Refratechnik aimed at developing a range of refractory concretes that are insensitive to rapid heating.
The result of our research and development work is the Nanobond technology.
1) Snowman formation occurs when dusty clinker blows back from the cooler into the kiln, creating a cycle that increases dust levels.
2) High secondary air velocities above 5m/s can carry finer dust from the kiln into the burning zone, stealing liquid and creating stickier clinker dust.
3) This dust builds up on the cooler surfaces, forming snowman-like structures, worsened by the presence of alkalis or sulfur that increase melting. Maintaining a short, radiant flame with oxidizing conditions and optimizing air flow can help control clinker dust levels.
Refractory Product Line | Optimum Solutions for Cement PlantsRefratechnik Group
To meet the globally increasing demand for cement, energy saving firing systems with high specific output have been developed in the industrialized countries and introduced throughout the world. One of the primary results of these developments is the precalciner kiln with a short rotary kiln
section.
As each kiln is unique, appropriate refractories are a major factor in terms of service life.
Circulating fluidizing bed combustion Boiler presentation Sawan Vaja
CFBC boilers operate at high temperatures of 850-900 degrees Celsius and velocities of 4-7 meters per second. They allow for the combustion of low-grade fuels like coal rejects, rice husk, and wood chips. In a CFBC boiler, fuel particles are suspended in a bubbling fluidized bed and burned using a mixture of air injected from below. Ash and partially burned fuel circulate and re-burn, improving efficiency. CFBC boilers have advantages like high fuel flexibility, reduced emissions, and simpler operation compared to traditional boilers.
This document provides information on four types of cement kiln coolers: planetary coolers, rotary coolers, grate coolers, and cross-bar coolers. It focuses on describing the design and operation of planetary coolers in detail. Planetary coolers consist of multiple rotating cooler tubes attached directly to the kiln that cascade clinker through counterflowing air. They provide good heat transfer efficiency but have higher clinker exit temperatures than grate coolers. The document also provides typical heat loss figures for a planetary cooler.
This document summarizes a new process for converting coal to ammonia using Kellogg Brown & Root's (KBR) Transport Reactor Integrated Gasifier (TRIG) technology. The process involves:
1. Gasifying coal using KBR's TRIG technology to produce syngas. The syngas is then purified through steps like acid gas removal.
2. Compressing the purified syngas and feeding it into an ammonia synthesis loop to produce ammonia using a conventional KBR ammonia process.
3. Recovering the ammonia produced and refrigerating it for storage or transport.
The paper provides details on the major unit operations in the coal gasification and ammonia
Iron making - Palletization process- Types of palletizers utkarshprajapati3
Detail of palletization process. Difference between Disc and drum pelletizer. Properties parameters and Norms for testings. List of difference agglomerates testings.
The document discusses various technologies for producing hydrogen and synthesis gas, including steam reforming, partial oxidation, coal gasification, and water electrolysis. It provides an overview of the main industrial processes used for ammonia synthesis gas production, noting that about 85% is based on steam reforming of natural gas or other light hydrocarbons. Various hydrogen and syngas production processes are also compared in terms of energy consumption, investment cost, and production cost.
1. The maximum recommended kiln shell temperature varies significantly based on factors like the age of the kiln shell and refractory lining, thickness of the shell, distance between tires, and location of hot spots.
2. Hot spots indicate abnormally high temperatures under 600°C, while red spots that are visible at night always require action as they pose a greater risk of damage.
3. A red spot can generate significant stresses on the kiln shell due to the confined expansion, with a temperature difference of just 200°C potentially exceeding the steel's creep limit and nearing its ultimate strength.
1) Snowman formation occurs when dusty clinker blows back from the cooler into the kiln, creating a cycle that increases dust levels.
2) High secondary air velocities above 5m/s can carry finer dust from the kiln into the burning zone, stealing liquid and creating stickier clinker dust.
3) This dust builds up on the cooler surfaces, forming snowman-like structures, worsened by the presence of alkalis or sulfur that increase melting. Maintaining a short, radiant flame with oxidizing conditions and optimizing air flow can help control clinker dust levels.
Refractory Product Line | Optimum Solutions for Cement PlantsRefratechnik Group
To meet the globally increasing demand for cement, energy saving firing systems with high specific output have been developed in the industrialized countries and introduced throughout the world. One of the primary results of these developments is the precalciner kiln with a short rotary kiln
section.
As each kiln is unique, appropriate refractories are a major factor in terms of service life.
Circulating fluidizing bed combustion Boiler presentation Sawan Vaja
CFBC boilers operate at high temperatures of 850-900 degrees Celsius and velocities of 4-7 meters per second. They allow for the combustion of low-grade fuels like coal rejects, rice husk, and wood chips. In a CFBC boiler, fuel particles are suspended in a bubbling fluidized bed and burned using a mixture of air injected from below. Ash and partially burned fuel circulate and re-burn, improving efficiency. CFBC boilers have advantages like high fuel flexibility, reduced emissions, and simpler operation compared to traditional boilers.
This document provides information on four types of cement kiln coolers: planetary coolers, rotary coolers, grate coolers, and cross-bar coolers. It focuses on describing the design and operation of planetary coolers in detail. Planetary coolers consist of multiple rotating cooler tubes attached directly to the kiln that cascade clinker through counterflowing air. They provide good heat transfer efficiency but have higher clinker exit temperatures than grate coolers. The document also provides typical heat loss figures for a planetary cooler.
This document summarizes a new process for converting coal to ammonia using Kellogg Brown & Root's (KBR) Transport Reactor Integrated Gasifier (TRIG) technology. The process involves:
1. Gasifying coal using KBR's TRIG technology to produce syngas. The syngas is then purified through steps like acid gas removal.
2. Compressing the purified syngas and feeding it into an ammonia synthesis loop to produce ammonia using a conventional KBR ammonia process.
