Pub Date : 2014-04-13DOI: 10.1109/CITCON.2014.6820123
H. Henry, P. Tran
An EPA stakeholders group has been chartered to develop the performance specification for HCl monitoring systems to comply with the Portland Cement MACT rule as well as Utility MATS. This presentation will exhibit results of a demonstration test and the challenges of developing a continuous emissions monitoring system (CEMS) for HCl on a cement kiln application. Data from a continuous four month trial in which a tunable diode laser (TDL) system was operating on a cement kiln will be presented, including initial certification testing requirements and RATA results.
{"title":"Tunable diode laser (TDL) based HCl continuous emission monitoring system (CEMS) development challenges and monitoring technologies to meet the Portland Cement MACT rule","authors":"H. Henry, P. Tran","doi":"10.1109/CITCON.2014.6820123","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820123","url":null,"abstract":"An EPA stakeholders group has been chartered to develop the performance specification for HCl monitoring systems to comply with the Portland Cement MACT rule as well as Utility MATS. This presentation will exhibit results of a demonstration test and the challenges of developing a continuous emissions monitoring system (CEMS) for HCl on a cement kiln application. Data from a continuous four month trial in which a tunable diode laser (TDL) system was operating on a cement kiln will be presented, including initial certification testing requirements and RATA results.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"35 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124008178","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2014-04-13DOI: 10.1109/CITCON.2014.6820118
G. McKervey, S. W. Miller, Jared B. Weston
The Company was left with more finish grinding capacity than the 4-stage preheater kiln could supply, emission credits set to expire in 2011 and one of the healthier cement markets in the USA after shutting down a wet kiln in 2006. A strong, successful and healthy relationship with the original equipment supplier (OEM) has allowed the Company to implement new technologies to drive the operation of the equipment throughout the 30 year history of the production line. Recently, the Company chose the OEM in undertaking a number of upgrades to achieve an increase in capacity and improved efficiency. This paper highlights the steps taken during a 2-phase upgrade to achieve 2,200 STPD (2,000 MTPD) of clinker and allow the Company to remain at the forefront in implementing new technologies in the industry.
{"title":"Pyro and raw mill modifications to achieve 2,200 STPD","authors":"G. McKervey, S. W. Miller, Jared B. Weston","doi":"10.1109/CITCON.2014.6820118","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820118","url":null,"abstract":"The Company was left with more finish grinding capacity than the 4-stage preheater kiln could supply, emission credits set to expire in 2011 and one of the healthier cement markets in the USA after shutting down a wet kiln in 2006. A strong, successful and healthy relationship with the original equipment supplier (OEM) has allowed the Company to implement new technologies to drive the operation of the equipment throughout the 30 year history of the production line. Recently, the Company chose the OEM in undertaking a number of upgrades to achieve an increase in capacity and improved efficiency. This paper highlights the steps taken during a 2-phase upgrade to achieve 2,200 STPD (2,000 MTPD) of clinker and allow the Company to remain at the forefront in implementing new technologies in the industry.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"72 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114737710","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2014-04-13DOI: 10.1109/CITCON.2014.6820109
G. Seggewiss, Jingya Dai, M. Fanslow
Synchronous motors continue to be a viable alternative to induction motors because of efficiency advantages. Long used for providing leading kVARs for PF improvement and helping with the device switching in Load Commutated Inverter (LCI) drives, these machines are efficient prime movers for large Mill applications. Both in motor efficiency and in low base speed configurations the synchronous motor has advantages of lower current and higher efficiency. Often used in large Mills in the cement and mining industry, these motors were driven by LCI variable-frequency drives (VFDs) or used with direct start with a clutch system that would synchronize the motor first to overcome low starting torques. This paper reviews various Mill drive configurations and improved synchronous motor characteristics when used with more advanced Current Source Inverter (CSI) drives. It will also review the different synchronous motor excitation types and resulting performance characteristics with VFD control for new or retrofit installations.
