VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD Horizon2020 Information Days on Public-Private Partnerships Brokerage event 16 October 2015 Project proposal for SPIRE-04-2016 Development of designs and operation of cement and lime kilns Sirpa Kallio, Satu Tuurna, Lars Kjäldman Sirpa.Kallio@vtt.fi
VTT Technology for business VTT Technical Research Centre of Finland Ltd is the leading research and technology company in the Nordic countries. VTT operates under the mandate of the Ministry of Employment and the Economy. We develop new smart technologies, profitable solutions and innovative services and cooperate with our customers to produce technology for business. VTT s Technology competence relevant for SPIRE includes - Strong modeling competence - system level analysis - detailed CFD simulation with strong emphasis on multi-phase flows (since 1982, team of 15 modelers, > 100 simulated furnaces) - Materials expertise (metals, refractory, etc.) - Comprehensive understanding of state-of-the-art process design methods and tools - Expertise in conversion processes OF FINNISH INNOVATIONS include VTT expertise. (* Turnover 277 M (VTT Group 2014), personnel 2,600 (VTT Group 1.1.2015 ) Unique research and testing infrastructure Wide national and international cooperation network 19/10/2015 *) Source: Roles, effectiveness, and impact 2 of VTT, VTT & Technopolis Group, 2013.
PROJECT IDEA Improvement of design and operation of processes that employ rotary kilns such as cement and lime kilns Change of fuel and firing/production method of the kiln and the process to favourably affect Emissions Energy efficiency Furnace and upstream and downstream process performance/availability Capex and Opex costs Investigate performance of new design ideas and develop the concepts Utilise simulation and materials analysis for furnace/process designs and to predict their performance Optimisation of operation of whole system 19/10/2015 3
KEY COMPONENTS AND ACTIONS Utilisation and further development of simulation for design CFD modelling of in-furnace and auxiliary processes: flow, heat transfer, emissions Materials modelling of components performance Thermodynamic modelling of cement and lime kiln bed processes Coupled to CFD modelling of in-furnace processes Techno-economical modelling of whole system Demonstrate performance of changed fuel/operation at 1-2 plants Interaction of furnace with the rest of the manufacturing process Compare with simulation results Monitoring and control system for NOx, SOx and CO emissions Constraints from legislation, compliance with standards 19/10/2015 4
EXPECTED IMPACT Optimal fuel & firing/process choices and new designs will Reduce energy consumption Reduce NOx, SOx and CO emission Reduce Capex and Opex costs of the furnaces Demonstration of the solutions in industrial environment Fuel and possible firing changes in furnaces including changes of material and heat transfers and possible changes in other units New design and process choices Techno-economical analysis to form the foundation for new business on the basis of project results 19/10/2015 5
KEY PARTNERS VTT Technical Research Centre of Finland Ltd Proposed coordinator/assistant coordinator organisation CFD simulation including bed thermodynamics Lab and pilot scale and material performance studies Partner 2: Techno-economical optimisation of whole system Partner 3: Monitoring and control sytems for the SOx, NOx and CO emissions Partner 4: Constraints from legislation, compliance with standards Partners 5-x Manufacturers of cement and lime kilns and of auxiliary equipment Industrial partner operating cement and lime kilns 19/10/2015 6
CONTACTS Sirpa Kallio, Dr. Senior Research Scientist, IPMA-C project manager sirpa.kallio@vtt.fi, mobile +358 40 015 7512 Satu Tuurna, Dr. Materials Performance team leader satu.tuurna@vtt.fi, mobile +358 40 566 8179 Lars Kjäldman, Dr. CFD Modelling team leader lars.kjaldman@vtt.fi, mobile +358 40 593 8672 http://www.vttresearch.com/ http://www.vttresearch.com/services/low-carbon-energy/combined-heat-and-power/boiler-operation-and-lifespan/cfdmodelling http://www.vttresearch.com/services/bioeconomy/industrial-process-efficiency-and-management/concept-developmentand-evaluation/techno-economic-feasibility-of-new-concepts 19/10/2015 7
TECHNOLOGY FOR BUSINESS