3. Recovering the ammonia produced and refrigerating it for storage or transport.
The paper provides details on the major unit operations in the coal gasification and ammonia
Iron making - Palletization process- Types of palletizers utkarshprajapati3
Detail of palletization process. Difference between Disc and drum pelletizer. Properties parameters and Norms for testings. List of difference agglomerates testings.
The document discusses various technologies for producing hydrogen and synthesis gas, including steam reforming, partial oxidation, coal gasification, and water electrolysis. It provides an overview of the main industrial processes used for ammonia synthesis gas production, noting that about 85% is based on steam reforming of natural gas or other light hydrocarbons. Various hydrogen and syngas production processes are also compared in terms of energy consumption, investment cost, and production cost.
1. The maximum recommended kiln shell temperature varies significantly based on factors like the age of the kiln shell and refractory lining, thickness of the shell, distance between tires, and location of hot spots.
2. Hot spots indicate abnormally high temperatures under 600°C, while red spots that are visible at night always require action as they pose a greater risk of damage.
3. A red spot can generate significant stresses on the kiln shell due to the confined expansion, with a temperature difference of just 200°C potentially exceeding the steel's creep limit and nearing its ultimate strength.
Ring and snowball formation can occur in the kiln due to various process, operational, and maintenance factors. Key factors include raw material chemistry variations, unstable kiln and calciner operations, refractory selection, and flame characteristics. The formation of rings is a dynamic process where deposit-forming forces outweigh destructive forces, such as melting/freezing due to heat changes and interlocking of particles. Common ring types include spurrite and sulfo-spurrite rings formed by clinker freezing in the calcining zone. Addressing issues like feed continuity, material segregation, and combustion can help reduce ring formation.
This document discusses pellets, which are spherical balls made from iron ore fines that are used as a feed material in blast furnaces. Some key points include:
- Pellets have good physical properties that make them suitable for mechanical transportation over long distances. They also have excellent metallurgical properties similar to or better than lump iron ore.
- Using pellets in ironmaking can reduce CO2 emissions by up to 44 million tonnes per year compared to using sinters. This is due to reductions in mining, transportation, agglomeration and steelmaking emissions.
- Increasing the proportion of pellets in a blast furnace burden can improve gas utilization by 4% and reduce co
This document summarizes the key components and design of ammonia synthesis converters. It describes the main parts of the converter including the pressure shell, basket for catalyst, and heat exchangers. It then discusses the two main types of converters - axial and radial flow. The document focuses on the Haldor Topsoe radial flow converter, describing its types and available versions. It provides details on design considerations for the pressure shell, catalyst basket, and material selection. The goals are to resist hydrogen attack, nitriding, and hydrogen induced cracking at high temperatures and pressures during ammonia synthesis.
This document discusses challenges in producing sponge iron using rotary kilns. It outlines various technological options for direct reduced iron (DRI) making, including coal-based and gas-based processes. Coal-based DRI uses rotary kilns while gas-based uses shaft furnaces with synthesis gas. Factors affecting productivity and emissions from each process are presented. Opportunities for cleaner technologies like using beneficiated coal or synthesis gas from coal gasification in rotary kilns or shaft furnaces are discussed along with challenges. The MIDREX and HYL gas-based shaft furnace processes and use of synthesis gas in these furnaces are also summarized.
This slides shows vocational training which i've done at ammonia-4 plant at GSFC LTD.
There are some tasks that given by our university that we have done here.
The document discusses the Hardgrove Grindability Index (HGI) test method for determining the grindability of coal. It describes how the HGI test works, factors that influence grindability values, and the effects of coal blending on HGI values. Experimentally determined HGI values for coal blends sometimes differed from calculated weighted average values, with the difference generally within ±2 HGI units. The optimal coal blends for different applications can be identified based on considering both HGI values and other coal properties.
The document provides information about the KHD PYRO-JET burner, a reliable kiln burner made by Prism Johnson Cement. The PYRO-JET burner aims to cut costs through reducing fuel, primary air, and electrical costs. It uses jet air at supersonic speeds and high pressure to mix fuel and secondary air, accelerating combustion. The burner can use various fuels and has components like the burner tube, tip, swirler, and telescopic pipe. It provides advantages like high efficiency, low NOx emissions, and an adjustable flame.
The document introduces TOPMAG® TR, a new high-performance magnesia-spinel brick developed by Refratechnik Asia for use in the transition zones of cement rotary kilns. TOPMAG® TR has enhanced thermochemical resistance and structural flexibility through an optimized spinel content and structure. Test results show TOPMAG® TR can achieve service lives of up to 24 months in the upper transition zone, significantly outperforming conventional magnesia-spinel bricks. TOPMAG® TR is well-suited for cement kilns with increased thermal and chemical loads in the transition zones.
The HYL process uses natural gas to directly reduce iron ore into DRI through a gas-based reduction process. It was developed in the 1950s in Mexico. The HYL process uses fixed bed reactors that are heated to reduce iron ore pellets or lumps into sponge iron using a mixture of carbon monoxide and hydrogen produced from the reforming of natural gas. Later developments included moving to a single rotating shaft furnace (HYL III) and allowing production of DRI, HBI, or hot briquetted iron.
This document discusses clinker burning and the formation of Portland cement clinker. It begins with an introduction on why studying clinker burning is important. It then covers normal and abnormal kiln operation, and discusses the analogy to metamorphic rock formation. The document outlines the two principal steps of raw material disintegration and structural rearrangement during heating. It also discusses features of clinker formation like being a complex system that requires energy and produces minerals that are not stable at normal temperatures. The document provides details on reaction pathways, mechanisms, kinetics, thermodynamics, and intermediate products involved in clinker formation. It closes with sections on controlling the burning process and assessing raw meal burnability.