{"title":"Evaluation of synchronous motors on grinding mills","authors":"G. Seggewiss, Jingya Dai, M. Fanslow","doi":"10.1109/CITCON.2014.6820109","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820109","url":null,"abstract":"Synchronous motors continue to be a viable alternative to induction motors because of efficiency advantages. Long used for providing leading kVARs for PF improvement and helping with the device switching in Load Commutated Inverter (LCI) drives, these machines are efficient prime movers for large Mill applications. Both in motor efficiency and in low base speed configurations the synchronous motor has advantages of lower current and higher efficiency. Often used in large Mills in the cement and mining industry, these motors were driven by LCI variable-frequency drives (VFDs) or used with direct start with a clutch system that would synchronize the motor first to overcome low starting torques. This paper reviews various Mill drive configurations and improved synchronous motor characteristics when used with more advanced Current Source Inverter (CSI) drives. It will also review the different synchronous motor excitation types and resulting performance characteristics with VFD control for new or retrofit installations.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"67 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127941736","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2014-04-01DOI: 10.1109/CITCon.2014.6820107
A. Edwards, S. Nielson
This paper will discuss the strategy taken by our Company in response to the ever-changing Portland Cement National Emission Standards for Hazardous Air Pollutants (PC NESHAP), also known as the Portland Cement Maximum Achievable Control Technology (PC MACT), requirements and compliance dates. The new regulations called for continuous monitoring for mercury, particulate matter, total hydrocarbon emissions, and hydrochloric acid. The company took the strategy to install equipment in anticipation of a September 2013 compliance date and use any additional time that might become available to refine techniques. These installations were being commissioned in the fall of 2012 and early in 2013. This paper discusses the process utilized to design and install various continuous emissions monitoring systems (CEMS), lessons learned since the installations, and developments in how industry is attempting to comply with regulations where the Performance Specifications still are not fully developed, or the technology is not commercially available to demonstrate compliance.
{"title":"CEMS strategy for portland cement maximum achievable control technology (PCMACT)","authors":"A. Edwards, S. Nielson","doi":"10.1109/CITCon.2014.6820107","DOIUrl":"https://doi.org/10.1109/CITCon.2014.6820107","url":null,"abstract":"This paper will discuss the strategy taken by our Company in response to the ever-changing Portland Cement National Emission Standards for Hazardous Air Pollutants (PC NESHAP), also known as the Portland Cement Maximum Achievable Control Technology (PC MACT), requirements and compliance dates. The new regulations called for continuous monitoring for mercury, particulate matter, total hydrocarbon emissions, and hydrochloric acid. The company took the strategy to install equipment in anticipation of a September 2013 compliance date and use any additional time that might become available to refine techniques. These installations were being commissioned in the fall of 2012 and early in 2013. This paper discusses the process utilized to design and install various continuous emissions monitoring systems (CEMS), lessons learned since the installations, and developments in how industry is attempting to comply with regulations where the Performance Specifications still are not fully developed, or the technology is not commercially available to demonstrate compliance.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"275 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123716250","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2014-04-01DOI: 10.1109/CITCon.2014.6820116
C. G. Ruffennach
The Mine Safety and Health Administration (MSHA) is a federal law enforcement agency that enforces electrical and other regulations at mining and cement operations. Many of the electrical regulations, which are set out at 30 C.F.R. Part 56.12, can be fairly characterized as simplistic, broad, dated and confusing. MSHA often reads requirements or prohibitions into its regulations that are not evident from the language of the regulations. Mine operators need to understand that the regulations are essentially interpreted by MSHA using a “reasonably prudent person” standard. An operator's failure to anticipate MSHA's changing expectations for a reasonably prudent person can result in substantial penalties, closure orders, abatement predicaments and even penalties against its management. Supervisors and managers with responsibility for electrical systems, particularly those using newer technologies that are beyond MSHA's expertise, need to be proactive in anticipating, avoiding and addressing creative MSHA enforcement.
{"title":"MSHA's electrical regulations: Use prudence to avoid pitfalls","authors":"C. G. Ruffennach","doi":"10.1109/CITCon.2014.6820116","DOIUrl":"https://doi.org/10.1109/CITCon.2014.6820116","url":null,"abstract":"The Mine Safety and Health Administration (MSHA) is a federal law enforcement agency that enforces electrical and other regulations at mining and cement operations. Many of the electrical regulations, which are set out at 30 C.F.R. Part 56.12, can be fairly characterized as simplistic, broad, dated and confusing. MSHA often reads requirements or prohibitions into its regulations that are not evident from the language of the regulations. Mine operators need to understand that the regulations are essentially interpreted by MSHA using a “reasonably prudent person” standard. An operator's failure to anticipate MSHA's changing expectations for a reasonably prudent person can result in substantial penalties, closure orders, abatement predicaments and even penalties against its management. Supervisors and managers with responsibility for electrical systems, particularly those using newer technologies that are beyond MSHA's expertise, need to be proactive in anticipating, avoiding and addressing creative MSHA enforcement.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128512002","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2014-04-01DOI: 10.1109/CITCon.2014.6820120
C. Leivo, J. Lange, D. Ramshaw
More than thirty years ago, the industrial gas cleaning industry began to explore low-pressure-pulse cleaning filtration as a means to improve baghouse installations in various process industries from the standpoint of simplicity, maintenance, and safety. “Low-Pressure High-Volume” cleaning pulse has come to be referred to as LPHV pulse-jet baghouse technology. Early introductions were in the metallurgical and power industries beginning in the late-seventies and early-eighties. By the second-half of the nineties, LPHV baghouses were being installed on cement kilns and clinker coolers. And by 2005 cement kiln ESPs were being converted to LPHV pulse-jet baghouses. Lower maintenance and operating costs have been significant factors in selection of this technology approach. Details of operation and maintenance with LPHV pulse cleaning are presented in this paper.
