ࡱ> -.,ܥhW eQ>VQ;PPPPPPPQQQQQQ Q.QU1JQJQJQJQJQJQJQJQQQQQBQbSTEUXUjUPJQ !JQJQJQJQUTQPPJQJQTQTQTQJQ PJQPJQQ ׽P&P@PPPPJQQTQ6TQ Experience of an Indian cement manufacturer with advanced kiln shell temperature scanning systems on an existing and new kiln. P. K. Goyenka Vasavadatta Cement Company Sedam Colin E. Brock Thermoteknix Systems Ltd Cambridge, England Synopsis Kiln shell temperature scanning systems are now accepted as a vital part of the instrumentation for both existing and new kilns. The authors describe the decision making process in the specification and purchase of such equipment for their existing kiln and the new kiln built at Sedam, together with the use to which the data obtained has been put and the benefits and payback obtained. Introduction In 1995 Vasavadatta Cement, a part of the B. K. Birla group decided to add a new kiln at their site at Sedam, Karnataka, to increase the existing 0.5MTY capacity by 0.7MTPY. An important part of the investment was to include various new equipment for the existing kiln. This included the decision to replace the existing outdated and difficult to maintain moving pyrometer kiln shell temperature scanning system with a modern, up to date, system. It was decided that the latest available state of the art equipment should be sought and purchased, as the investment would be very long term and as a result should be the best available, within sensible budgetary limits. A search was made of the available suppliers, whose equipment was assessed in detail, technically, by the companies instrumentation, production and process departments, following which a detailed specification was prepared, in association with leading consultants, Entech Ltd., Madras. Expected Benefits The main expected benefit was to obtain immediate information about the kilns surface temperature and thus be notified of any potential hotspots or coating ring formation. It was estimated that the prevention of a single unplanned shutdown, due to a hot spot would repay the full cost (and more) of the equipment proposed. Hence the budget for the kiln shell temperature scanning system was based on this premise. It was also hoped that the equipment purchased would be able to provide information regarding the thickness of the clinker coating and refractory bricks, with ideally the detailed thickness for both. An added benefit would be interfacing with kiln shell cooling fans to minimise their use. Management reports, such as daily historical printouts, temperature trending in critical areas coupled with refractory and production data would also be of considerable use in the ongoing operational management. Selection The detailed specification called for: High resolution for temperature measurement, to ensure that the maximum temperature detail, if possible to measure the temperature behind each brick. State of the art and proven digital equipment, for reliability, availability and accuracy. Complete coverage of the whole of the visible kiln shell, bearing in mind a restricted location for the existing kiln and ease of location for the new kiln. Thus operational flexibility should be a consideration. Robust scanning motor designed for long life, as modern infrared linescanners all include a motor to spin the optical assembly, which collects the infrared radiation from the kiln shell, to provide the temperature information sought. High accuracy optical assembly. Digital communications, for high speed on line display of temperature data. Easy to use software, for control room operatives who may not be familiar with computers. Integrated refractory display and management system. Full after sales support in India. Following the detailed technical and commercial evaluation of the offers from a number of potential suppliers, Thermoteknix Systems Ltd , a well established British micro electronic infrared hardware and software manufacturer was selected. Established over 15 years ago, they have a world wide reputation for infrared thermal imaging and linescanning. In addition they were well established in India, having consistently supplied the Indian Cement market with kiln shell temperature scanning systems for the past 8 years. The system chosen was based on the Centurion TK20 infrared linescanner with WinCem software for the analysis of the temperature information and WinBrix Refractory Expert for refractory management, record keeping and new installation planning. The reasons for the selection were: Thermoteknix Centurion TK20 Infrared linescanner (Fig 1) 100( Field of view, for ease of location in the restricted location for kiln1. 100 - 700 (C temperature range. 2 milliradian temperature measurement spot size for a high degree of temperature measurement accuracy over the whole length of the kilns. (Fig 2) Reflective, gold plated, optics for maximum energy transmission to the infrared detector. 