Ammonia production from natural gas, haldor topsoe processGaurav Soni
The document provides information about the various sections of an ammonia plant, including the desulfurization, reforming, shift, CO2 removal, methanation, and ammonia synthesis sections. It details the processes that occur in each section, including catalysts used and operating parameters. The goal is to produce 99.73% pure ammonia from natural gas feedstock using a high-pressure synthesis process.
This document provides information on the Benfield process for removing carbon dioxide from gas streams. It discusses key aspects of the process including:
- Absorption of CO2 into a potassium carbonate solution and regeneration of the solution by heating.
- Use of an activator like DEA to improve CO2 absorption.
- Comparison with other CO2 removal processes like Rectisol and considerations for process selection.
- Parameters that affect the absorption and regeneration steps like pressure, temperature, and flow rates.
- Causes and prevention of corrosion in the system through vanadium addition and factors that can cause foaming of the solution.
Soot Blowing Optimization- Field ExperiencePooja Agarwal
The document discusses soot blower optimization strategies implemented at Jindal Power Limited coal-fired power plants. Previously, all 56 furnace wall soot blowers were operated once every 8 hours, consuming substantial steam. Through a study, JPL found that operating soot blowers in certain areas and sequences had little effect on boiler parameters. This allowed reducing operations to only blowing 14 blowers once daily and 28 blowers every other day, saving over 1,300 tons of steam annually. Financial savings from reduced steam and coal usage were estimated at over 4 lakh rupees annually. The optimized strategy improved boiler performance and heat rate while reducing emissions and maintenance costs.
Rotary kilns have become the backbone of many industrial processes, with new applications being developed all the time. This presentation gives an overview of what types of processes rotary kilns are used for, as well as how both direct-fired and indirect-fired rotary kilns work.
1. The residence time in a rotary kiln is calculated using a formula that considers the angle of repose of the limestone, length of the kiln, kiln inclination, effective diameter, and rotation speed.
2. A rotary kiln's capacity is determined by considering factors like the capacity of the ID fan, preheater cyclone design, proclaimed design and volume, kiln inclination and volume, kiln filling percentage, specific volume and thermal loading, and kiln drive capacity.
3. Important kiln parameters include the specific volume loading, specific thermal loading, cooler specific loading, and kiln percentage filling, which should be between 4-16%.
The document discusses the inputs and process for manufacturing sponge iron in a rotary kiln. It describes the chemical and physical composition of iron ore, coal, and dolomite that are fed into the kiln. It then outlines the rotary kiln process which involves preheating and combustion zones, use of primary and secondary air, coal injection, and rotary cooling before magnetic separation and screening to produce sponge iron and char as outputs. Waste heat is recovered to generate steam for power generation and gas is cleaned by an electrostatic precipitator before emission.
India is the world's largest Sponge Iron producer and mostly uses the Coal based process. The down-side of this industry is that it generates significant amounts of solid waste in the form of ESP Flyash and Bag House Filter Dust. Now as this Flyash contains considerable unburned carbon ( 10% and above), it cannot be utilized in cement manufacturing. Likewise the Bag Filter dust contains upto 25% unburned carbon and above 70% ash which again doesn't allow it to be reused viably as a fuel. Meanwhile, reducing the carbon content by the Carbon-burnout method is too expensive and polluting just to convert the wastes into usable Flyash.
As a result most of these wastes go into landfill, where they again contribute to ground and water pollution.
Surprisingly there are technologies which can not only effectively convert these wastes into usable items like recovered fuel and low carbon Flyash, but at the same time clean up the environment and save the companies great expenses. Its is called Carbon-Ash Separation and there are several ways of doing the same.
The document discusses aerodynamics concepts related to blast furnaces including:
- Higher blast rates can increase productivity but also risks irregularities like channeling if bed permeability is not uniform
- Pressure drop in a packed bed reactor is calculated using the Ergun equation and depends on factors like voidage, particle size, gas properties
- Pressure drop increases significantly with decreasing voidage or with mixed vs. layered beds, and is very sensitive to particle size differences
- Minimum gas velocities needed for fluidization depend on temperature, particle properties, and can limit maximum productivity
- Channeling occurs when gas flows through distinct channels due to non-uniform packing, and higher top pressure can help address this
The document discusses different types of reformers used in ammonia plants, including pre-reformers, primary reformers, and secondary reformers. It provides details on the process, internals, catalysts, and operating conditions of each reformer type. Primary reformers are described as duplex reforming furnaces containing nickel catalyst-loaded tubes that are fired by natural gas burners to drive the endothermic reforming reactions. Key variables that impact the reforming reactions such as temperature, pressure, steam-to-carbon ratio, and catalyst activity are also summarized.
Intelligent Refractory Technology for the Aluminium Industry. Casthouse. Refratechnik Group
High-performance products and intelligent refractory concepts.
Refratechnik is one of the most important companies in the refractory industry and, with its shaped and unshaped products, a global partner of the cement, steel and aluminium industry.
Monolithic products, soon to include pre-shaped products (bricks and prefabricated components), are playing an increasingly important part in Refratechnik's service spectrum, enjoying a notable increase in sales and commanding the highest of respect on the market.
This document discusses refractory lining concepts for electric arc furnaces. It summarizes the refractory products from Refratechnik Steel that are commonly used in different areas of electric arc furnaces, including the roof, slag line, tap holes, and hearth. The MACARBON grades of high-purity fused magnesia have proven most successful for hot spots and slag areas due to their high quality, density, and cold crushing strength properties. Using Refratechnik Steel's refractory lining concepts and products can help extend furnace service life and reduce maintenance costs.
Ring and snowball formation can occur in the kiln due to various process, operational, and maintenance factors. Key factors include raw material chemistry variations, unstable kiln and calciner operations, refractory selection, and flame characteristics. The formation of rings is a dynamic process where deposit-forming forces outweigh destructive forces, such as melting/freezing due to heat changes and interlocking of particles. Common ring types include spurrite and sulfo-spurrite rings formed by clinker freezing in the calcining zone. Addressing issues like feed continuity, material segregation, and combustion can help reduce ring formation.
