A/S
Østergade 58-60
DK-7900 Nykøbing Mors
Tel: +45 9669 1243 direct
Cell: +45 4194 6364
Fax: +45 9772 4975
www.skamol.com
VII Encontro de Refrataristas e Usuários de Refratários (ERUR), Curitiba, Brazil
ABSTRACT:
Rotary kilns – Energy Savings (Design, Pitfalls and Improvements)
Rotary kilns are used in many processing industries for Drying, Sintering and Calcination of raw
materials. This paper will focus on the use of rotary kilns in Cement- and Lime industries, and how to
improve the energy efficiency of kilns, the lifetime of refractory lining and auxiliary mechanical
equipment as well as safety issues. As energy prices are soaring and high efficiency is increasingly
becoming important in an ever more competitive business environment globally, and CO2, NOx, SOx
and other noxious gas-emissions are gaining political awareness, it is important to address
alternative and improved designs of rotary kilns, by implementing good insulation materials in
linings.
SKAMOL, August 17th 2012
Christian Bach
Sales Manager
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SKAMOL A/S
Skamol is a world leading developer, manufacture and supplier
of energy-saving, high temperature insulation solutions.
We offer high quality products and solutions based on:
* Diatomaceous Earth - MOLER
* Calcium Silicate
* Vermiculite
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DIATOMACEOUS EARTH
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Diatomaceous earth
SKAMOL quarries the moler from its own pit
and heaps the moler in accordance with the
specific recipe. When ready, the moler is
crushed and milled in the facility. The raw
materials are mixed in a pug mill with steam to
raise temperature
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Diatomaceous earth
When baked, the bricks are
machined on all sides in order to
obtain precise dimensions following
the baking process. When the
desired dimensions are obtained, the
bricks are packaged on pallets and
stored in the outdoor storage area
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CALCIUM SILICATE
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Calcium Silicate
The first part of the facility is used for
mixing the calcium silicate as a soup.
Once the soup has the exactly right
properties, it is poured into a mould
and the soup is then pressed to the
desired thickness
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Calcium Silicate
The boards are then placed in
autoclave wagons where they are
autoclaved at high pressure for
reaction to xonolite. Following this,
the boards are dried, cut and
machined to the specific dimensions.
The boards are then packed on
pallets and stored until shipment to
customers.
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APPLICATIONS
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INDUSTRIES & APPLICATIONS
•
* CEMENT & LIME
•
* PULP & PAPER
•
* ALUMINIUM
•
* IRON & STEEL
•
* POWER & GASIFICATION
•
* PETROCHEMICAL
•
* GLASS
•
* CERAMIC & TILE
•
* STOVES & FIREPLACES
•
* FIREPROTECTION
•
* MOLD FUNGUS REMEDIATION
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CEMENT & LIME – PULP & PAPER
•
The Cement and Lime production in the world is growing
•
Cement:
•
World: 3,3 billion TPY – Brazil: 59 million TPY
•
Since 2010 the Brazilian cement production has grown with
7,5%/year
•
Produced on the 72 cement plants in Brazil, and the number is
rapidly increasing
•
Lime:
•
World: 130 million TPY – Brazil: 7 million TPY
•
To this is added the lime regenerated in rotary kilns in the pulp &
paper industry
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CEMENT & LIME – PULP & PAPER
•
The amount of energy consumed and the CO2 released in these
processes are truly enormous
•
There are several different technologies to produce Cement &
Lime
•
* Traditional with pre-heaters, pre-calciners and calciners –
followed by rotary kilns – where the kilns tends to be shortened
and more of the calcining process is moved into the “tower”
•
* Fluid bed sinter kilns
•
* Shaft kilns
•
Energy consumption still remain high, even if the theoretical
energy of approx. 1,7 MJ/Kg cement clinker or lime is
approached
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ROTARY KILNS
@ Aalborg Portland
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ROTARY KILNS
•
Rotary kilns are used in a multitude of industries to heat or
