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© Paul Wurth IHI 2017 1 SEAISI 2017 – Paul Wurth's PCI Technology
Pulverized Coal Injection
-
Paul Wurth’s Technology for New Installations and Plant Upgrades
P. Mahowald, Head of Injection Technologies, Paul Wurth S.A. - Luxembourg
E. Censi, Senior Project Engineer, Paul Wurth S.A. - Luxembourg
D. Michels, Technical Manager, Paul Wurth IHI Co., Ltd. - Japan
Presenter: D. Michels, Paul Wurth IHI Co., Ltd. - Japan
© Paul Wurth IHI 2017 2 SEAISI 2017 – Paul Wurth's PCI Technology
• Basics of pneumatic conveying Dilute vs. dense phase conveying
Cost comparison
• Distribution types Static vs dynamic distribution
Gritzko flow rate control valve
• Plant upgrades ROI case study for upgrade from static to dynamic distribution
• Upgrade of dilute phase PCI plants General
PWIHI R&D program
Results
• Recent references
Contents
© Paul Wurth IHI 2017 3
Basics of Pneumatic Conveying
SEAISI 2017 – Paul Wurth's PCI Technology
Gas retention Fluidization
© Paul Wurth IHI 2017 4
Dilute vs. Dense Phase Conveying
SEAISI 2017 – Paul Wurth's PCI Technology
Dilute phase
- High speed (pipe wear )
- More pneumatic power per
coal unit mass
- More N2 required
- Lower combustion eff.
+ Low operating pressure
Dense phase
+ Low speed (pipe wear )
+ Less pneumatic power per
coal unit mass
+ Less N2 required
+ Higher combustion eff.
- Higher operating pressure
© Paul Wurth IHI 2017 5
Cost Comparison
SEAISI 2017 – Paul Wurth's PCI Technology
• Reduced operational cost for dense phase conveying Less pneumatic power per coal unit mass
Less N2 required
• Lower lifecycle costs despite higher initial capital cost
Time
Total costs
100%
7 months in recent project
© Paul Wurth IHI 2017 6
Static Distribution
• Same equivalent pipeline length (same flow resistance) of all injection lines
• Improved distribution accuracy by installing a calibrated nozzle (sub-critical expansion tuyere) in each Injection Line
• Equal distribution onto all the Injection Lines by means of a coal flow rate measurement device, a coal flow rate control valve and a closed loop control installed in each Injection Line
• Best distribution accuracy through individual flow rate control
Dynamic Distribution
Static vs Dynamic Distribution
SEAISI 2017 – Paul Wurth's PCI Technology
© Paul Wurth IHI 2017 7
Static vs Dynamic Distribution
SEAISI 2017 – Paul Wurth's PCI Technology
With individual flow rate control
Individual flow rate control switched off
BF 6 – Cockerill Sambre Seraing - Belgium
© Paul Wurth IHI 2017 8
Dynamic Distribution
SEAISI 2017 – Paul Wurth's PCI Technology
• Closed-loop-control with GRITZKO® flow rate control valve and flow rate measurement device installed in main conveying line and in each injection line.
• Excellent accuracy
Global flow ± 2 % *
Distribution accuracy ± 2.5 % *
• High availability
• Proven and reliable technology
* On 5 minute average
© Paul Wurth IHI 2017 9
Upgrade ArcelorMittal Gent - Results
ArcelorMittal Gent, BF B – Belgium: Equal distribution with average deviation below 1.5% on 5 minutes average
0.0 %
0.5 %
1.0 %
1.5 %
2.0 %
2.5 %
3.0 %
3.5 %
4.0 %
4.5 %
5.0 %
1500
1550
1600
1650
1700
1750
1800
1850
1900
1950
2000
0 1000 2000 3000 4000 5000 6000 7000
Time (s)
Ave
rage
De
viat
ion
(%
)
Ind
ivid
ual
Co
al F
low
Rat
e (
kg/h
)
AM Gent BFBEqual Distribution of the Global Flow onto the Injection Lines
Average Deviation
SEAISI 2017 – Paul Wurth's PCI Technology
© Paul Wurth IHI 2017 10
GRITZKO® Flow Rate Control Valve
SEAISI 2017 – Paul Wurth's PCI Technology
• High resistance to abrasive material
• Used for global flow control on conveying line or individual flow control in injection lines
• Usually linked to a Cabloc device
© Paul Wurth IHI 2017 11
Plant Upgrades
SEAISI 2017 – Paul Wurth's PCI Technology
• Increase of grinding and drying capacities
• Increase of storage capacities
• Intermediate transports
• Increase of conveying flow rates
• Increase of injection rates
• Increase of accuracy of global injection flow rate control
