CANADA CEMENT LAFARGE - InfoHouseinfohouse.p2ric.org/ref/30/29407.pdf · Canada Cement Lafarge is...

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CANADA CEMENT LAFARGE

ST CONSTANT PLANT

SCHREDDED RUBBER F I R I N G

KILN NO. 2

LCL # l o o 0 9

Prepared B y :

M r . S. S t a s h i n L a f arge C o n s u l t a n t s L t d .

Montreal, C a n a d a

O c t o b e r 198 2

1.

2 .

3 .

4 .

5 .

6.

7 .

8.

9.

10.

11.

12.

13.

14.

15.

16.

TABLE O F CONTENTS

ABSTRACT

INTRODUCTION

O B J E C T I V E S OF P R O C E S S T E S T S

DURATION OF T E S T S

D E S C R I P T I O N O F RUBBER F I R I N G SYSTEM

SAMPLING PROCEDURES

CHEMICAL AND P H Y S I C A L ANALYSES

D E S C R I P T I O N OF T E S T S

KILN P R O C E S S PARAMETERS

KILEJ S T A B I L I T Y

K I L N S P E C I F I C HEAT CONSUMPTION

COMBUSTION O F RUBBER

SHREDDED RUBBER C H A R A C T E R I S T I C S

C L I N K E R APJALY S E S

V O L A T I L E FLOW C A L C U L A T I O N S

V O L A T I L E REC I R C U L A T I OM ANALYSES

CONCLUSION

A P P E N D I C E S

LCL

ABSTRACT

I n o r d e r t o lower t h e opera t iona l cost o f i t s p l a n t s , Canada Cement L a f a r g e is c o n s i d e r i n g u s i n g l o w g r a d e or g a r b a g e f u e l wheneve r p o s s i b l e as a p a r t i a l s u b s t i t u t i o n t o t h e h i g h g r a d e f u e l s , s u c h as coa l , o i l and g a s .

S h r e d d e d r u b b e r t i r e s are a v a i l a b l e i n Q u e b e c . As t h e S t . C o n s t a n t p l a n t is c o n s i d e r i n g u s i n g t h e r u b b e r t i r e s as a s e c o n d a r y f u e l , a ser ies o f t e s t s h a v e b e e n s c h e d u l e d t o assess t h e f e a s i b i l i t y o f p a r t i a l l y f i r i n g t h e k i l n w i t h r u b b e r . LCL h a s b e e n asked to e x a m i n e t h e process impl ica t ions o f r u b b e r f i r i n g a t S t . C o n s t a n t .

The first t e s t i n e a r l y J u n e d e m o n s t r a t e d t h e d i f f i - c u l t i e s o f h a n d l i n g a n d a c c u r a t e l y c o n t r o l l i n g t h e f low o f s h r e d d e d r u b b e r t o t h e k i l n . A f t e r i m - p r o v e m e n t s t o t h e r u b b e r f i r i n g s y s t e m were made, a s e c o n d s e r i e s o f tes ts were done f rom J u l y 11 t o J u l y 1 6 , 1982 .

T h i s report c o n t a i n s a d e s c r i p t i o n o f t h i s s e c o n d series of t e s t s , t o g e t h e r w i t h t h e a n a l y t i c a l r e s u l t s of t h e samples c o l l e c t e d d u r i n g t h e f i r s t and s e c o n d series o f tests. U n f o r t u n a t e l y , it was a g a i n i m p o s s i b l e t o m a i n t a i n a s t a b l e k i l n and a s t a b l e r u b b e r f l o w f o r a s i g n i f i c a n t l e n g t h o f t i m e t o d e f i n i t e l y e v a l u a t e t h e impact on t h e p r o c e s s .

T h e r e were t w e n t y - n i n e u p s e t s d u r i n g t h e f i v e d a y s of t e s t i n g , i n c l u d i n g :

- Twenty s t o p p a g e s o f r u b b e r f l o w :

. F i f t e e n associated w i t h b l o c a g e s o f t h e system ( a i r l o c k ) .

. One a s s o c i a t e d w i t h b i n w i t h d r a w a l .

. Four a s s o c i a t e d w i t h a i r p r e s s u r e p r o b l e m s .

- S i x s h o r t k i l n s h u t d o w n s i n d i r e c t l y c a u s e d by t h e i n s t a b i l i t y o f r u b b e r f l o w ( h o t f e e d end or c o l d b u r n i n g z o n e ) .

- T h r e e k i l n s h u t d o w n s n o t l i n k e d t o t h e t e s t .

