TECNICELPA

Lime kilnWhat are the newestprojects using?March 04, 2015 Golegã

TECNICELPA conferenceMarch 04, GolegãLime Kiln: 11.15 – 12.45

� Valmet continues the FLS Lime kiln technology.� Lime kiln sizing� Cooler technology� Flash dryer technology� Kiln supports� Trust� Refractory� Modern emission levels� New instrument� Questions?

The Valmet lime kiln

License agreementwith FLS

Valmet lime kiln technology

In July 2013, Valmet acquired anexclusive license to use FLSmidth’slime kiln and recausticizingtechnology

The acquisition complementsValmet’s portfolio as a full-scopesupplier to the pulp & paper industry

The acquisition involves resources inDenmark, USA, India and China

Pulp millSödra Cell, Värö, Sweden

Valmet lime kiln technology

A new technology center has beenestablished in Copenhagen.

30 key-persons from FLS continuesin Valmet from all functions includingSpare parts and Service.

The acquisition involves resources inDenmark, USA, India and China

ValmetCopenhagen, Denmark

Name: John Middelhede

Education:

- Bachelor degree in Mechanical/process Engineering

Professional Experience:

- Valmet (2013 – now):

* Sales Manager Lime Reburning Kilns

- FLSmidth (2003 – 2013):

* Sales Manager Lime Reburning Kilns

- FLSmidth (1989 – 1997):

* Process engineer Lime reburning kilns (5 years)

* Process engineer Flue Gas Cleaning (3 years)

Contact: john.middelhede@valmet.com

Cellular: +45 6023 8812

The modern Pulp mill

Getting bigger

120 tDS/24h1933

1,500 tDS/24h1976

2,000 tDS/24h1986

3,800 tDS/24h1996

7,000 tDS/24h2006

15 t/d1905

1.8 × 22 m

450 t/d1991

4.15 × 120 m

600 t/d1992

4.15 × 95 m

1,050 t/d1996

5.0 × 115 m

1,250 t/d2014

5.5 × 140 m

Ready for next-generationrecovery boilers withstandard kiln components

Getting biggerRecovery boilers and lime kilns

The Valmet lime kiln

Cooler technology

Until 1991:FLSmidth Unax™

From 1992:FLSmidth Compax™

Now:FLSmidth Cross-Bar™ cooler

3% less fuel 3% less fuel

Cooler technology reduces fuel consumption

Valmet Rotating Cooler compared to Satelite Cooler

Plusses:� Less radiation� Less noise� Improved fuel economy� Shorter burner

Minusses:� Higher investments cost� More complex� Max. 900 MTPD

FLSmidth Cross-Bar™ cooler for large lime kilns

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FLSmidth Cross-Bar™ cooler for large lime kilns

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FLSmidth Cross-Bar™ cooler for large lime kilns

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• Self-adjusting air flow regulators• Compensates for variations in bed resistance• Ensures even air distribution throughout the cooler

CB Cooler versus rotating coolers

• CB cooler has no need for nose ring.

• CB cooler has no restrictionsbetween the kiln and the cooler

CB Cooler versus rotating coolers

• CB cooler has norestrictions for thelime to pass throughthe cooler

CB Cooler versus rotating coolers

• No risk of material build-up in CB cooler.• Free passage of balls andpieces of ring formation

FLSmidth Cross-Bar™ cooler for large lime kilns

� Even better thermal efficiency

� Product temperature <150 °C

� Rigid mechanical construction

� High reliability & availability

� Low, predictable maintenance

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The Valmet lime kiln

Kiln supports

Kiln support – base plate

Rigid support

Kilns < 4.35 m

Semi-rigid support

Kilns ≥ 4.35 m

Features:• Always a full line contact• Avoid hardening anddamages on components• Designed for heavy loads• Proven in operation (> 100)

Flexible support (semi-rigid suspension)

Alignement

Normal Rollermisaligned

Tyremisaligned

Flexible support (2)

Fixed

Flexible support, example

Other supplier Semi rigid support

Flexible support, Stendal, Germany

Flexible support, Suzano, Brazil

The Valmet lime kiln

Trust

Thrust roller

Kiln with 3 supports

Kiln with 4 supports

Trust in the middle of the kiln

Trust at support #3.