20 Hz scanning speed, with 1120 points of temperature measurement along the kiln, thus ensuring maximum coverage of the kiln shell surface. Fig1 Centurion TK20 infrared linescanner Robust, brushless dc motor, with very large bearings to withstand the vibrations experienced in a cement works, to overcome the high frequency of motor failure reported by users of some systems installed in India. (Fig 3) Digital control of all internal operations including control of the two (250(C and 100(C blackbody references) and motor speed. Digital transmission of temperature information to the computer located in the kiln control room. On line diagnostics for ease of trouble shooting. WinCem software, (Fig 4) which includes the following features: On line, live, temperature profile display, for each point along the kiln shell Maximum and minimum temperatures for each point along the kiln shell. Map of kiln surface temperatures. Historical trapping of data for at least 2 years. Temperature alarm annunciation and interfacing for automatic fan control. Trending of temperature data, past, present and future projection. Calculation of coating an brick thickness. Automatic printouts of historical data at user defined intervals. PosiTrak patented, built in, alignment software for linear measurement and display. Measurement of kiln speed and tyre slip (live ring migration) Event log. WinBrix Refractory expert Full Kiln geometry, features and zones. Full current and historical record keeping of refractory usage, with bricking diagrams and drilling data. Estimation of bricking wear rates and expected life. Brick performance analysis. Manufacturers data base. Planning facility for estimation of bricking requirements for shutdowns. Installation and requirement reports. Expert brick selection based on past performance comparisons. Material stock lists. Event log. Indigenous Support Full support from Thermoteknix Indian agents, SB Engineers, Ahmedabad. This includes fully trained technical staff for both pre and post sales support, with all necessary equipment to re-calibrate and provide service. Operational Benefits Vasavadatta were happy with the ease of installation of the system and setting up of the software. Thermoteknix provided all necessary calculations for scanner locations for both kilns and pre installation and commissioning site visits, which ensured that the 5 day commissioning and training period went smoothly. The systems installation and commissioning was planned for a period shortly after light-up of the new kiln. This was for two reasons: Operational staff were being trained and becoming familiar with the new control system during the pre-lightup, lightup and post-lightup periods, so were not free for hands on training in the use of this new equipment. For optimum installation and alignment, the kiln should be hot. The operational staff, nevertheless, very rapidly became familiar with the easy to use WinCem software. The detailed temperature information was used to provide information for the most beneficial location of the kiln shell cooling fans. Five fans are, in fact fixed and five are moveable. These fans are also controlled from the alarm function in the software, thus ensuring that they are used only when the shell temperature exceeds preset limits. Thus coating is encouraged to reform and, as the fans can be kept running until a lower temperature than the trigger set point, the coating can be built up to ensure that a good thickness is in place when the fans are turned off. There have been no occurrences of Hot Spot on either kiln, since installation, due to the use of the scanning system and advance preventative action being taken on the available information. Another very useful benefit has been the identification of an eccentric burner, which was identified by a ring of high temperature and whose realignment was confirmed by a reduction in the temperature in the subject area. Ring formation and elimination has also been an area in which the operators have been able to asses problems more effectively that with the moving pyrometer system that has been replaced on kiln1. As a result steps can be taken to minimise the effect of ring formation and also uneven development of coating, thus preventing uneven electrical load on the kiln drive. Historical temperature information, which is trapped on an hourly basis and can be stored for the whole of the campaign, is also used to identify areas of coating change and brick wear. Recent improvements in an upgrade of the software, issued at the end of the 1 year guarantee period, should make this valuable function even more accurate. (Fig 5) All temperatures can always be related to the installed refractory, as the current bricking chart is displayed at the same time as the temperature information. It is usually possible to see the changes in brick lining, due to the change in conductivity of the bricks, which results in the shell temperature being slightly different. Management Benefits The entire package has been found to very beneficial tools for Managers as well as the above benefits for operators. Daily printouts. The WinCem software is set up to provide a daily printout