2. fluidcon-conveying - ALUMINIUM MIDDLE EAST 2015

Report
ALUMINIUM MIDDLE EAST 2013
Innovative Process Technology for the Aluminium Industry of the Middle East Region
Dipl.-Ing. Jens Garbe
Territory Sales Manager
A Langley Holdings Company
1 Projects GmbH
Claudius Peters
Index
1. INTRODUCTION
2. FLUIDCON-CONVEYING
3. ANTI SEGREGATIONSYSTEM
4. ALUMINA DISTRIBUTIONSYSTEM
5. ANODE COKE GRINDING
6. SUMMARY
A Langley Holdings Company
2 Projects GmbH
Claudius Peters
CLAUDIUS PETERS history
Evolution of Claudius Peters Projects GmbH
1906
1933 - 1995
Glockengiesserwall The ESTE at Buxtehude 1954
A Langley Holdings Company
2001
Cityhof 1954
City Nord
Officesince 1988
Claudius Peters Projects GmbH
The Claudius Peters Group
ClaudiusPetersTechnologies
S.A.S.
A Langley Holdings Company
ClaudiusPetersAmericas
Inc.
ClaudiusPetersProjects
GmbH
Claudius Peters
(Ibérica) S.A.
Claudius Peters
(Románia) SRL
Claudius Peters
(India) Pvt. Ltd.
Claudius Peters
(UK) Ltd.
Claudius Peters
(Italiana) srl.
Claudius Peters
(Asia Pacific) PTE. LTD.
Claudius Peters
(China) Ltd.
Hong Kong
Claudius Peters
(China) Ltd.
Beijing
Claudius Peters
do Brasil Ltda.
Claudius Peters Projects GmbH
Territory Assignment of Claudius Peters Offices
A Langley Holdings Company
Claudius Peters Projects GmbH
Claudius Peters’ Target Industries
Cement &
Building Materials
Lime
Iron & Steel
Solid Fuel
Power Plants
Alumina Refineries
Aluminium Smelters
Light Weight
Aggregates
Gypsum
Fertiliser and
Other Materials
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Claudius Peters Projects GmbH
Claudius Peter´s Scope of Supply
Delivery of Plant Engineering
Plant Process Control / Automation
Project Management
Calculation of Process Parameters
Manufacturing of Key-Components
Quality Control of Local Manufacturing
Delivery of Plant Equipment
Supervision of Erection
Erection
Commissioning & Training
After Sales Services
Spare Part Services
Bulk Material Tests (Technical Centre)
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Claudius Peters Projects GmbH
Claudius Peters System Components
A Langley Holdings Company
Claudius Peters Projects
Technologies
GmbH
Claudius Peters Manufacturing
A Langley Holdings Company
Claudius Peters Projects GmbH
Claudius Peters Aerospace
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Claudius Peters Projects GmbH
Claudius Peters Research & Development
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Claudius Peters Projects GmbH
WHICH EQUIPMENT WE ARE
ABLE TO SUPPLY FOR YOUR
INDUSTRY?
A Langley Holdings Company
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Claudius Peters Projects GmbH
Alumina Refinery
Ship Unloader
PrimaryAlumina Silo
Alumina Day Silo
SecondaryAluminaSilo
Aluminium Reduction Cell
Carbon Plant
Stacker &
Reclaimer
BM H
BM H
Aluminium Smelter
A Langley Holdings Company
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Claudius Peters Projects GmbH
Index
1. INTRODUCTION
2. FLUIDCON-CONVEYING
3. ANTI SEGREGATIONSYSTEM
4. ALUMINA DISTRIBUTIONSYSTEM
5. ANODE COKE GRINDING
6. SUMMARY
A Langley Holdings Company
14 Projects GmbH
Claudius Peters
EQUIPMENT FOR THE ALUMINIUM INDUSTRY
Smart Pneumatic Conveying
FLUIDCON
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Claudius Peters Projects GmbH
FLUIDCON CONVEYING SYSTEM
Combine advantages – …
Advantages
• low conveying velocities
• low wear
• low power requirement
Advantages
• flexiblepipeline routing
• horizontal and vertical conveyance
• dusttight
… eliminate disadvantages
Disadvantages
• installation height required
• installation not flexible
• only inclined conveyance
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Disadvantages
• high conveying velocities
• no diagonal conveyance
• high power requirement
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Claudius Peters Projects GmbH
FLUIDCON-Design
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Claudius Peters Projects GmbH
FLUIDCON-Design
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Claudius Peters Projects GmbH
ALUMINA CONVEYING WITH 10° SLOPE
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Claudius Peters Projects GmbH
FLUIDCON SYSTEM
135 t/h Alumina 440m horizontal,elevation32,6m (25° Pipe inclination)
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Claudius Peters Projects GmbH
CHALLENGES OF FLUIDCON
1.
Application of all known feeding devices
→ Optimization of existing plants
2. Horizontal, vertical and diagonal conveying sections
→ Optimumpipeline routing
3. Energy savings of up to 75%
→ Operationalcosts saving
4. Low conveying velocities
→ Reduction of wear
→ Constant materialproperties (low attrition)
5.