• Upgrade to dynamic distribution: increase of accuracy of the equal distribution of global injection flow onto the injection lines For existing dense phase plants
For existing dilute phase plants
© Paul Wurth IHI 2017
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Cu
mu
late
d s
avin
gs
[Mio
. €]
Months of plant operation after upgrade
ROI of a Plant Upgrade from Static to Dynamic Distribution - Case study: Nom. BF prod. = 4 500 [tHM/d] - Price Delta between Coke and Coal* = 60 [€/t] - Coal-Coke-Replacement ratio = 0,85 *including OPEX for GAD & PCI Savings at an injection rate increased by 10 kg/tHM PCI rate
Savings at an injection rate increased by 8 kg/tHM PCI rateSavings at an injection rate increased by 6 kg/tHM PCI rate
Savings at an injection rate increased by 4 kg/tHM PCI rate
Savings at an injection rate increased by 2 kg/tHM PCI rate
CAPEX range for Upgrade from static to dynamic
distribution
12
ROI for Upgrade to dynamic distribution
SEAISI 2017 – Paul Wurth's PCI Technology
© Paul Wurth IHI 2017 13
Upgrade of Dilute Phase PCI Plant
SEAISI 2017 – Paul Wurth's PCI Technology
• PW has proven track record for new installations & plant upgrades in dense phase More than 100 references
More than 1.000 GRITZKO® valves installed
• Next step: adopt GRITZKO® valves to existing dilute phase plants Upgrade of existing dilute flow PCI plants from static distribution to
dynamic distribution
For reaching significantly better equal distribution accuracy between individual injection lines
• PWIHI undertook a significant R&D program in this regard Test campaign conducted by operating a physical test plant with
two GRITZKO® valves in dilute phase environment
CFD analysis
© Paul Wurth IHI 2017 14
PWIHI Test Installation
SEAISI 2017 – Paul Wurth's PCI Technology
• Located at IHI R&D centre, Yokohama, Japan
• Main characteristics:
Two full size GRITZKO® valves installed
Testing in actual operating conditions
Flow rate of up to 1.000 kg/h of coal
Dilute load level from 10 to 20 kg coal/N2
© Paul Wurth IHI 2017
• Main results from test plant:
Excellent controllability of GRITZKO® valves in dilute phase
Clear relationship established between differential pressure and opening position as well as flow rate
15
PWIHI Test Installation
SEAISI 2017 – Paul Wurth's PCI Technology
Dif
fere
nti
al p
ress
ure
bet
wee
n u
pst
ream
an
d d
ow
nst
ream
of
GR
ITZK
O®
val
ve (k
Pa)
GRITZKO® valve opening position (%)
© Paul Wurth IHI 2017 16
CFD Analysis
SEAISI 2017 – Paul Wurth's PCI Technology
• Main results from CFD analysis
Good correlation with physical tests
Definition of necessary wear protection upstream and downstream of GRITZKO® valves
Dense phase
Dilute phase
© Paul Wurth IHI 2017 17
References for Individual Flow Control
SEAISI 2017 – Paul Wurth's PCI Technology
Dense phase dynamic distribution ArcelorMittal Gent (Belgium)
BF ‘A’ & BF ‘B’
ArcelorMittal Liège (Belgium)
BF ‘B’ & BF ‘6’
ArcelorMittal Fos-sur-Mer (France)
BF ‘1’ & BF ‘2’
ArcelorMittal Gijón (Spain)
BF ‘A’ & BF ‘B’
Trinecke (Czech Republic)
BF ‘4’ & BF ‘6’
DMKD (Ukraine)
BF ‘1M’, BF ‘8’, BF ‘9’ & BF ‘12’
Kardemir (Turkey)
BF ‘5’
NSSMC Kashima (Japan)
BF ‘1’ & BF ‘3’
NSSMC Wakayama (Japan)
BF ‘1’ & BF ‘2’
Dense phase distribution hopper with individual flow control ThyssenKrupp (Germany)
BF ‘1’, BF ‘2’, BF ‘4’ & BF ‘9’
ROGESA (Germany)
BF ‘3’, BF ‘4’ & BF ‘5’
Salzgitter (Germany)
BF ‘A’ & BF ‘B’
ArcelorMittal Dunkirk (France)
BF ‘2’, BF ‘3’ & BF ‘4’
Hyundai Steel (Korea)
BF ‘1’, BF ‘2’ & BF ‘3’
Dilute phase upgrade from static to dynamic distribution NSSMC Kashima (Japan)
BF ‘1’& BF ‘3’
NSSMC Nagoya (Japan)
BF ‘1’ & BF ‘3’ (upcoming)
© Paul Wurth IHI 2017
Paul Wurth IHI Co., Ltd. Toyosu Center Building, 3-3, Toyosu 3-chome, Koto-ku,
Tokyo 135-6009 Japan Phone: +81-3-6630-4786
Daniel Michels Phone: +81-3-6630-4786 Fax: +81-3-3536-4014
Mobile: +81-90-2455-2932 e-mail: [email protected]
18 SEAISI 2017 – Paul Wurth's PCI Technology
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