Under s u c h c i r c u m s t a n c e s it was d i f f i c u l t t o make c o n c l u s i o n s a b o u t t h e impact o f r u b b e r f i r i n g on k i l n o p e r a t i o n . I n p a r t i c u l a r , i t w a s d i f f i c u l t t o d e t e r m i n e w h e t h e r t h e h i g h r e c i r c u l a t i o n o f SO3 i n t h e

I

i i ABSTRACT ( c o n t ' d )

k i l n d u r i n g r u b b e r f i r i n g w a s d u e t o k i l n i n s t a b i l i t y o r t o loca l r e d u c i n g c o n d i t i o n c a u s e d by l a r g e r c h i p s of r u b b e r f a l l i n g on t h e l o a d . F u r t h e r m o r e , t h e impact of t h i s h i g h c i r c u l a t i o n o f SO3 o n k i l n s t a b i l i t y c o u l d n o t be assessed.

The m e a s u r e m e n t o f t h e impact o f r u b b e r f i r i n g on t h e s p e c i f i c h e a t c o n s u m p t i o n was i m p a i r e d by t h e damaged k i l n nose r i n g . Among t h e f a c t o r s i n c r e a s i n g t h e h e a t c o n s u m p t i o n were t h e i n s t a b i l i t y o f t h e r u b b e r f l o w n e c e s s i t a t i n g a n i n c r e a s e i n t h e e x c e s s a i r a n d t h e g e n e r a l i n s t a b i l i t y of t h e k i l n d u r i n g t h e t e s t . L a b o r a t o r y g r o u n d c e m e n t s o b t a i n e d f r o m c l i n k e r sampled d u r i n g and a f t e r t h e t e s t s h o w e d n o s i g n i f i c a n t d i f f e r e n c e i n s t r e n g t h e v e n a t t h r e e d a y s , a l t h o u g h r u b b e r f i r i n g i n c r e a s e s t h e z i n c c o n t e n t of t h e c l i n k e r .

Because of t h e l a c k o f r e l i a b i l i t y o f t h e r u b b e r d e l i v e r y system a n o t h e r tes t was s c h e d u l e d for t h e week o f O c t o b e r 1 8 , 1982.

1. INTRODUCTION

P u r s u a n t t o t h e t e s t s d o n e b e t w e e n May 3 1 and J u n e 4 1 9 8 2 , a s e c o n d ser ies o f tests u s i n g r u b b e r a s a p a r t i a l f u e l s u p p l e m e n t f o r k i l n # 2 a t t h e S t . C o n s t a n t p l a n t were c a r r i e d o u t d u r i n g t h e p e r i o d of J u l y 11 t o J u l y 1 6 , 1 9 8 2 . As b e f o r e , t h e k i l n f u e l u s e d was Bunker C o i l . S u b s t i t u t i o n s of 25% and 32% of t h e Bunker C o i l c o n s u m p t i o n w i t h s h r e d d e d r u b b e r were a t t a i n e d .

The o b j e c t i v e o f t h i s . s e c o n d series o f t e s t s was t o f u r t h e r e x a m i n e t h e e f f e c t s of f i r i n g r u b b e r on t h e p y r o p r o c e s s and c l i n k e r q g a l i t y , and to g a t h e r i n f o r m a t i o n o n v o l a t i l e r e c i r c u l a t i o n w i t h i n t h e k i l n wh ich was n o t examined d u r i n g t h e p r e v i o u s t e s t s d u e t o mater ia l h a n d l i n g p r o b l e m s .

Ron Huard o f LCL was p r e s e n t a t t h e p l a n t f o r t h e process a s p e c t s of t h e tests. H e was a s s i s t e d by N i c h e 1 Beaupre, t h e p l a n t p r o c e s s e n g i n e e r a t S t . C o n s t a n t . Samples of r u b b e r , as w e l l as c l i n k e r , k i l n f e e d and k i l n ma te r i a l , were s e n t t o B e l l e v i l l e f o r a n a l y s i s .

