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On-Line Sensing for Integrated Monitoring the Reactions and Processes in Industrial Scale Metallurgical and Mineral Processing Furnaces


In many areas of mineral and metallurgical processing
industry in the area of pyrometallurgy the industrial
scale furnaces are operated partly substituting feeding
materials and fuels. Two of the most important areas are
steel and cement production. The substitutions of coke by
pulverised coal (often mixed with ore) and oil on a
regular basis, and experimentally by plastics and other
materials in the blast furnaces (BF) of iron
metallurgical industry and the substitution of fuel by a
wide spectrum of organic wastes in the rotary kilns (RK)
of the cement industry offer, besides the economic
benefits arising from the actual differences in price,
the benefit of performing mineral or metallurgical
processing and waste treatment and recycling by one
operation. To know and to use full the limits of this
substitution is the actual need of the industrv. For
this, the technical and environmental limits and
constraints of the furnaces operation must be full

In the rotary kiln furnaces of cement production industry
actually organic wastes are used as fuel, like petroleum
wastes, spent solvents, byproducts of the pharmaceutical
industry a.o. Comparable proportions as in the USA, where
about 1 million tons of waste a year are burned, hold
also for Japan and the EU. The industrial needs adress to
ensure clean combustion of these materials, this means to
fullfil the official regulations (EC Directives) for
emissions from combustion processes. To enable this a
main objective of the cement industry is to detect the
combustion flame temperature within the rotary kiln and
to monitor the chemical reactions taking place.

The aim of this project is to develop an integrated
measurement system for the temperature and the chemical
components enabling on line monitoring the combustion
processes in industrial scale furnaces of metallurgical
and mineral processing industry. It consists of two
components, to be adapted to the specific conditions:
modern, non intrusive, laser based sensing methods
(Coherent Anti Stokes Raman Spectroscopy, CARS, and Laser
Induced Breakdown Spectroscopy, LIBS) and of advanced
mathematical modelling techniques (Computational Fluid
Dynamics, CFD). This system will be adapted in the frame
of this two years project in lab scale furnaces of
different size, simulating very closely pig iron and
cement production conditions, to prove its feasibility.
After two years and if successfull and feasible it is
intended to transfer and adapt it to the full industrial
scale furnaces in situ, in the frame of a bigger
industrial project.

The main objectives of the project OSIRIS are:
To adapt CARS and LIBS in two steps, a small lab scale
and a large lab scale for monitoring on line the
temperature and the molecules CO, CO2, H2, O2 and the
elements C (and if successfull S) for the blast furnace
operation and the temperature and CO, CO2, SOx, COx and
NOx, CH4, CHx and the elements C (and S) for the rotary
kiln operation.
To adapt and to develop suitable CFD models on the basis
of the PHOENICS code for modelling the turbulent
combustion in the lab scale furnaces, to validate these
models and to support the interpretation of the results
of the sensing system
To integrate these parts, sensing and modelling, and the
results into a measurement system for injection and
combustion control and optimisation and to performe
indicative tests in situ in two BF's (coal and oil) and
one RK in order to detect the difficulties and constrains
of scaling up for preparing the follow up project, if
successfull and feasible on this stage.

If the development of a continuously operating method for
measurement in the combustion zone will succeed, there is
the opportunity to transfer the results to a wide range
of existing industrial high temperature processes.

Funding Scheme

CSC - Cost-sharing contracts


Thyssen Krupp Stahl GmbH
100,Kaiser Wilhem Sraße
47166 Duisburg

Participants (5)

Intzestrasse 1/2
52074 Aachen
Concentration Heat and Momentum Ltd
United Kingdom
Bakery House 40 High Street
SW19 5AU London
Vasilika Vouton
71110 Iraklion
Quantel SA
17,Avenue De L'atlantique 17
91941 Les Ulis
Rautaruukki Oy
51-53,Fredrikinkatu 51-53
00101 Helsinki