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High temperature clinker cooler gas filtration without water injection: Thomas Wyen, Ecospray Technologies (Italy)

Filmed at Cemtech Europe 2015, 20-23 September, Intercontinental Hotel, Vienna, Austria.

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We are going to speak about high temperature clinker cooler gas filtration without water infection. So this is an index of this presentation in which we very first go to some different arguments. First of all we will speak a little bit about Ecospray research and product development for cement applications, then hot gas filtration and use solution for an old problem in cement plants, then fifth pilot plant in Calusco, this was the first step and then the second step was the industrial plant in rezzato for Italcementi, then I will speak about some ceramic elements main features about some information about the filter, generally layout of distribution system temperate or pressure drop, compressity are gone some shown and then some consideration about main advantage of high temperate or filtration for example.

Eco-spray, generally speaking developed and designed innovative technologies for AR in gas cleaning or gas cooling in many industrial application and power generation plants. So it's best that you can hear me better, since 2005 Ecospray research and development section has lead to important technical advanced solution applicable to cement production plants, amongst other things water injection in syclone for a heater, spray sentinel, this is an automatic monitoring of spray lense that allows to detect malfunctions before that you have problems in the gas cooling tower.

Then spill ayer technology, this is a high pressure nozzle characterized by low power requirement and droplet size similar to what is obtainable with compressed air automizing then SNCR urea external gasification. Practically we inject the urea in the preheater in the same place where it's with the normal plants.

But the external evaporation allows to have less urea consumption, almost half. And then at the last point, ceramic elements for high temperature filtration. So normally, cement manufacturers are always interested in new technologies that enable them to make their plant more profitable by reusing energy excesses.

Typical example of this is the filtration of hot gas containing dust. The limiting factor is the maximum operative working temparature of the bags that are normally used it is up to 300 degrees, and in this case, we have a waste of energy because we inject water to cool down the gas or we use false air so Ecospray has developed and introduced into the market the innovative ceramic filtering elements.

The new type are these elements. This new type of filter elements allowed to work at very high temperatures up to 800 degrees and to maintain excellent efficiency along the time. Additionally as earlier presentation has given a lot of details. Additionally, these ceramic elements can also be combined with suitable catalyst for making some removal of nitrogen oxide VOC with excellent results.

So the first step was working together with Italcementi was to have pilot plant. You can see here is the first filter that we have worked on. This was a relatively small filter this was in operation from January 2012 to May 2013, with only 70 Islamic elements, the length was 3, 000 millimeter and the diameter 115 millimeter.

Total filtration area was about 14 square meters. You can see here the temperature was almost high, 420 degrees, delta P, 210 millimeters of water column the next step was then to have an industrial plant. Italcementi has some special requirement for this industrial plant and this was to have the cooler vent air to be evacuated directly to the atmosphere always in continuously respecting the dust emission limitation by law.

And then an alternative to send this hot air from the cooler to the cold, dry and grinding system. The possibility to send this hot and clean air important clean air at 250-350 degree to the secondary combustion of the wide kiln Clinker cleaner. And last possibility was to install to have the possibility position to install heat recovery system in the future. So, we have a standard solution that is shown here in which you have the Clinker cooler to offer gas that goes to cyclones and then to possible parts and one part now the gas is relatively clean eventually go to a future heat recovery system then go to heat exchanger and then go to a back filter and then via an exhauster send to the stack.

Other part of the gas in the requirement of the Italcementi was to send to electrostatic precipitator and then via a boaster fan to the wide kiln and to the coal mill. The thinking was is it possible to have only have one equipment instead of these that you can see in the circle here, it was solved in this way practically, it was foreseen a filter made from two bodies but these bodies are parallel at the exit of these filter we have the heat recovering system and an exhauster that sends to the stack and to the wide kiln and to the coal mill.

This is the innovative solution, here a course price applied to complete filter with ceramic elements, the cores jet cleaning system including the vento system that allows less complacenty or consumption making a variable threshold cores jet compressed air available so ceramic elements main features.

They're self supporting. No cages are required as for the bags, cleaning system that are no big difference compared to standard cores jet system in the filter of Rezzato, there were installed two elements coming from two different suppliers, supplier A and supplier B with two different density and weight, but the process characteristics were very similar.

We've a hindering constraint because they've to be carefully ended. Once installed it's better to lead in position without moving for every maintenance so here you can see A ceramic element, the element installed in the Rezzato were 3000 millimeter in height, the filter foreseen to use 4000 millimeter candles.

You can around 120000 normal cubic meter per hour coming at a temperature between 250 and 350 degrees. This is actually the biggest application in the world. So, high temperate filtration distribution system, we use in ecospray technologies computation of food dynamic to simulate the filter, there're some plates inside, you have a series of blades here, that makes the vertical distribution, and then we have a distribution on the right and on left side of the filter.

Conversation of free dynamic makes a simulation of the volume of the gas inside of the filter and it begins with the mesh and every point of this mesh the computer, the software make the calculation of navigation stocks equation for energy must balance and so you have a very good simulation of the flow inside of filter.

The results will be displayed is shown in this picture here where you can see that the gas distribution is equally distributed in this direction and also on the left and on the right side. Here is a graph of the temperature in and temperature out you can see the temperature in this period were around 270 and 290 degree with pick temperature about 350 degrees, Delta P was about 78 milli bars.

Some infomation about compressed air consumption 250 normal cubic meter per hour operating pressure at 3 4 bars this is referred to a specific operation case. So, main advantage of high temperature filtration Rezzato saving the investment cost in comparison with the standard solution 7% lower.

Saving in the power consumption this is about 30% less, and then foreseen saving in all of our maintenance cost thanks to licensed equipment and possible future installation of high efficiency weight heat recovery system of course you do not need special execution for wear product protection of this machine.

So, additional consideration operational optimization is still in progress in Italcementi filter maintenance is similar for both that solution and this innovative solution and we expect less longer life from the ceramic elements more than five years and less skills shut down due to high availability.

The cost increase compared to standard decks roughly information is that it's almost about four time it's expensive but it is good. So acknowledgement special thanks to Italcementi group for the provided material and for the corporation and thank you for your attention.

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