I n a d d i t i o n t o t h e t e s t s c a r r i e d o u t by Ron Huard , a s a m p l i n g o f t h e k i l n was s u p e r v i s e d by S. S t a s h i n o f LCL o n J u l y 1, When no f i r i n g of r u b b e r o c c u r e d . T h i s was t o s e r v e a s a c o m p a r i s o n w i t h t h e tests c o n d u c t e d w i t h r u b b e r f i r i n g . S. S t a s h i n w a s r e s p o n s i b l e f o r t h e i n i t i a l se r ies of t e s t s c a r r i e d o u t i n J u n e ,

The e f f e c t s o f r u b b e r f i r i n g o n t h e p y r o p r o c e s s and c l i n k e r q u a l i t y are d i s c u s s e d i n t h i s r e p o r t The r e p o r t w r i t t e n o n t h e p r e v i o u s ser ies o f t e s t s is i n c l u d e d i n t h e Append ix .

The a n a l y t i c a l r e s u l t s f o r t h e c l i n k e r and r u b b e r samples c o l l e c t e d i n J u n e were n o t a v a i l a b l e a t t h e t i m e of w r i t i n g of t h e p r e v i o u s report . T h e r e f o r e , t h e y are i n c l u d e d i n t h i s report w i t h t h e r e s u l t s of t h e month o f J u l y .

2. OBJECTIVES OF PROCESS TESTS

The o b j e c t i v e s o f t h e tests were t h e same a s t h o s e o f t h e p r e v i o u s t es t s c o n d u c t e d i n J u n e . They were:

(1) D e t e r m i n e t h e e f f e c t s of rubbe r f i r i n g on t h e o p e r a t i o n of t h e k i l n , n o t i n g a n y c h a n g e s i n process parameters.

2.

3.

4.

OBJECTIVES O F PROCESS TESTS

P a g e 2

( c o n t ' d )

( 2 ) D e t e r m i n e t h e s p e c i f i c h e a t c o n s u m p t i o n of t h e k i l n f o r v a r i o u s f l o w r a t e s of r u b b e r .

( 3 ) A s c e r t a i n a n y e f f e c t s on c l i n k e r q u a l i t y .

(4) D e t e r m i n e v o l a t i l e r e c i r c u l a t i o n w i t h i n t h e k i l n w i t h d i f f e r e n t l e v e l s o f r u b b e r f l o w .

The l e v e l s of k i l n f u e l s u b s t i t u t i o n w i t h r u b b e r , deemed t o b e o f most i n t e r e s t , were 25% a n d 32% r e s p e c t i v e l y . 1 5 % s u b s t i t u t u i o n was n o t a t t e m p t e d .

DURATION OF TESTS

A s w i t h t h e p r e v i o u s t e s t s , t h e c l i n k e r p r o d u c e d w h i l e f i r i n g r u b b e r had t o b e i so l a t ed u n t i l i t s q u a l i t y c o u l d b e a s s u r e d . The c l i n k e r was s e n t t o t h e raw mater ia l s to rage h a l l , where t h e r e w a s space a v a i l a b l e f o r o n l y f i v e d a y s p r o d u c t i o n . The k i l n was t h e r e f o r e f i r e d f o r f i v e days.

Rubber f i r i n g b e g a n a t 2:15 PM o n J u l y 11, and c o n t i n u e d o n a r o u n d - t h e - c l o c k b a s i s t o 2:15 PM o n J u l y 1 6 .

DESCRIPTION OF RUBBER FIRING SYSTEM

A d i a g r a m o f t h e r u b b e r f i r i n g s y s t e m is shown i n F i g u r e I . A f r o n t end l o a d e r t r a n s p o r t s s h r e d d e d r u b b e r f r o m t h e s t o c k p i l e i n t h e p a r k i n g l o t t o t h e b i n , a l so l o c a t e d i n t h e p a r k i n g l o t . A screw c o n v e y o r a t t h e bottom of t h e b i n moves t h e mater ia l t o a r o t a r y a i r l o c k , a f t e r which it is blown t h r o u g h a 4 " pipe t o t h e s u r g e b i n on t h e b u r n e r p l a t f o r m . A w e i g h f e e d e r a t t h e bottom of t h e b i n c o n v e y s t h e material t o a ro ta ry a i r l o c k , f rom which it is blown t h r o u g h a 3" pipe t o t h e k i l n where it is i n s u f f l a t e d i n t o t h e b u r n i n g z o n e .

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e I

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! I .

i

I

I i !

i ! !

I

I I

I I I I

! i 1

. .

P a g e 5 5. SAMPLING PROCEDURES

To e v a l u a t e c l i n k e r q u a l i t y , s h r e d d e d r u b b e r c h a r a c t e r i s t i c s , and v o l a t i l e r e c i r c u l a t i o n w i t h i n t h e k i l n , s a m p l e s were t a k e n a t t h e f o l l o w i n g l o c a t i o n s a r o u n d k i l n # 2.

