More than 50 years of expertise

Reducing emissions by monitoring the gas composition at the kiln inlet
= Saving Money

ITECA SOCADEI SAS
445 Rue Denis Papin
Europôle de l’Arbois
CS 30478
13592 Aix en Provence
Cedex 3
FRANCE
+ 33 (0)4 42 97 77 00
+ 33 (0)4 42 97 77 33 info@iteca.fr
www.iteca.fr
Europe - North, Central &
South America - Asia -
Middle East - Africa
Paris
Aix en Provence

3 DIVISIONS
- Analysers for on line process control
- Centralised laboratories
Production equipments (kiln seals…)
Dedicated to the solid bulk industry
(food, calcium carbonate, sugar, cement…)
On line analysis

CEMENT DIVISION
Process optimization  ON LINE
CONTROLS
Quality control  CENTRALIZED
LABORATORIES
PRODUCTS RANGE
Process optimization
Quality
Sustainability
SUSTAINABILITY
ENERGY SAVING  PRODUCTION EQUIPMENTS

Kiln Inlet Gas Sampling & Analysis: WHY?
The most important gases to be monitored for kiln control are:
Oxygen : too low
 fuel may not be burning correctly
 wasting energy. too high  possible to increase fuel input and raw material input and therefore possible to increase production
CO : This gas is created in the flame, when the flame is not burning correctly
Dangerous, toxic loss of energy (incomplete combustion)
NOx : This gas is also created in the flame. Flame Surface T
°  NOx creation  .
NOx = indicator of the temperature of the clinkering zone in the kiln = indicator of the end quality of the clinker that is manufactured.
All these gases can be measured using our sampling system, and the measurement of these gases already provides a great deal of valuable information on the operation of the kiln.

Gas Sampling and Analysis
Different sampling locations
Precalciner
Kiln
Cooler
Gas sampling
Our experience: all cement plants are facing the same trouble
 Clogging of the sampling probe in the Fume Box
Analyser
Output

Gas Sampling and Analysis
Requirements for an efficient kiln back end gas sampling
Low Maintenance - High availability
Withstand high dust concentration without blockage
Withstand high temperatures
Quick response time : high gas flow rate
Sturdy construction to withstand build-up fall

Filter
Gas Sampling and Analysis
Traditional technology : basic principle
Gas is sampled and then filtered through a ceramic/metal/glass filter
The gas sampling is stopped and the filter and the probe are cleaned using compressed air

Gas Sampling and Analysis
Traditional technology : limitations
Clogging problems (probe and filter): high maintenance
Sample contamination due to purge air : low availability
High maintenance on the membrane pump
Low gas flow rate (max 120 l/h) : slow response time
Bending due to blocks falling from the tower

Gas Sampling and Analysis
Case study 1 – Reliability
Continuous operation for 20 consecutive days
4300 TPD Line with 63% alternative fuels

Tower
O2 no change
Iteca
O2 Drop
CO Rise
Gas Sampling and Analysis

Tower
O2 no change
Iteca
O2 Drop
CO Rise
Gas Sampling and Analysis

Gas Sampling and Analysis
ITECA’s system: principle
Wet sampling
Analysis Cell
CO, O
2
, NO x,
CH
4
Dryer
Gas analysis
Gas conditioning
Closed circuit double cooling system

Gas Sampling and Analysis
ITECA’s Wet sampling probe
Cooled jacket
Cooled probe
Cooled jacket
GAS
Water spray
3 bars-30 l/h
The sampled gas passes through the water spray, dust is trapped outside the probe before entering the line
No ceramic filter to clean or to replace

Cooled jacket
Cooled probe
Gas Sampling and Analysis
Efficient probe cleaning system
High pressure water pulses
(4 to 5 l)
Every 10-20 min
(adjustable), high pressure water (8 bars) is sent through the sampling line to clean the probe
Cooled jacket

Connections to suction gas pump and water
Gas Sampling and Analysis
Sturdy sampling probe
Resistance to accidental fall of blocks
Jacket Ø 168 mm
Sampling line Ø 34 mm
Sampling end
Weight (without water): 150 to 200 kg
(depends on probe’s length)
Double cooling system: jacket + sampling line

Gas Sampling and Analysis
Sampling Probe installation
Avoid inlet seal false air influence
The probe is installed so that its tip is at least 500 mm beyond the inlet seal

Gas Sampling and Analysis
Sampling Probe
3D design to check the feasibility and find optimum probe location

Gas Sampling and Analysis
Sampling Probe Automatic Extraction
High torque extraction for the extraction of the probe in case of any problem on the power supply or the cooling circuit on a regular basis used to remove the coating around the probe

Gas Sampling and Analysis
ITECA’s Sampling Probe Automatic Extraction
Safe and Reliable for the extraction of the probe in case of any problem on the power supply or the cooling circuit on a regular basis used to remove the coating around the probe

Gas Sampling and Analysis
ITECA’s Sampling Probe Automatic Extraction
Safe and Reliable

Gas Sampling and Analysis
Close loop cooling circuit
Oversized capacity closed cooling circuit (water T ° < 65°C)
+ High cooling water flow rate : 2 500 l/h
No hot fluid
No high pressure

Electrical control
Gas Analysis
Gas Sampling and Analysis
Gas Conditioning and Analysis
Gas
Conditioning

The gas is then dried in the gas dryer by reducing its temperature to 3
°C
Water + Gas
Water
Gas
Gas Sampling and Analysis
Cyclone separator : any remaining water as liquid is removed here
Water / gas separation circuit
Water / gas separator : most of the water is removed here
Liquid ring pump

Gas Sampling and Analysis
Gas Analysis
Infrared analyser : CO, NO, CO
2
Paramagnetic oxygen analyser
Gas dryer
Command and display
Gas flow regulators - One for each analyser (70 l/h /analyser)
+ evacuation
Dust filter

Gas Sampling and Analysis
Performances - Advantages
Working temperature : max 1400 °C
Working dust concentration : up to 2 kg/m 3
Gas sampling flow rate : 1800 litres/hour
Response time (sampling and conditioning): 5 to 10 s
No sample contamination from air purge
No wear parts on the liquid ring pump
Heavy duty probe able to withstand build-up fall

Gas Sampling and Analysis
Case study 2 – cement plant
Pre-calciner kiln
Kiln capacity 4200 tpd
Partial fuel substitution with pet coke
The Iteca system was installed in parallel with an existing traditional probe
Tests were conducted over an 8 month period

OXYGEN READING
Traditional
ITECA
Gas Sampling and Analysis
Case study – cement plant
Air purges

ITECA
GAS READING
NOx
O2
CO
Gas Sampling and Analysis
Case study – cement plant

CO READING
ITECA
TRADITIONAL
Gas Sampling and Analysis
Case study – cement plant

Gas Sampling and Analysis
Case study – cement plant
CONCLUSION
The reliability factor achieved was greater than 95% over an 8 month period
The gas sampling provided accurate and reliable data for
O2, CO and NOx
The plant decided to purchase 2 more gas sampling systems from ITECA
Reduction of emissions, reducing consumption while increasing production:

bernard.seemann@iteca.fr