Building Capacities for the Improvement of the Air Quality

Transcription

1 Building Capacities for the Improvement of the Air Quality Dust State of the Art Lima, Dr. Hubert Baier General Manager - Europe

2 Size range of airborne particles 2

3 Comparison of filters and its efficiency < 1µm 1-3µm 3-10µm >10µm Multi cyclone ESP Bag house filter >99.95 >

4 Gas cleaning device Fabric filter 4

5 Disclaimer: The following presentation is designed by 5

6 Development of the Company Own development of the 1 st bag filter 1985 First patent cleaning system Company Building of a new workshop in Ried

7 Five Main Business Segments Synergies Multi-sector know-how Wood Processing Industry Wood Based Panel Industry Metals Industry Industrial Minerals Energy Industry Company 7

8 Services Plant planning Engineering fresh air

9 Research & Development Casing geometry Numerical flow analysis

10 Success Factors Excellent Knowledge of Customer Processes Each business segment has its own technical sales experts and process engineers Long-standing and collaborative partnerships as the basis for process know-how Work collaboratively to re-define the state of technology (win-win partnership) R&D alliances: From the idea to pilot plant to full-scale implementation Company 10

11 Success Factors Complete Product and Service Program Bag filters Electrostatic precipitators Scrubbers Fans Conveying and discharge devices Classifiers Company 11

12 Company 12 Success Factors Complete Product and Service Program

13 Industrial Minerals Exhaust and dedusting plants, process filters in the cement, limestone and gypsum industries, the basic material and building material industries, and the recycling of construction waste. Kiln / raw mill Clinker cooler Coal grinding plant Company 13

14 Range of Products Bag filter Standard filter bag Ø 165mm up to 2,5 Mio m³/h Compact filter bag Ø 100mm up to m³/h

15 Range of Products Radial fans (up to m³/h up to Pa) Sound insulation

16 Range of Products Pipelines and channel parts (plant planning) Steel construction for filter plants

17 Range of Products Heat exchanger, Gas conditioning tower

18 Products in the Cement Industry From quarry to cement shipment Crude material transport and treatment Kiln and raw mill dedusting Chlorine bypass dedusting Heat exchanger Cement transport and shipment Clinker transport dumping Gas conditioning tower Coal mill drying Transport and crude material dumping Clinker cooler dedusting Cement mill and separating plants Packing plants and loading systems

19 Products in the Lime Industry Hot gas producer Over temp. chimney Bag filter Kiln Hot gas fan to avoid drops below the dew point Minimum temperature 165 C Over temperature stack for protection of filter bags, maximum temperature: 200 C

20 Products in the Lime Industry 1 Rotary kiln 2 Air/air heat exchanger 3 Rotary valve 4 Emergency temp. flap 5 Pulse-Jet chamber filter 6 Shut-off slide 7 Main fan 2 fresh air

21 Application Examples Coal / pet coke grinding plant Customer: Polysius SAS, France Proj. VICAT SOCOCIM Senegal Application: Coal mill plant Air volume: 110,000 Am 3 /h Commissioning: 2004

22 Südbayerisches Portlandzementwerk Gebr. Wiesböck & Co. GmbH Customer: Südbayerisches Portlandzementwerk Gebr. Wiesböck & Co. GmbH D-Rohrdorf Application: Kiln Dedusting Air ratio: 711,000 Am 3 /h Start-up: 2006

23 Polysius AG Proj. Tudela Veguin/La Robla (Spain) Customer: Polysius AG D-Beckum Proj. Tudela Veguin/La Robla (Spain) Application: Clinker Cooler dedusting Air ratio: 280,000 Am 3 /h Start-up: End 2004

24 F.L. Smidth A/S Proj. Holcim Rohoznik / SK Customer: F.L. Smidth A/S DK-Valby, Copenhagen Proj. Holcim Rohoznik / SK Application: Clinker Cooler dedusting Air ratio: 270,000 Am 3 /h Start-up: 2004

25 Cementos Balboa Customer: A.G. Cementos Balboa, S.A. E-Jerez de los Caballeros Application: Dedusting of a kiln Air ratio: 600,000 Am 3 /h Start-up: 2004