calcine minerals:
•
* Cement
•
* Lime
•
* Kaolin
•
* LWA (Leca)
•
* Magnesia
•
* Iron ore
•
* Olivine
•
* Perlite, and many more
•
This is why Skamol has developed an insulating brick that we sell
under the name of M EXTRA which in many cases has the
sufficient strength to be installed in many of these rotary kilns
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CEMENT & LIME – PULP & PAPER
•
A central part of cement and lime production or regeneration is
the heat transfer taking place in the:
•
* Dryer
•
* Preheater
•
* Calciner
•
And the more energy efficient these unit operations are - the
more money are saved and the less carbon footprint is set
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CEMENT
Insulation is, or can be used in
•
* Preheater tower
•
* Calciners
•
* Grate coolers
•
In this case Calcium Silicate
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CEMENT
•
Typical scenario in a cement
plant:
•
The Rotary kiln
•
In this case – no insulation
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LIME - PULP
•
Lime sludge kiln:
•
* Exterior view
•
* Isolation lining under
installation
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LIME - PULP
•
Lime sludge kiln –
•
or MESA kiln:
•
From drying, calcining to
outlet – drying zone without
insulation:
•
Double lining:
•
* Skamol insulating bricks – M
EXTRA as back-up lining
•
* Refractory hot-face lining
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LIME - PULP
•
Rotary kiln in pulp industry:
•
New dual layer lining is
installed with M EXTRA bricks
as back-up insulation
•
During a kiln-stop, the ”old”
insulation lining in M EXTRA
bricks is still in an excellent
state
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LIME – PULP
Hot Crushing Strength Skamol MEXTRA with temperature
From a CCS of 18 MPa it rises to a
HCS of about 40 MPa
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LIME - PULP
Name of Zone
Typical
Lengths
m
Inlet Zone
0,2-0,3
Chain Zone
10-20
Heating Zone:
30-60
Intermediate Zone
Consumption of Lining Materials in
Mesa Kilns
Zone
Burning Zone
20-35
Dam Zone
1-2½
Discharge Zone (Outlet)
2-4½
Materials
Low Cement Castable (1400oC)
Low Cement Castable (1400oC)
Fire Clay Brick (2150 kg/m3,
1350oC)
M-EXTRA (64 mm)
Intermedia Fire Brick (2250 kg/m3, 1650oC)
te
M-EXTRA (64 mm)
Burning
Fire Clay Brick (2150 kg/m3,
1350oC)
M-EXTRA (50 mm)
IFB 26 High Density (50 mm)
Dam
Low Cement Castable (1300oC)
Outlet
Low Cement Castable (1300oC)
Inlet
Chain
Heating
5-15
Unit
t
t
t
D 3.1 m
L 80 m
1
36
96
D 4.75 m
L 130 m
2
92
395
m3
t
m3
t
21
25
5
82
75
62
13
225
m3
m3
t
t
10
0
12
12
0
27
55
36
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The SKAMOL M-EXTRA Insulating Brick
Saves energy and prolongs lining life
in Rotary Kilns
SKAMOL M-EXTRA
Insulating bricks cover temperatures
up to 1,000 °C / 1,832 °F
www.skamol.com
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M-EXTRA in rotary kilns have several purposes
Kilns size less than 4.0 m diameter are lined by M-EXTRA Bricks
Results of an analysis of a Rotary Kiln:
Capacity 240.000 tons calcined Kaolin per year
75 m long and 3.6 m diameter - Vatutinsky - Ukraine
•
•
•
•
•
•
Lower heat flow from kiln ≈ 36 %
Lower shell temperatures by 72°C ≈ 64 %
Decreasing carbon footprint by 64.400 T CO2 p.a.
16,5 % lower weight of lining - means less wear of
bearings
Longer life of wear resistant lining, Increasing wear
capacity by 33 %.
Strong stable insulating layer secures less hot spots
Cold Crushing Strength 18 MPa
Hot Crushing Strength up to 40 MPa
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Thermal calculations origin vs. proposed in a Rotary kiln
Kaolin Calcining kiln, 240,000 tons per year
Length 75 m – diameter 3.6 m
Old Lining 230 mm
New Lining 230 mm
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1st yr BUSINESS CASE: Rotary kiln for kaolin Calcining 240,000 tpy
1st years savings if installing the
new insulation material
INSULATION OF A ROTARY KILN FOR KAOLIN CALCINING
Application areas: Full redesign in a diameter 3,6 m and 75 m long.
Old lining design:
• HASSIA 40
• SHELL
New lining design:
• HASSIA 40
• M-EXTRA
• SHELL
1. Installation costs
EUR
+
2. Material savings
EUR
• The new design with super insulation materials secures less
heat flow from Kiln - approx. 36 %.
• Lower shell temperature, approx. 64%.