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Low conveying pressures
→ Use of blowers instead of compressor
→ Use of pumps,star feeders, double pendulum flaps
→ Low construction heights, low investment cost
6. Simplerestart after e.g. emergency stop
→ High availability
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Claudius Peters Projects GmbH
Referencesof Alumina Conveying
Year
Country
Material
Distance
Feeder
Capacity[t/h]
2005
Russia
Alumina
80
Pump
150
2005
Russia
Alumina
80
Pump
150
2006
Russia
Alumina
400
Pump
135
2007
Norway
Alumina
216
Pump
15
2007
Norway
Alumina
35,5
Pump
4
2007
Norway
Alumina
119
Pump
4
2007
Russia
Alumina
250
Rotarylock
3
2007
Norway
Alumina
30
Doublependulumfla
p
1
2008
Montenegro
Alumina
300
Rotarylock
18
2008
Montenegro
Alumina
290
Rotarylock
18
A Langley Holdings Company
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Claudius Peters Projects GmbH
Index
1. INTRODUCTION
2. FLUIDCON-CONVEYING
3. ANTI SEGREGATIONSYSTEM
4. ALUMINA DISTRIBUTIONSYSTEM
5. ANODE COKE GRINDING
6. SUMMARY
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23 Projects GmbH
Claudius Peters
Storage Silo with
Anti Segregation System
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Target
• Prevent Air Current Segregation
• Maximizing Silo Capacity
• Maximizing Homogenization of Alumina
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Claudius Peters Projects GmbH
AIR CURRENT SEGREGATION
IDENTIFIED MECHANISM
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Claudius Peters Projects GmbH
AIR CURRENT SEGREGATION
PRINCIPLE PATTERN
Separation by drag forces on the individual particles.
Particle below 50 µm may be carried by the air
flows,
Settles out when air flow slows down or changes
direction.
Found to be dominant when handling Alumina
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AIR CURRENT SEGREGATION
COURSE OF EVENT
Segregation means local changes
in the grain size distribution,
separation into
fine and coarse material particles
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Claudius Peters Projects GmbH
50-KTON ALUMINA STORAGE SILO
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Claudius Peters Projects GmbH
ALUMINA SILO WITH ASS
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Claudius Peters Projects GmbH
ALUMINA HEAP
AT SILO BOTTOM
Alumina Heap
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Claudius Peters Projects GmbH
ASS Alumina Storage
Silo Feeding System
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Claudius Peters Projects GmbH
ALUMINA SILO
FEEDING SYSTEM
An typical example for an:
Anti-Segregation
Feeding System:
•8Anti- SegregationTubes
•1st 8 BypassFeeding Points
•2nd 8 BypassFeeding Points
•1 Central Feeding
Point
A Langley Holdings Company
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Claudius Peters Projects GmbH
Conclusions
Minimizing segregation in alumina storage
silos has been improved with the development of a charging and
discharging technology.
- Filling the silo with vertical installed AS-Tubes
- Blending with differentpattern layers on silo bottom
- Sectional discharge flow through silo bottom
A Langley Holdings Company
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Claudius Peters Projects GmbH
Anti Segregation System / References
Year
Country
Diameter[m]
2000
Norway
18
6,000
2001
Jamaica
39
50,000
2001
Brazil
32
25,000
2004
Brazil
42.7
50,000
2007
Brazil
42.7
50,000
2011
Russia
27.5
18,000
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Capacity[t]
Claudius Peters Projects GmbH
Index
1. INTRODUCTION
2. FLUIDCON-CONVEYING
3. ANTI SEGREGATIONSYSTEM
4. ALUMINA DISTRIBUTIONSYSTEM
5. ANODE COKE GRINDING
6. SUMMARY
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36 Projects GmbH
Claudius Peters
Alumina Distribution System
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Claudius Peters Projects GmbH
ADS© AERATED DISTRIBUTION SYSTEM
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Claudius Peters Projects GmbH
ALUMINA DISTRIBUTION SYSTEM (ADS)
Inlet box
Distribution airslide
Buffer silo
Inlet box
Separator
Distribution box
●capacity of cell airslide10 tph inclination 0.5°
●capacity of each distribution airslide 50 tph39
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Claudius Peters Projects GmbH
Function of ADS
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FUNCTION OF THE ADS
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Claudius Peters Projects GmbH
OUTDOOR POTROOM
CLIMATE CONDITION
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Claudius Peters Projects GmbH
Alumina Distribution System / References
Year
Country
Plant
System
2006
Russia
Khakas
Sayanogorsk
2ADSservingintotal336pots
2010
Qatar
Qatalum
4ADSservingintotal704pots
* Related to 32 HGI and 25%R74 µm
A Langley Holdings Company