{"title":"Reduced baghouse maintenance with LPHV pulse cleaning technology","authors":"C. Leivo, J. Lange, D. Ramshaw","doi":"10.1109/CITCon.2014.6820120","DOIUrl":"https://doi.org/10.1109/CITCon.2014.6820120","url":null,"abstract":"More than thirty years ago, the industrial gas cleaning industry began to explore low-pressure-pulse cleaning filtration as a means to improve baghouse installations in various process industries from the standpoint of simplicity, maintenance, and safety. “Low-Pressure High-Volume” cleaning pulse has come to be referred to as LPHV pulse-jet baghouse technology. Early introductions were in the metallurgical and power industries beginning in the late-seventies and early-eighties. By the second-half of the nineties, LPHV baghouses were being installed on cement kilns and clinker coolers. And by 2005 cement kiln ESPs were being converted to LPHV pulse-jet baghouses. Lower maintenance and operating costs have been significant factors in selection of this technology approach. Details of operation and maintenance with LPHV pulse cleaning are presented in this paper.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"7 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125561762","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2014-04-01DOI: 10.1109/CITCon.2014.6820117
G. Cinti, J. Riva
This paper will highlight the innovations associated with a new dry line which will substitute two (2) existing semidry lines for grey clinker production first started-up in the middle of the 1960s. Important reserves of high quality limestone guarantee long life for the new installation which is designed to fulfill both the present and future needs of a sustainable production - in particular related to the minimization of local environmental impacts and total energy consumption. The new line combines several innovative solutions, some of which have a limited number of installations (such as the installation of a roller press in the finishing configuration of the raw meal grinding installation) while some are entirely unique to the cement industry (such as the installation of a ceramic bag filter for the direct dedusting of the cooler vent air and the reuse of its hot, clean air for multiple energy recovery systems).
{"title":"New 3000 TPD line in Italy: Innovation for a sustainable production","authors":"G. Cinti, J. Riva","doi":"10.1109/CITCon.2014.6820117","DOIUrl":"https://doi.org/10.1109/CITCon.2014.6820117","url":null,"abstract":"This paper will highlight the innovations associated with a new dry line which will substitute two (2) existing semidry lines for grey clinker production first started-up in the middle of the 1960s. Important reserves of high quality limestone guarantee long life for the new installation which is designed to fulfill both the present and future needs of a sustainable production - in particular related to the minimization of local environmental impacts and total energy consumption. The new line combines several innovative solutions, some of which have a limited number of installations (such as the installation of a roller press in the finishing configuration of the raw meal grinding installation) while some are entirely unique to the cement industry (such as the installation of a ceramic bag filter for the direct dedusting of the cooler vent air and the reuse of its hot, clean air for multiple energy recovery systems).","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"79 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132592679","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2014-04-01DOI: 10.1109/CITCon.2014.6820119
E. L. Morton
Optimization of TSR in cement kilns can be achieved by using a high quality and consistent alternative fuel product. This case study indicates how a rigorous QC based approach to the production of solid alternative fuels in cement kilns was developed that contributes to maximum TSR. PEF differs from conventional solid alternative fuels in that production begins with the best material possible as the main feedstock and then selected industrial and commercial by-products of known and consistent composition are added to improve the overall mix and thus achieve the desired quality specifications. The PEF concept allows for maximum thermal substitution rates at either a main burner or in a calciner because the product is matched to the specific cement kiln needs and limits.
{"title":"Quality based process engineered fuel concept","authors":"E. L. Morton","doi":"10.1109/CITCon.2014.6820119","DOIUrl":"https://doi.org/10.1109/CITCon.2014.6820119","url":null,"abstract":"Optimization of TSR in cement kilns can be achieved by using a high quality and consistent alternative fuel product. This case study indicates how a rigorous QC based approach to the production of solid alternative fuels in cement kilns was developed that contributes to maximum TSR. PEF differs from conventional solid alternative fuels in that production begins with the best material possible as the main feedstock and then selected industrial and commercial by-products of known and consistent composition are added to improve the overall mix and thus achieve the desired quality specifications. The PEF concept allows for maximum thermal substitution rates at either a main burner or in a calciner because the product is matched to the specific cement kiln needs and limits.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129823751","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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