of the worst case kiln temperatures in the last 24 hours. This information is used at the daily production meetings and becomes more important as the campaign advanced into its end phase. At this time the trending facility becomes very beneficial. Trending As the campaign approached its end the WinCem trending facility becomes increasingly useful. It is able to show the past trending information, current detailed on line trends and project forward for a user defined period on Max, Mean and Min temperatures, at either a point on the kiln or over a range. Using this information, management have additional detail to assist in their operational decisions. Event Log The WinCem software contains an event logging facility, which not only traps all information regarding the operation of the program, but also alarm details and can take the place of the CCR log. This enables full details of any operational changes to be related to the kiln shell temperature and any incidents can be fully investigated, with all the necessary information to hand. Process improvements with assessment and ongoing training Use of the historical data has enabled management and staff to fully assess temperature associated kiln problems, the steps taken to correct them and thus incorporate this information into the ongoing staff training programme. This has helped to provide improvements in process operation and control, which is in turn contributing to cost reduction. WinBrix Refractory Expert (Fig 6 & 7) While providing a computerised version of the traditional kiln bricking diagram, this powerful software has been found to be very useful in other areas. Using the temperature information from WinCem to establish areas which will need attention at either short shutdowns or at the end of a campaign, when major re-bricking is needed, WinBrix is employed to calculate all the bricking requirements. This included the necessary castables as well as the exact number of bricks required for each section. Tabular information is instantly available for senior management and greatly assisted both stock control and the procurement operations. WinBrix contains an Expert section that can be used, over the medium to long term, to completely optimise the bricks in our kiln and will, we believe, provide good reductions in refractory consumption costs, due to this optimisation. We have been advised by the supplier that other companies have been able, by relating temperature information to brick performance, to identify areas in which different types of bricks should be tried to reduce the formation of rings and rapid refractory wear. While this may mean that the length of a section is increased or reduced, it may also mean that the type of brick can beneficially be changed. We hope that we shall benefit from this in the future, if we experience this problem. Production graph In order to estimate brick wear and life, daily production information is put into the WinBrix program. As a result of its Windows operating system, this information can also be provided in graphical form for management reports. Conclusion. Vasavadatta are very pleased with their investment in the Thermoteknix hardware and software. While there have been many expected and obvious benefits, there have also been areas in the management information facilities that have been very useful in the companies overall operational strategy. Vasavadatta believe that their decision to purchase this has given the best possible return on investment with an estimated payback of the order of 18 to 24 months. The fact that we have not had a hotspot since installing this equipment surely justifies this investment! Author Mr P. K. Goyenka President Vasavadatta Cement, Sedam Co-author Mr Colin E. Brock Sales Manager, Thermoteknix Systems Ltd, Cambridge, England The authors acknowledge the assistance of the staff of Vasavadatta Cement in the preparation of this paper. Captions to Figures: Fig1 Centurion TK20 infrared linescanner Fig 2. Centurion TK20 resolution calculation for kiln1. Note that the scanner is looking at an oblique angle to the kiln. It is located 21m from the kiln and 18 m from the discharge end of the kiln. The WinCem software fully linearises the x-axis for accurate distance measurements. Fig 3. Centurion TK20 brushless DC motor and Optics Fig 4. Screen shot of Vasavadatta Kiln 2, soon after commissioning. Note the change in temperature associated with the change in lining at 10.5m and 42 m. This screen display includes tyre slip information, as well as other vital data for on line information. Fig 5. Uneven coating development and start of ring formation. Fig 6 WinBrix is being used to calculate the optimum brick requirement for each section of the kiln. This is a typical summary. (NB! Brick prices are fictitious!) Fig 7. Typical bricking arrangement in the new Kiln2, with ongoing brick chart, part of the data available instantaneously in WinBrix Refractory Expert software. Fig 8. 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