Cement is rather difficult to be replaced nowadays, therefore it plays a crucial role in modern construction. The demand for the products of cement plants continues to grow steadily, and in the medium term, it will surpass the offer. It should be noted that the cement industry is cyclical in nature and depends on the place of construction in the country. Russia is now on the upward trend of the cycle industry and in the medium term will have high growth rates of production volumes.

At the same time, cement production is a complex process in which fuel-energy resources (FER) and raw materials are the most essential components in the cost structure of final products. The cost of electricity, gas and raw materials (clinker, limestone, clay, gypsum, granulated slag) is constantly growing for objective reasons from year to year and in aggregate reaches 45-50% of all costs.

The growth of costs for raw materials and energy resources occurs due to the high prices set by its´ providers. Therefore the companies (cement manufacturers) are nor able to influence these factors.

On the other hand, the reserve for the growth of competitiveness of the industry in the domestic and foreign markets can be seen as the improvement of technological processes, such as application of modern hardware design. This allows to identify the ways of rational use of existing equipment as well as to choose the most efficient ways of using raw materials, other materials, and fuel.

There are several methods of cement production such as dry, wet, semi-dry, and combined. Each method of cement production has its own technological features and is characterized by the presence of hot, corrosive and highly dust-laden gases. At the same time, the analysis of these gases allows to obtain valuable information not only for process control but also for process optimization in a continuous mode.

The use of gas analysis systems “Analytic 001” manufactured by our company optimizes technological process, saves fuel, increases productivity and the quality of the final product as well as to reduce costs for the maintenance.

The system of gas analysis “Analytic 001” is operating in the arduous conditions of the production of clinker and ensures not only a continuous analysis of highly dust and hot gases, but also allows the obtained data to optimize the technological process in real time.

Gas system “Analytic” consists of the following functional blocks:

– the system of selection and preparation of gas sample for analysis;
– analyzer;
– output unit of visual information and data to the remote process control.

To implement functional and accurate gas analysis in the extreme environment of cement production it is required the continuous gas sampling. Taking into account the aggressive environment in which the systems of sampling and sample preparation are to operate, our specialists together with technologists of several cement enterprises have chosen an optimum scheme of selection system and system of gas analysis, which provides not only absolute reliability of the results of continuous analysis, but also the continuous functioning of “Analytic 001” without special maintenance.

Measurement of the concentration of all gases, essential for the process of clinker production, allows to:
– control the firing process in the furnace by maintaining optimal levels of O2;
– optimize fuel consumption by controlling the level of O2. Since the process of each kilo of clinker excessively consumes 15 kcal (the error in the determination of the coefficient of excess oxygen by 1%), cement plant which produces 3,500 tons of cement per day is losing approximately 50,000 kcal. In other words, optimization of the combustion process is very important;
– reduce emissions of harmful substances by adjusting the levels of O2 and CO in the process;
– prevent an explosive situation by controlling the O2, CO and CH4. In particular, the system is used for the protection of electrostatic precipitators included in the standard equipment of cement production, shutdown (according to the data from “Analytic” system) which prevents the explosive situation by measuring the concentration of CO in flue gases either in the precipitators, or in immediate proximity to them;
– control the quality of clinker throughout the analysis of NO;
– increase the overhaul life of equipment and prevent emergency shutdowns of the furnace by controlling the O2, CO and SO2.
Thus, it can be stated that the application of the system “Analytic 001” allows to see the problematic points of the technological process, saving energy and raw materials, as well as to automate and optimize processes. The use of modern scientific equipment can also be an additional incentive to attract young workers who prefer working with the brand new equipment. On aggregate with a low payback period (less than one year) use of gas analysis systems “Analytic 001” gives the company additional opportunity to enhance the quality and competitiveness of its products and, thereby, to achieve a leading position in the industry.

Запись Possibilities of gas analysis in Cement industry впервые появилась Gas-Granat.ru.

Core points of complex processes which analysis allows to identify include the course of the process as a whole; optimal mode of technologic units; correspondence between resource costs and given parameters of final product; volumes of emissions of harmful substances into the environment and into the working area. Such a complex analysis cannot be carried out without adequate modern equipment, analysis of the results in real-time mode and proper feedback.

At the same time, modern analytical equipment requires great personnel awareness of manufacturing processes on the one hand and, on the other hand it becomes an attractive tool for intellectual development of employees. Such employees are one of the main assets of any enterprise, although it often is undervalued as a whole.

Everything above can be applied to all kinds of enterprises regardless of their form of ownership.

In recent years, when economic and other sanctions were imposed on Russian economy, the country has announced a program of import substitution and started the program of development and implementation of its own domestic technological advances. However, the question is whether Russian leading companies are ready for this? The experience of our company shows that not all companies are ready for that. Only those who think about the development of their company, its industrial, technological and scientific potential, give other companies an example by using modern gas detection equipment, which develops, produces and implements Research Centre “Analytic”.

Coke production.
Coke production is characterized by complex chemical, physical and physical-chemical processes. The entire cycle of coking process can be divided into five stages depending on the heating temperature. Almost all of them are associated with the formation of gaseous products of combustion, which volumes at modern coke plants are considerably great. Consequently, the use of gas analysis results, its competent interpretation allows to: observe and improve technological processes, make decisions about the air quality in the working area, adequately assess and manage the negative impact of emissions into the environment.

Coke is the essential raw material of steel industry together with iron ore. Therefore, its constant supply and quality improve are extremely important. The greatest costs are associated with the acquisition of metallurgical coke. Consumption and quality of this material, in addition to the price factor (more than 20% of steel production costs), has a significant impact on the technical and economic indicators of the blast furnace process as well as metallurgical enterprise in general.

The use of gas analytical systems such as “Granat” and “Analytic” can reduce the costs of coke production by 2-8%. This in turn reduces the cost of production, allows to make best decisions, improve working conditions and reduce harmful emissions into the environment. Experience of the use of our gas analytical systems shows that the cost of the enterprise of its´ implementation recouped within 3-9 months.

Thus, as long as the greatest costs are associated with the acquisition of metallurgical coke, the consumption and quality of this material, in addition to the price factor (more than 20% of steel production costs), has a significant impact on the technical and economic indicators of the blast furnace process and the enterprise as a whole. Therefore, optimization of the coke production as well as the reduction of costs affects not only the economic performance of the production, but also metallurgical production related to it. Gas analytical equipment is playing the leading role in conducing the processes with minimum costs by:
– improving technical characteristics of the existing coke production plants in order to improve the material utilization rates, reducing waste and losses, etc;
– facilitating the introduction of advanced resource-saving technologies;
– allowing real-time monitoring of harmful emissions into the environment and working area.

All the given aspects represent the main source of the company’s profit growth and profitability increase. In addition, the enterprise reputation should also be taken into account as it attracts new specialists, for whom the cumulative assessment of the enterprise, rather than its individual success plays one of the main roles in modern conditions.

Запись Economic, technological, environmental, and social aspects of gas analysis впервые появилась Gas-Granat.ru.