106.500
+
3. Lower heat flow
428,000
EUR
• Energy consumption decreases considerably, in the end it lead
to considerable energy savings. Decreasing Carbon footprint
reduction by 64.400 T CO2 per year.
• Longer life of wear resistant lining approx. 33%
- 32.400
+
4. Loss in idle time
- 48,500
EUR
=
• Less weight of total Kiln lining 16.5 %
Total 1st yr benefit
Carbon footprint reduction
EUR
CO2
453,500
64,400 T
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2nd-5th yr BUSINESS CASE: Rotary kiln for kaolin Calcining 240,000 tpy
2nd-5th year savings if installing
the new insulation material
INSULATION OF A ROTARY KILN FOR KAOLIN CALCINING
Application areas: Full redesign in a diameter 3.6 m and 75 m long.
Old lining design:
• HASSIA 40
• SHELL
New lining design:
• HASSIA 40
• M-EXTRA
• SHELL
• The new design with super insulation materials secures less
heat flow from Kiln - approx. 36 %.
Lower heat flow
EUR
428,000
• Lower shell temperature, approx. 64 %.
• Energy consumption decreases considerably, in the end it
leads to considerable energy savings.
=
Total annual benefit
OBS;
(Lifetime of major part of lining is 5 years)
EUR
428.000
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Selected references:
Skamol provides M EXTRA bricks for rotary kilns, non ferrous casthouses and
to the steel industry to more than 100 customers in 28 countries all over the
world
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Summary, conclusion and proposal from Skamol:
Which effects does the use of back-up insulation have on the performance of a rotary kiln?
1) Less weight of lining:
a) Less sterss / mal-wear on
1) Gear
2) Bearings
3) Trust rollers
4) Tyres
5) Mecanical structures
b) Less ovality / deformation of shell
c) Less energy required for thrust
d) Less vibrations on Pier
e) Better alignment
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Summary, conclusion and proposal from Skamol:
Which effects does the use of back-up insulation have on the performance of a rotary kiln?
2) Lower shell temperature:
a) Lower energy loss
b) Steel shell is ”stiffer” – meaning less ovality / deformation of shell
c) Less longitudinal thermal expansion of the kiln
3) Use of insulation as such:
a) Longer time between stoppages / re-linings due to increased ”wear-capacity”
b) Smother run- and better control of kiln temperature during adverse weather conditions
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Summary, conclusion and proposal from Skamol:
Which effects does the use of back-up insulation have on the performance of a rotary kiln?
4) Drawbacks & limitations on the use of M EXTRA bricks as back-up lining:
a)
Skamol does not recommend to use M EXTRA bricks in rotary kiln with larger diameters than +/- 4m
however the bricks have been used with succes in a kiln in Finland with 4,75 m in diameter 135 m
long (Wisaforest – UPM) and a Mesa kiln in USA with Ø 5,2 m
b)
The M EXTRA bricks do not come as circular bricks to match curvature of different diameter kilns –
however, this has never proved to be a problem
c)
M EXTRA bricks are relatively more expensive as Side- or End Arches
d)
Double lining is slightly more time consuming to install than single layer linings
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Summary, conclusion and proposal from Skamol:
How Skamol can help users of rotary kilns:
Skamol dispose of an expert tean who can assist you in calculating savings with the use of M EXTRA bricks in
the following way:
Provided we get the actual physical data of the kiln, the operating conditions and materials used today as well
as fuel type and cost, we can:
•
Make an ”as is” drawing of your kiln in ”SOLID WORKS” and vizualize changes and modifications of the
lining in 3D
•
Make heat transfer calculations on each of the different kiln sections in ”W-DURCH” (www.f-soft.com)
These services can be provided to our customers against nominal fee without obligations to
purchase M EXTRA bricks from Skamol – and in case of a purchase, this fee will be reimbursed
Currently, Skamol are working with several other customers to improve the ecomony of their rotary kiln
operations along these lines – to the benefit for our customers and to the environment
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Summary, conclusion and proposal from Skamol:
All-in-all
• Less energy consumption
• Less CO2 emmissions
• Less stress on lining
• Longer lining-life
Save money
less carbon foodprint
That is true CSR
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Skamol Products
Since 1912
Saving Energy and Reducing Pollution!
High efficiency insulation for any heat-intensive industry
Join the team and use our products made from natural resources
www.skamol.com
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Thank you for your attention