This document discusses pellets, which are spherical balls made from iron ore fines that are used as a feed material in blast furnaces. Some key points include:
- Pellets have good physical properties that make them suitable for mechanical transportation over long distances. They also have excellent metallurgical properties similar to or better than lump iron ore.
- Using pellets in ironmaking can reduce CO2 emissions by up to 44 million tonnes per year compared to using sinters. This is due to reductions in mining, transportation, agglomeration and steelmaking emissions.
- Increasing the proportion of pellets in a blast furnace burden can improve gas utilization by 4% and reduce co
This document summarizes the key components and design of ammonia synthesis converters. It describes the main parts of the converter including the pressure shell, basket for catalyst, and heat exchangers. It then discusses the two main types of converters - axial and radial flow. The document focuses on the Haldor Topsoe radial flow converter, describing its types and available versions. It provides details on design considerations for the pressure shell, catalyst basket, and material selection. The goals are to resist hydrogen attack, nitriding, and hydrogen induced cracking at high temperatures and pressures during ammonia synthesis.
This document discusses challenges in producing sponge iron using rotary kilns. It outlines various technological options for direct reduced iron (DRI) making, including coal-based and gas-based processes. Coal-based DRI uses rotary kilns while gas-based uses shaft furnaces with synthesis gas. Factors affecting productivity and emissions from each process are presented. Opportunities for cleaner technologies like using beneficiated coal or synthesis gas from coal gasification in rotary kilns or shaft furnaces are discussed along with challenges. The MIDREX and HYL gas-based shaft furnace processes and use of synthesis gas in these furnaces are also summarized.
This slides shows vocational training which i've done at ammonia-4 plant at GSFC LTD.
There are some tasks that given by our university that we have done here.
The document discusses the Hardgrove Grindability Index (HGI) test method for determining the grindability of coal. It describes how the HGI test works, factors that influence grindability values, and the effects of coal blending on HGI values. Experimentally determined HGI values for coal blends sometimes differed from calculated weighted average values, with the difference generally within ±2 HGI units. The optimal coal blends for different applications can be identified based on considering both HGI values and other coal properties.
The document provides information about the KHD PYRO-JET burner, a reliable kiln burner made by Prism Johnson Cement. The PYRO-JET burner aims to cut costs through reducing fuel, primary air, and electrical costs. It uses jet air at supersonic speeds and high pressure to mix fuel and secondary air, accelerating combustion. The burner can use various fuels and has components like the burner tube, tip, swirler, and telescopic pipe. It provides advantages like high efficiency, low NOx emissions, and an adjustable flame.
The document introduces TOPMAG® TR, a new high-performance magnesia-spinel brick developed by Refratechnik Asia for use in the transition zones of cement rotary kilns. TOPMAG® TR has enhanced thermochemical resistance and structural flexibility through an optimized spinel content and structure. Test results show TOPMAG® TR can achieve service lives of up to 24 months in the upper transition zone, significantly outperforming conventional magnesia-spinel bricks. TOPMAG® TR is well-suited for cement kilns with increased thermal and chemical loads in the transition zones.
The HYL process uses natural gas to directly reduce iron ore into DRI through a gas-based reduction process. It was developed in the 1950s in Mexico. The HYL process uses fixed bed reactors that are heated to reduce iron ore pellets or lumps into sponge iron using a mixture of carbon monoxide and hydrogen produced from the reforming of natural gas. Later developments included moving to a single rotating shaft furnace (HYL III) and allowing production of DRI, HBI, or hot briquetted iron.
This document discusses clinker burning and the formation of Portland cement clinker. It begins with an introduction on why studying clinker burning is important. It then covers normal and abnormal kiln operation, and discusses the analogy to metamorphic rock formation. The document outlines the two principal steps of raw material disintegration and structural rearrangement during heating. It also discusses features of clinker formation like being a complex system that requires energy and produces minerals that are not stable at normal temperatures. The document provides details on reaction pathways, mechanisms, kinetics, thermodynamics, and intermediate products involved in clinker formation. It closes with sections on controlling the burning process and assessing raw meal burnability.
Ammonia production from natural gas, haldor topsoe processGaurav Soni
The document provides information about the various sections of an ammonia plant, including the desulfurization, reforming, shift, CO2 removal, methanation, and ammonia synthesis sections. It details the processes that occur in each section, including catalysts used and operating parameters. The goal is to produce 99.73% pure ammonia from natural gas feedstock using a high-pressure synthesis process.
This document provides information on the Benfield process for removing carbon dioxide from gas streams. It discusses key aspects of the process including:
- Absorption of CO2 into a potassium carbonate solution and regeneration of the solution by heating.
- Use of an activator like DEA to improve CO2 absorption.
- Comparison with other CO2 removal processes like Rectisol and considerations for process selection.
- Parameters that affect the absorption and regeneration steps like pressure, temperature, and flow rates.
- Causes and prevention of corrosion in the system through vanadium addition and factors that can cause foaming of the solution.
Soot Blowing Optimization- Field ExperiencePooja Agarwal
The document discusses soot blower optimization strategies implemented at Jindal Power Limited coal-fired power plants. Previously, all 56 furnace wall soot blowers were operated once every 8 hours, consuming substantial steam. Through a study, JPL found that operating soot blowers in certain areas and sequences had little effect on boiler parameters. This allowed reducing operations to only blowing 14 blowers once daily and 28 blowers every other day, saving over 1,300 tons of steam annually. Financial savings from reduced steam and coal usage were estimated at over 4 lakh rupees annually. The optimized strategy improved boiler performance and heat rate while reducing emissions and maintenance costs.