26 Polysius AG Proj. Fujairah Cement / U.A.E. Customer: Polysius AG D-Beckum Proj. Fujairah Cement / U.A.E. Application: Dedusting of a kiln Air ratio: 268,000 Am 3 /h Start-up: 2004

27 Loesche GmbH Proj. Thi Vai / Vietnam Customer: Loesche GmbH D-Düsseldorf Proj. Thi Vai / Vietnam Application: Dedusting of cement mill Air ratio: 622,000 Am 3 /h Start-up: 2004

28 Application Examples Kiln-/Raw mill dedusting Customer: Lafarge Beocinska Fabrika Cementa YU-Beocin/Serbia Application: Kiln dedusting Air volume: 560,000 Am 3 /h Commissioning: 2003

29 Application Examples Cement mill dedusting Customer: Loesche GmbH, Düsseldorf, Germany Proj. Vassiliko Cement Cyprus Application: Cement mill dedusting Air volume: 220,000 Am 3 /h Commissioning: 2002

30 Application Examples Compact filter for additives

31 Disclaimer: The following presentation is designed by 31

32 LEGISLATION AND DUST LIMIT VALUES European Regulations EN Stationary source emissions - Quality assurance of automated measuring systems EN CEN standard for testing and certifying automated measuring systems (AMS) EN Stationary source emissions - Determination of low range mass concentration of dust German Regulations Bundes-Immissionsschutzgesetz (BImschG) German law on protection against harmful environmental influences Bundes-Immissionsschutzverordnungen (e.g. 17. BImschV, 30. BImSchV) Specific regulations for small and medium particle emission sources EN /30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

33 LEGISLATION AND DUST LIMIT VALUES Some examples: Germany (13./17. BImSchV large combustion plants & waste incineration) Solid fuels: Liquid fuels: Gaseous fuels: Waste incinerators: average) Cement plants: average) 10 mg/m³ - 20 mg/m³ 10 mg/m³ - 20 mg/m³ 5 mg/m³ - 10 mg/m³ 5 mg/m³ (daily average); 20 mg/m³ ( ½ hr. 10 mg/m³ (daily average); 30 mg/m³ (½ hr. Waste gasification plants: average) 10 mg/m³ (daily average); 20 mg/m³ (½ hr. 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

34 LEGISLATION AND DUST LIMIT VALUES Some examples: India (Environment Protection Amendment Rules 2017+): Thermal Power plants: 100 mg/m³ (<2013) 50 mg/m³ ( ) 30 mg/m³ (>2016) China (GB ): Coal fired power plants: Oil fired power plants: Gas fired power plants: 20 mg/m³ mg/m³ 20 mg/m³ - 30 mg/m³ 5 mg/m³ - 10 mg/m³ 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

35 Continuous dust measuring technologies Transmission Scattered light Tribo-Electric Semi-continuous dust measuring technologies Beta-Radiation Discontinuous dust measuring technologies Gravimetric measurement For CEMS according to local regulation Bag filter/electrostatic precipitator efficiency meas. 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

36 Transmission principle Measuring of the amount of light received as a fraction of the amount of light emitted in an optical cross stack monitoring. Opacity is the %-age of light lost Transmission is the %-age of light received Calculation of the dust concentration (for high dust concentrations) In-situ measurement I o I Sender/Receiver Reflector 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

37 Transmission principle 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

38 Transmission principle 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

39 Transmission principle 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

40 TRANSMISSION: STRENGTHS AND WEAKNESSES Typical Applications Mainly for medium to high dust concentrations Emission and process monitoring Strengths Representative measurement (cross-stack) Little maintenance effort Automatic self-check functions for control of stability of the measurement signal Contamination compensation functions Independent of gas velocity, moisture content of the particles and operating conditions of the separator Weaknesses Two-sided installation means higher investment and installation effort Physical detection limits for low dust concentrations in small stacks Purge air necessary 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

41 Scattered light (forward) Radiation of the dust loaded measuring volume with visible laser light (wavelength approx. 655 nm); Receiver is on the transmitter side (for low to medium dust concentrations) 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

42 Scattered light (forward) Diffraction Light Absorption Everyday situations Refraction Reflection High sensitivity Very low dust concentrations can be measured independent of path length 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