Mechanical trust

Hydraulic trust

• For heavy loads• ”Soft” contact• Kiln can be moved• Overpressure valveprevents damage on shaft• Compensation of tyrewobbling• Proven in operation (120 +)

Hydraulic thrust roller

Thrust roller w. Accumulator

Fixed thrustroller

Hydraulicroller w. accu

Hydraulic thrust roller, Stendal, Germany

The Valmet lime kiln

Flash dryer technology

Flash dryer technology

� Purpose:

– Reduce kiln length for new installations– Increase capacity of existing installations

Flash dryer is not a fuel saving item!

3.rd. Generation Flash dryer with recirculation

Hot kiln gas

Exhaust gas andlime mud

Dryer

Mud feeder

fdprincp

Flash dryingprinciple

Flash dryer

Tight seal preventsdusting and false

air

No mechanicalparts or flow

obstructions in thehot gas

Round riser, nocorners

Inclined ductprevents dustaccumulation

Backwall flushed bymud; prevents lime

deposits

No feed pipeinside the hot gas

Compact 2-diameter cyclone w.

high efficiency

Mechanical gate: nodrive, no

maintenance

Flow by gravity, nodrive, no

maintenance

Smoke gas chamber

No internals

Round design

Back wall cleaned by hot lime

Smoke gas chamber

� Specially designedfor high temperatureapplications

Dryer features

� No mud going directly to the kiln� Flow control outside hot gas� No need for scoops in smoke chamber

Water injection, typical P&I

Water injection system

� Objective:

– To cool the kiln gases, protecting ESP and ID fan– To reduce urgency of operator intervention– To maintain operation with abnormal feed (extreme LMDS

etc.)

The Valmet lime kiln

Refractory

RefractoryAs used today

No drying zone in a flash kiln.

Heating zone(approx. 44 %)

Calcination zone(approx. 16 %)

Burning zone(approx. 40 %)

Big kilnSingle layer 220 mm≈ Refraterm 150

Big kilnSingle layer 300 mmChamotte (≈ 40 % Al2O3)

Big kilnSingle layer 300 mmHigh Alumina (≈63 % Al2O3)

Small kilnSingle layer 220 mm≈ Refraterm 150

Small kilnDouble layer 200+65 mmChamotte (≈ 40 % Al2O3)+ insulation

Small kilnDouble layer 200+65 mmHigh Alumina (≈63 % Al2O3)+ insulation

The Valmet lime kiln

Emission levels

Modern emission levels

Dust H2S SO2 NOx

Oil

20-50mg/Nm3.

10 mg/Nm3, dry,8 % O2, basedon 0.2 % WSAas NaOH.

50 mg/Nm3 , dry,8 % O2, based on2 % S in the oil.

250 mg/Nm3 ,dry, 8 % O2,based on 0.4 %N in the oil.

Naturalgas

5 mg/Nm3, dry, 8% O2.

360 mg/Nm3,dry, 8 % O2.

The ACS 820

Fully automatedresidual CaCO3analyzer

ACS 820AUTOMATIC CARBON/SULPHUR

ANALYSER

ACS 820On-line sampling

Crusher BB200 (option)

Sampler A-17.2

APT-40P

Chute

Transport Tube(max.75m)

Analyzer ACS820Cabinet

APT-40L + Filter

Crusher MK25

Transport Blower

Mill CM800 (option) Vacuum cleaner

Screw Doser

ACS 820Site housing

Reference list for the ACS 800/810/820

� FLSA - IC Limerick Ireland ACS800 2005� FLSA - IC Platin Works Ireland ACS800 2007� Italcementi Sarche Italy ACS800 2007� Aalborg cement Denmark ACS800 2008� FLSA - Xstrata Canada ACS810 2008� Suzano Pulp & Paper Brazil ACS810 2011� CMPC Guiaba Brazil ACS820 2014

Advantages of a fully automated CaCO3 analyzer

� Frequent results within minutes delivered to theoperator� Optimizes the lime kiln operation� Will produce the most optimal quality continuously

for the recaust plant� Can prevent lining damage due to over fueling� Reduces work load in the laboratory

ACS 820Optimized kiln control

ProductionKiln speed

Feed

Fuel

1st control: Kiln speed as a function of Production (PID regulator)Production * X (individual constant) = kiln speed

2nd control: Variable parameter controlled by ACS 820Y = 6300 kJ/kg (individual) * ACS 820 control

3rd control: Fuel as a function of productionProduction * Y (limited to 7000 kJ/kg) = fuel flow