Rotary kilns have become the backbone of many industrial processes, with new applications being developed all the time. This presentation gives an overview of what types of processes rotary kilns are used for, as well as how both direct-fired and indirect-fired rotary kilns work.
1. The residence time in a rotary kiln is calculated using a formula that considers the angle of repose of the limestone, length of the kiln, kiln inclination, effective diameter, and rotation speed.
2. A rotary kiln's capacity is determined by considering factors like the capacity of the ID fan, preheater cyclone design, proclaimed design and volume, kiln inclination and volume, kiln filling percentage, specific volume and thermal loading, and kiln drive capacity.
3. Important kiln parameters include the specific volume loading, specific thermal loading, cooler specific loading, and kiln percentage filling, which should be between 4-16%.
The document discusses the inputs and process for manufacturing sponge iron in a rotary kiln. It describes the chemical and physical composition of iron ore, coal, and dolomite that are fed into the kiln. It then outlines the rotary kiln process which involves preheating and combustion zones, use of primary and secondary air, coal injection, and rotary cooling before magnetic separation and screening to produce sponge iron and char as outputs. Waste heat is recovered to generate steam for power generation and gas is cleaned by an electrostatic precipitator before emission.
India is the world's largest Sponge Iron producer and mostly uses the Coal based process. The down-side of this industry is that it generates significant amounts of solid waste in the form of ESP Flyash and Bag House Filter Dust. Now as this Flyash contains considerable unburned carbon ( 10% and above), it cannot be utilized in cement manufacturing. Likewise the Bag Filter dust contains upto 25% unburned carbon and above 70% ash which again doesn't allow it to be reused viably as a fuel. Meanwhile, reducing the carbon content by the Carbon-burnout method is too expensive and polluting just to convert the wastes into usable Flyash.
As a result most of these wastes go into landfill, where they again contribute to ground and water pollution.
Surprisingly there are technologies which can not only effectively convert these wastes into usable items like recovered fuel and low carbon Flyash, but at the same time clean up the environment and save the companies great expenses. Its is called Carbon-Ash Separation and there are several ways of doing the same.
The document discusses aerodynamics concepts related to blast furnaces including:
- Higher blast rates can increase productivity but also risks irregularities like channeling if bed permeability is not uniform
- Pressure drop in a packed bed reactor is calculated using the Ergun equation and depends on factors like voidage, particle size, gas properties
- Pressure drop increases significantly with decreasing voidage or with mixed vs. layered beds, and is very sensitive to particle size differences
- Minimum gas velocities needed for fluidization depend on temperature, particle properties, and can limit maximum productivity
- Channeling occurs when gas flows through distinct channels due to non-uniform packing, and higher top pressure can help address this
The document discusses different types of reformers used in ammonia plants, including pre-reformers, primary reformers, and secondary reformers. It provides details on the process, internals, catalysts, and operating conditions of each reformer type. Primary reformers are described as duplex reforming furnaces containing nickel catalyst-loaded tubes that are fired by natural gas burners to drive the endothermic reforming reactions. Key variables that impact the reforming reactions such as temperature, pressure, steam-to-carbon ratio, and catalyst activity are also summarized.
Intelligent Refractory Technology for the Aluminium Industry. Casthouse. Refratechnik Group
High-performance products and intelligent refractory concepts.
Refratechnik is one of the most important companies in the refractory industry and, with its shaped and unshaped products, a global partner of the cement, steel and aluminium industry.
Monolithic products, soon to include pre-shaped products (bricks and prefabricated components), are playing an increasingly important part in Refratechnik's service spectrum, enjoying a notable increase in sales and commanding the highest of respect on the market.
This document discusses refractory lining concepts for electric arc furnaces. It summarizes the refractory products from Refratechnik Steel that are commonly used in different areas of electric arc furnaces, including the roof, slag line, tap holes, and hearth. The MACARBON grades of high-purity fused magnesia have proven most successful for hot spots and slag areas due to their high quality, density, and cold crushing strength properties. Using Refratechnik Steel's refractory lining concepts and products can help extend furnace service life and reduce maintenance costs.
Intelligent refractory technology for the primary aluminium industryRefratechnik Group
With decades of experience in refractory technology for the aluminium industry, Refratechnik is one of the world's most innovative companies in this field.
For your activities in the aluminium industry, we offer comprehensive and customized refractory solutions. Our company's aim is to respond to the significantly increased demands made on refractory materials during recent years, by developing new and high-grade products.
The new development: Hybrid technology With the development of REFRACAST®️ Hybrid castables, Refratechnik Steel has optimized the technology of Sol-Gel bonded, cement-free castables even further.
This document discusses case studies and applications of K-Flex oil and gas insulation products. It provides examples of how K-Flex products solve installation difficulties, reduce costs, and allow for easy maintenance. Applications discussed include insulating BOG compressors, nitrogen cycle cryogenic equipment, process lines for nitrogen and oxygen, and heat tracing. K-Flex products are shown to effectively fill gaps, install on uneven surfaces, and be easily removable for maintenance. Potential cost savings are shown through reduced material, labor, and maintenance costs compared to other insulation materials.
Weber Manufacturing Technologies is a leading manufacturer of precision tooling for the aerospace and composites industries located in Midland, Ontario. Over the past 15 years, Weber has developed nickel shell tooling using nickel vapor deposition, which provides high quality, durable molds. They have extensive experience producing self-heated molds using this technique for out-of-autoclave composites manufacturing.
When repairing or re-lining furnace stacks, installation time and the selection of suitable material are decisive criteria for construction site planning.
Qualified consultation by our experienced employees enables the customer to find the best solution for the respective lining requirements from the wide range of material groups. Hereby, the customer's needs and the task on hand are always the central issues: Minimum costs, minimum time, and maximum quality regarding input of labour and product.