43 Scattered light (backward) Radiation of the dust loaded measuring volume with visible laser light (wavelength approx. 655 nm); Sender/Receiver unit (for low to medium dust concentrations) Sender Sender Measuring range Messvolumen Empfänger Receiver 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

44 SCATTERING LIGHT : STRENGTHS AND WEAKNESSES Typical Applications For very low to medium dust concentrations For emission monitoring Qualitative and quantitative process monitoring Strengths Well suited for low dust concentrations One-sided installation (Back scattered, Probe version) Wide application range Automatic function checks available Contamination compensation functions Independent of gas velocity, moisture content of the particles, operating conditions of the separator and contamination of the probe-well suited for low dust concentrations Weaknesses Purge air necessary 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

45 Tribo-electric Particles, which collide with the probe or fly past, transfer their charge to the measuring electrode Physical effects: friction & induction Charge exchange is proportional to dust concentration through application specific calibration factor Measurement is influenced by: Gas velocity, Electrical charge and moisture content of particles, Operating conditions of the separator, Contamination of the probe 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

46 TRIBO ELECTRIC: STRENGTHS AND WEAKNESSES Typical Applications Qualitative and quantitative process monitoring Simple monitoring tasks (bag filter leakage) Not suited for CEM, only simple dust measurement Strengths One-sided installation Cost-Effective (no purge air necessary) Weaknesses Measurement depends on gas velocity, moisture content of the particles, operating conditions of the separator and contamination of the probe very limited use No automatic function tests with zero- and span-value. Only with standard reference method unreliable measurements can not be detected during normal operation, only by work-intensive manual linearity check The probe needs to be cleaned very often as it get less sensitive with more contamination short maintenance intervals and hence high cost-of-ownership 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

47 Beta-Radiation Particles in the extracted partial gas flow are collected on a filter paper in defined time intervals (approx. 5 min). Beta-radiation on the filter paper provides measured values directly proportional to the dust weight, not influenced by particle size and color. Device provides only mean values (normally 5 to 20 min), no information about actual measured values Radiation source needs high safety effort High costs for consumables 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

48 BETA-RADIATION: STRENGTHS AND WEAKNESSES Typical Applications Low to high dust concentrations For emission monitoring in dry and wet gas Strengths Output directly in mg/m³ without calibration (but for representative network measurement, e.g. for emissions monitoring, calibration is necessary) Suited for gases above and below dew point Weaknesses Single Point Measurement Needs to be calibrated as well for CEM Discontinuous measurement Measurement only every ten minutes! High investment costs ( Approx ) High spare part consumption, especially filter paper (cost intensive) High maintenance effort Beta-Radiation source requires qualified staff (with certificate) 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

49 CALIBRATION Why is a calibration on site needed? Dust concentrations can not be measured in a direct way. The measurement signal is influenced by: Number of particles, Particle properties (size, structure, color) Material density Calibration is strictly required for exact dust measurements using optical, electro-dynamic or tribo-electric monitors European Standards: EN 14181: Stationary source emissions - Quality assurance of automated measuring systems (AMS) QAL2: Calibration and validation of the automated measuring system QAL3: Ongoing quality assurance during operation EN : Determination of low range mass concentration of dust Part 1: Manual gravimetric method 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

50 CALIBRATION Determination of the relationship between the ma signal of the automated measurement system and the real dust concentration in the stack in mg/m³ Calculation of a regression function (quadratic or linear formula) and implementation in a measurement computer or dust monitor mg/m 3 Gravimetric measuring system mg/m³ ma AMS 0 ma At least 15 measurements at different plant operation conditions (e.g. full load, half load) 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

51 CALIBRATION Isokinetic extraction of a partial gas volume Collection of the dust particles, contained in the extracted gas volume on/in a filter element Weighing the filter element before and after the dust collection Determination of the relationship between dust content in mg and extracted volume in m³ v extract. Measurement of the gas velocity and gas temperature in the stack for normalization v stack of the results (calculation of mg/nm³ in standard conditions) Requirements: Distance to the dust monitoring level at least 500 mm above in flow direction Isokinetic extraction: v extract. = v stack 6/30/2016 No mutual influencing of dust meter and calibrating device. Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

52 CALIBRATION - GRAVIMETRIC MEASUREMENT PROCEDURE 6/30/2016 Felix Bartknecht Symposium: Building capacities for the improvement of the air quality Lima,

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