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Claudius Peters Projects GmbH
Operational Results
• Preventing foreign particles entering the transport system (Screening)
• No grain abrasion and no grain fracture
• Slow alumina conveying velocity, no grain destruction and no scaling
• Closed system and controlled material flow and no dust emission
• No leakage or material spillage within the potroom area
• PLC monitor and record the status of material conveying & distribution
• Energy saving due to intermittend feeding
A Langley Holdings Company
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Claudius Peters Projects GmbH
Index
1. INTRODUCTION
2. FLUIDCON-CONVEYING
3. ANTI SEGREGATIONSYSTEM
4. ALUMINA DISTRIBUTIONSYSTEM
5. ANODE COKE GRINDING
6. SUMMARY
A Langley Holdings Company
45 Projects GmbH
Claudius Peters
Modern Claudius Peters EM mill with
dynamic classifier
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46
Claudius Peters Projects GmbH
Claudius Peters mill type EM 65-592
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Claudius Peters Projects GmbH
Grinding elements of EM-mill
Upper grinding ring
Grindingballs
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Lower grinding ring
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Photograph of the grinding elements
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Claudius Peters Projects GmbH
Grinding system of EM-mill
Spring tensioning frame
Pressure
ring
Hydraulic
cylinders
Mill yoke
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Claudius Peters Projects GmbH
Claudius Peters grinding system
for calcined Petcoke
System Fan
M
Filter Plant
Raw Petcoke
Off Gas
F
Stack
M
M
Rotary
Feeder
with FC
M
Pulverized Petcoke
Dynamic
Classifier
with FC
M
EM Mill
∆P
P
Ambient Air
M
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Claudius Peters Projects GmbH
Comparison between vertical and horizontal mill
Calcinedpetcokecokegrindingsystems
Technique
Operationmode
Verticalballmill
Horizontalballmill
Continuous
Start/Stop
Throughputregulation
range
25%-100%
90%-100%
NoiseLevelMill
 85dB(A)
 100dB(A)
3000-5000±150
2500-4500±500
Grindingelementsfreeof
maintenance
Addingsteelballs
everyweeks
appr.80g/t(0032+0032)
150-300g/t
Fineness
(Blaine)
Maintenance
MetalcontentinFines
(wear)
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Claudius Peters Projects GmbH
Comparison between vertical and horizontal mill
Technique
Verticalballmill
Horizontalballmill
Throughput
Constantgrindingarea
constantthroughput
Ballwearing
throughputreduced
Dynamicclassifier
InternalClassifier
simplesystem
ExternalClassifier
RawMaterialsize
0–50mm
0–6mm
Materialleftinmill
afterstop
0.1-0.5t
Systempower
consumption
32-36kWh/t
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6-7t
55-60kWh/t
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Claudius Peters Projects GmbH
Anode coke grinding plants – references
Year
Country
Millsize
System
2002
China
EM65
Centralgrinding
system
12t/h
2003
China
EM65
Centralgrinding
system
12t/h
2007
UAE
EM73
Mill
14,25t/h
2007
UAE
EM73
Mill
14,25t/h
2007
China
EM73
Centralgrinding
system
14t/h
2008
Kazakhstan
EM59
Centralgrinding
system
8t/h
2010
China
EM80
Centralgrinding
system
20t/h
2011
UAE
EM80
Mill
Capacity
15,4t/h*
* Related to 32 HGI and 25%R74 µm
A Langley Holdings Company
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Claudius Peters Projects GmbH
PatentedAnode Coke Grinding System
Remark:
Patent granted for Germany, France, Great Britain, Italy, USA, China, Japan and India (pending)
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Claudius Peters Projects GmbH
Index
1. INTRODUCTION
2. FLUIDCON-CONVEYING
3. ANTI SEGREGATIONSYSTEM
4. ALUMINA DISTRIBUTIONSYSTEM
5. ANODE COKE GRINDING
6. SUMMARY
A Langley Holdings Company
56 Projects GmbH
Claudius Peters
EQUIPMENT SUPPLY FOR
ALUMINA REFINERY
Claudius Peters Supply
Alumina Refinery
BMH
BMH
Handling Bauxite
ClaudiusPeters
COMPONENTS
PETERSAirlift
Dedusting
Feeding
Bin with
conveying pipe
Conveying air nozzle
Aeration bottom
Main components
Claudius Peters
COMPONENTS
Pressure vessel systems
P icture no.2 1
SILO ASS
STOCKYARD
FLUIDCON
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EQUIPMENT SUPPLY FOR
ALUMINIUM SMELTER PLANT
Claudius Peters Supply
BM H
BM H
ClaudiusPeters
COMPONENTS
Dedusting
PETERSAirlift
Feeding
Bin with
conveying pipe
Aeration bottom
Claudius Peters
COMPONENTS
Conveying air nozzle
Main components
Pressure vessel systems
P icture no .21
AIRLIFT
Pressure Vessel
A Langley Holdings Company
POT FEEDING
SILO AS-Sys
FLUIDCON
58
GRINDING SYSTEM
Claudius Peters Projects GmbH
Thank you for your kind attention
A Langley Holdings Company
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Claudius Peters Projects GmbH

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