The document describes the various steel treatment and painting processes used on Atlas Copco generators and light towers to protect them from corrosion when exposed to outdoor environments. Different components receive different treatments based on their exposure and importance. All steel components receive a galvanization treatment before further treatments and painting. The canopy receives powder coating, while critical components and the base frame undergo nitrogen laser cutting and cataphoresis before final painting. These treatments help provide long-term corrosion protection and extend the life of components.
Sandvik Materials Technology conducted qualification tests on Sandvik Sanicro 28 (UNS N08028) alloy to evaluate its performance in sour gas well applications. Specimens of the alloy in cold worked and non-annealed condition were exposed to simulated sour gas conditions for 720 hours. The conditions included a temperature of 150°C, H2S partial pressure of 5.5 bar, CO2 partial pressure of 41 bar, and chlorides of 75,000 mg/l. After exposure, microscopic examination found no cracks in any of the U-bend or tensile specimens, confirming the alloy's suitability for use in the specified sour gas environment. Previous literature studies and laboratory tests on the alloy also indicated it should provide
Longer running times and shorter down-times for repairs or new linings mean that specific solutions are more and more frequently required for the refractory lining of blast furnace runners.
This is why we provide concepts tailored to suit the requirements of any particular section of runner and to take account of latest developments.
The document describes hot applied, hot cured ultra high build epoxy coatings called Interzone 954XS and Sigmasheild 880XS. It discusses their automatic application process which includes blasting, pre-heating steel, overlapping spray application and post curing to achieve full hardness in 10 minutes. The coatings provide improved performance through a LongKey process and have a track record of protecting structures for 15 years.
Advancement in surface engineering processes by spraymetAnand, P T Bindagi
This document provides an overview of various surface coating processes including a timeline of their development. It describes processes such as nitriding, hard chrome plating, electroless nickel plating, physical vapor deposition, chemical vapor deposition, plasma spraying, detonation gun spraying, high-velocity oxy-fuel spraying, and high-velocity air-fuel spraying. It discusses the working mechanisms, advantages, applications and comparison of these different coating techniques. The document aims to outline the key advancements in surface engineering processes for modifying material properties.
Goel Scientific General information and introductionGoel Scientific
Borosilicate glass represents unmatched standardized glass for construction of plant
and piping in the chemical, dyestuff, food pharmaceutical, petrochemical industries. Its
steadily growing use is due to many advantages over conventional materials.
This document provides information about monolithic refractories produced at Vesuvius India Ltd. It discusses the advantages of monolithic refractories over precast refractories. It also categorizes and describes different types of monolithic refractories like low cement castables, conventional castables, ultra low cement castables and no cement castables. Furthermore, it lists the raw materials used and their properties, including various aluminas, alumino silicates, silica based materials, zircon sand and insulating materials. The document aims to give an overview of the manufacturing and applications of monolithic refractories.
SWEPCO 704 Synthetic Anti-Wear Hydraulic Oil delivers industry-leading performance for demanding stationary or mobile hydraulic applications. It uses proprietary Syntheon synthetic base stock blends and LUBIUM II oxidation and corrosion resistant chemistry to provide long lubricant life, system cleanliness, superior wear protection, improved efficiencies and reduced energy consumption. SWEPCO 704 can significantly extend equipment life, reduce waste oil disposal and costs, and lower electrical utility costs through improved hydraulic efficiency.
The document provides an overview of surface engineering processes and their timeline of development. It discusses various nitriding, plating, thermal spraying, and coating processes such as gas nitriding, plasma nitriding, hard chrome plating, electroless nickel plating, physical vapor deposition, chemical vapor deposition, high-velocity oxy-fuel spraying, high-velocity air-fuel spraying, detonation gun spraying, plasma spraying, and cold spraying. It provides details on the process, applications, advantages, and issues with some of these surface modification techniques.
Flexible, durable, individual.
Nowadays, and apart from the actual tasks, hot metal transport vessels are sometimes used to carry out metallurgical processing steps that go far beyond the transport from blast furnace to steel plant, and for filling the converters.
We have taken this into account, and for all standard lining concepts we supply bauxite, calcined or carbon-bonded andalusite and – to an increasing degree – high-grade carbon-bonded bauxite with SiC additive. And of course, refractory castables for pouring areas and repair are also included in the product range.
Low pressure Molding could protect LED strip, PCB and magnetic very well. Macromelt & Technomelt as a common molding materials play in an encapsulating and environmentally protection on sensitive electronic components, IC molding sealing, Magnetic over molding and other sensitive components pakage. The main intention is to protect the sensitive electronic components during the molding stress, because high pressure molding would harm the properties of these components. Additionally, low pressure seal molding also protects electronic components against dust, moisture and vibration stress. It is also commonly used for Cable relief and sealing connectors.
Low Cost & High Performance “Refractories & Insulation Boards
manufacturing company many years of Expertise in manufacturing and supplying High Temperature Refractory Insulation Boards, Gaskets, Insulation Rollers, and Hitech Advanced Materials for Steel Industry, Aluminium Industry, Power Plant.
Steel Industry/Aluminium Industry/Cryogenic Application/Casting/Boiler/ Power Plant etc.
PAN INDIA / IMPORT/EXPORT
Similar to NANOBOND The next generation of refractory technology (20)
Lining Concepts for the Lead Industry - Short Rotary FurnacesRefratechnik Group
The processes to produce non-ferrous metals are as varied and complex as the equipment required for the purpose.
For new linings, repair, and servicing of short rotary furnaces, Refratechnik Steel offers high-fired magnesia chromite products with low porosity and low SiO2 contents.
Saving energy with insulation.
A decisive role in modern process guidance for reducing energy consumption is played by the insulating materials used in every refractory lining.
As invisible but important components in every refractory lining, high-temperature insulating materials reduce the lining's thermal profile and thereby protect the furnace's steel shell from excesive heating effects.
With our newly developed PROLITE®, we offer our customers a highly insulating material made of biogenic silicilic acid, which combines these factors in a sustainable way.
You know the problem: The MgO-based bricks for lining your rotary and shaft furnaces react with air humidity during storage. Refratechnik has now developed a pioneering solution: The PLUS Concept.
The gas purging of steel or metal melts is an important part of modern secondary metallurgy. Added alloying agents are dissolved more rapidly and better distributed by the injection of inert gases (argon and nitrogen) through a purging plug in the bottom or the wall of the casting ladle. In addition, homogenisation of the bath temperature is improved by gas purging.
The insulating covering agent for ingots.
NERMAT® AF's excellent insulating properties guarantee a slow solidification of the ingot top and a higher amount of impurities can be eliminated from the steel.
For all areas of production in the steel industry where there is a demand for refractory technology, Refratechnik Steel offer concepts and solutions which are adapted fundamentally to our customer`s individual situation. In this endeavour, we are able to draw on our extensive range of refractory products.
CERAMAC® – the smart solution for the longest service life without emissions.
In the beginning, the original goal in developing CERAMAC® was to make it easier to meet environmental regulations and to improve the service life. In the lining concepts, the pre-fired material reduces the smoke emissions and the release of particles while also improving mechanical properties.
REPROMAT - The Perfect Slag Conditioner for Steel ProductionRefratechnik Group
The use of reactive MgO has become established as an excellent solution for minimizing the attack on the refractory material by aggressive slags, and to obtain an optimum degree of saturation range in the slag. For this purpose, and as specialists for refractory products and process materials, Refratechnik has developed the special product REPROMAT.
Our Road to Becoming the World's Largest Family-run Refractory CompanyRefratechnik Group
For more than 65 years we have been pioneers in refractory technology.
Based on an initial bright idea of the company founder, and followed by modest successes in the production and sales of refractory bricks in 1950 in Vogelbeck near Göttingen (Germany), we have grown to become a globally operating company.
Our family-based background is a substantial part of Refratechnik‘s success story. Our team spirit, our expert competence, our consistency, and the personal focus on our customers are unique in our field of business.
Meanwhile, our family-owned company is in the third generation, and today we are proud of our achievements, and excellently set up for the future.
www.refra.com/en/History
The document describes REFRA-Training International Cement, an 11-day training course provided by Refratechnik Cement GmbH to customers involved in refractory materials. The training focuses on providing practical instruction and hands-on experience in selecting, installing, and using refractory materials efficiently and effectively in cement production. It covers topics like refractory material selection, installation methods, quality control, and the influence of process conditions on refractory lifetime. Experienced trainers provide morning lectures and participants engage in afternoon practical exercises. At the end, participants can test their knowledge and receive a certificate upon successful completion.
Perfect Insulating Materials for the Steel Industry.
For more than 40 years Refratechnik has been developing products with this natural raw material. With the foundation of Refratechnik Casting in 1997 a re-orientation of Refratechnik’s activities, in this field, took place.
The Casting experts have 25 years of experience in the production and application of biogenic silicas. This know-how has helped put Refratechnik Casting into a commanding position.
Present Status and Future Demand of Refractories for SteelmakingRefratechnik Group
Article by Prof. Dr. Helge Jansen
Refratechnik Steel GmbH
Refractory technology for steelmaking has been developed and updates significantly over the last 35 years in response to upgradation and changes in steel making process for making different special qualities steel e.g. stringent secondary refining like LF, VD, VOD, RH, etc., higher share of continuous casting process, low non-metallic inclusion and less hydrogen content in steel, ultra-low carbon steel for automobile sector with high demand of clean steel and many more.
First published on Iron & Steel Review Magazine, July 2018
Installation of Refractory Materials in Rotary Kilns ”Essential principles"Refratechnik Group
This guide provides a brief overview of the steps for the installation materials in rotary kilns.
Please note that this guide does not claim to be complete, especially with regard to work safety and prevention of accidents.
For any further questions you may have, please do not hesitate to contact your local Refratechnik representative.
The REFRAJET® Addmix system injects a liquid binder into dry refractory materials during spraying to improve bonding and mechanical properties. It centrally injects a reactive aerosol into the dry material flow before adding a liquid binder via nozzle. This pre-wetting process reduces dust, rebound, and improves strength, density, and reduces porosity compared to traditional dry spraying. The system works with standard spraying equipment and improves properties of cement-free refractory concretes like REFRAJET® Nanobond types.
This document describes REFRASPRAY®, a refractory concrete that allows for fast and effective hot or cold repairs in industrial plants. REFRASPRAY® can be spray or trowel applied, enabling repairs without shutting down the plant. It provides significant savings in time, material, energy and increased plant availability compared to standard repair methods. The document outlines the product range of REFRASPRAY® concretes made from andalusite, corundum, tabular alumina or fireclay.
Refractory Concepts for Chemically and Mechanically Highly Stressed Industria...Refratechnik Group
Nowadays, topics such as recycling, waste disposal, energy recuperation, and energy balance are gaining in importance. Hereby, refractory materials can make decisive contributions. As a systems supplier, Refratechnik develops and manufactures refractory concepts for specific processing technologies to achieve optimum plant efficiency.
REFRA-Shell II is a measurement tool for rotary kilns that is used to determine the curvature of the kiln shell during operation. This elastic deformation is called ovality and is primarily present in the area of a kiln tyre. The measurement gives some accurate information on the degree of mechanical load the refractory material/kiln shell are exposed to, allowing to define countermeasures in terms of refractory selection and/or mechanical maintenance in advance and thus to increase the lifetime of the kiln components.
Take it Easy! Easy Dry (ED) Refractory Concrete TechnologyRefratechnik Group
During the past years, the technological and economic demands of the global cement industry have increased significantly. This leads to clear specifications for our refractory products, as required for modern production processes.
REFRA-Rig II provides a complete installation system satisfying every requirement in respect of long-life technology, and its extensive equipment meets every need.
Refratechnik Casting develops, produces, and supplies highgrade process materials for steel production.
The Casting experts have 25 years of experience in the production
and application of biogenic silicas. This know-how has helped put
Refratechnik Casting into a commanding position.
Redefining brain tumor segmentation: a cutting-edge convolutional neural netw...IJECEIAES
Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
image analysis and enhance healthcare outcomes. This research paves the way
for future exploration and optimization of advanced CNN models in medical
imaging, emphasizing addressing false positives and resource efficiency.
The CBC machine is a common diagnostic tool used by doctors to measure a patient's red blood cell count, white blood cell count and platelet count. The machine uses a small sample of the patient's blood, which is then placed into special tubes and analyzed. The results of the analysis are then displayed on a screen for the doctor to review. The CBC machine is an important tool for diagnosing various conditions, such as anemia, infection and leukemia. It can also help to monitor a patient's response to treatment.
Null Bangalore | Pentesters Approach to AWS IAMDivyanshu
#Abstract:
- Learn more about the real-world methods for auditing AWS IAM (Identity and Access Management) as a pentester. So let us proceed with a brief discussion of IAM as well as some typical misconfigurations and their potential exploits in order to reinforce the understanding of IAM security best practices.
- Gain actionable insights into AWS IAM policies and roles, using hands on approach.
#Prerequisites:
- Basic understanding of AWS services and architecture
- Familiarity with cloud security concepts
- Experience using the AWS Management Console or AWS CLI.
- For hands on lab create account on [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
# Scenario Covered:
- Basics of IAM in AWS
- Implementing IAM Policies with Least Privilege to Manage S3 Bucket
- Objective: Create an S3 bucket with least privilege IAM policy and validate access.
- Steps:
- Create S3 bucket.
- Attach least privilege policy to IAM user.
- Validate access.
- Exploiting IAM PassRole Misconfiguration
-Allows a user to pass a specific IAM role to an AWS service (ec2), typically used for service access delegation. Then exploit PassRole Misconfiguration granting unauthorized access to sensitive resources.
- Objective: Demonstrate how a PassRole misconfiguration can grant unauthorized access.
- Steps:
- Allow user to pass IAM role to EC2.
- Exploit misconfiguration for unauthorized access.
- Access sensitive resources.
- Exploiting IAM AssumeRole Misconfiguration with Overly Permissive Role
- An overly permissive IAM role configuration can lead to privilege escalation by creating a role with administrative privileges and allow a user to assume this role.
- Objective: Show how overly permissive IAM roles can lead to privilege escalation.
- Steps:
- Create role with administrative privileges.
- Allow user to assume the role.
- Perform administrative actions.
- Differentiation between PassRole vs AssumeRole
Try at [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
Optimizing Gradle Builds - Gradle DPE Tour Berlin 2024Sinan KOZAK
Sinan from the Delivery Hero mobile infrastructure engineering team shares a deep dive into performance acceleration with Gradle build cache optimizations. Sinan shares their journey into solving complex build-cache problems that affect Gradle builds. By understanding the challenges and solutions found in our journey, we aim to demonstrate the possibilities for faster builds. The case study reveals how overlapping outputs and cache misconfigurations led to significant increases in build times, especially as the project scaled up with numerous modules using Paparazzi tests. The journey from diagnosing to defeating cache issues offers invaluable lessons on maintaining cache integrity without sacrificing functionality.
International Conference on NLP, Artificial Intelligence, Machine Learning an...gerogepatton
International Conference on NLP, Artificial Intelligence, Machine Learning and Applications (NLAIM 2024) offers a premier global platform for exchanging insights and findings in the theory, methodology, and applications of NLP, Artificial Intelligence, Machine Learning, and their applications. The conference seeks substantial contributions across all key domains of NLP, Artificial Intelligence, Machine Learning, and their practical applications, aiming to foster both theoretical advancements and real-world implementations. With a focus on facilitating collaboration between researchers and practitioners from academia and industry, the conference serves as a nexus for sharing the latest developments in the field.
Comparative analysis between traditional aquaponics and reconstructed aquapon...bijceesjournal
The aquaponic system of planting is a method that does not require soil usage. It is a method that only needs water, fish, lava rocks (a substitute for soil), and plants. Aquaponic systems are sustainable and environmentally friendly. Its use not only helps to plant in small spaces but also helps reduce artificial chemical use and minimizes excess water use, as aquaponics consumes 90% less water than soil-based gardening. The study applied a descriptive and experimental design to assess and compare conventional and reconstructed aquaponic methods for reproducing tomatoes. The researchers created an observation checklist to determine the significant factors of the study. The study aims to determine the significant difference between traditional aquaponics and reconstructed aquaponics systems propagating tomatoes in terms of height, weight, girth, and number of fruits. The reconstructed aquaponics system’s higher growth yield results in a much more nourished crop than the traditional aquaponics system. It is superior in its number of fruits, height, weight, and girth measurement. Moreover, the reconstructed aquaponics system is proven to eliminate all the hindrances present in the traditional aquaponics system, which are overcrowding of fish, algae growth, pest problems, contaminated water, and dead fish.
Discover the latest insights on Data Driven Maintenance with our comprehensive webinar presentation. Learn about traditional maintenance challenges, the right approach to utilizing data, and the benefits of adopting a Data Driven Maintenance strategy. Explore real-world examples, industry best practices, and innovative solutions like FMECA and the D3M model. This presentation, led by expert Jules Oudmans, is essential for asset owners looking to optimize their maintenance processes and leverage digital technologies for improved efficiency and performance. Download now to stay ahead in the evolving maintenance landscape.