- C l i n k e r : c l i n k e r e v a c u a t i o n d r a g c h a i n a f t e r cooler

- S h r e d d e d r u b b e r : a t t h e s u r g e b i n o n t h e b u r n e r p l a t f o r m

- K i l n f e e d : be low t h e homo s i l o

- K i l n mater ia l : por t h o l e c lo ses t t o b u r n i n g zone

F i g u r e I1 shows t h e l o c a t i o n of t h e k i l n f e e d , k i l n mater ia l and c l i n k e r s a m p l i n g p o i n t s .

T h e s e samples were t a k e n o v e r a f o u r h o u r p e r i o d , o n v a r i o u s days , t o o b t a i n a ' s n a p s h o t ' o f v o l a t i l e r e c i r c u l a t i o n i n t h e k i l n . I n J u l y t h e k i l n was s a m p l e d o n t h r e e d a y s :

- J u l y 1s t : t o a s c e r t a i n v o l a t i l e r e c i r c u l a t i o n w i t h o u t f i r i n g r u b b e r .

- J u l y 1 4 t h : t o a s c e r t a i n v o l a t i l e r e c i r c u l a t i o n f i r i n g r u b b e r a t 25% s u b s t i t u t i o n of f u e l o i l .

- J u l y 1 5 t h : t o a s c e r t a i n v o l a t i l e r e c i r c u l a t i o n f i r i n g r u b b e r a t 3 2 % s u b s t i t u t i o n of f u e l o i l .

The s a m p l i n g p r o g r a m was as f o l l o w s :

T e s t D u r a t i o n : 4 H o u r s

S amp l e

Rubber

C l i n k e r

K i l n Feed

K i l n Material

F r e q u e n c y N o . o f Samples

e v e r y h o u r 4

e v e r y h o u r 4

e v e r y h o u r 4

e v e r y t w o h o u r s 2

LCl

P a g e 6

5 . SAMPLING PROCEDURES ( c o n t ' d )

Composites were made of i n d i v i d u a l samples and were s e n t t o B e l l e v i l l e f o r a n a l y s e s .

6 . CHEMICAL AND P H Y S I C A L ANALYSES

The f o l l o w i n g t e s t s were c a r r i e d o u t a t B e l l e v i l l e :

- On C l i n k e r :

B B l O g r i n d a b i l i t y , m i n e r a l o g y p h a s e c o m p o s i t i o n , c h e m i c a l a n a l y s e s , L.0.I a t 1O5O0C, and p h y s i c a l s t r e n g t h a t 3 , 7 and 28 days on cemen t made w i t h c l i n k e r g r o u n d i n t h e B B l O m i l l .

- On S h r e d d e d Rubber :

H i g h e r h e a t v a l u e , p e r c e n t v o l a t i l e s , c a r b o n , a s h and s u l p h u r , p l u s c h e m i c a l a n a l y s e s o f t h e a s h and s i e v e a n a l y s e s o f s h r e d d e d r u b b e r on l", 3 / 4 " , and 5/8" s i e v e s .

- On K i l n Feed , a n d K i l n Mater ia l

P e r c e n t a g e of a l k a l i e s , c h l o r i n e , s u l p h u r and L . 0 . I a t 1050OC.

O f c r i t i c a l i m p o r t a n c e were t h e s t r e n g t h tests o n c e m e n t made w i t h t h e c l i n k e r samples. T h e s e t e s t s i n p a r t i c u l a r d e c i d e i f c l i n k e r p r o d u c e d w h i l e f i r i n g r u b b e r is s u i t a b l e f o r s a l e .

7. DESCRIPTION O F TESTS

On J u l y 1, 1 9 8 2 , a s a m p l i n g of t h e k i l n was u n d e r t a k e n t o d e t e r m i n e v o l a t i l e r e c i r c u l a t i o n w i t h i n t h e k i l n w i t h o u t r u b b e r f i r i n g . The s a m p l i n g was d o n e be tween 1 0 AM a n d 2 : O O PM. The k i l n was s t a b l e and s p e e d and p r o d u c t i o n were a t a maximum.

A t 2:15 o n J u l y 11, t h e i n s u f f l a t i o n of r u b b e r i n t o t h e k i l n commenced. The k i l n was f i r e d w i t h r u b b e r u n t i l 2:15 PM o n J u l y 16 . Rubber w a s i n i t i a l l y i n t r o d u c e d a t a r a t e of a p p r o x i m a t e l y 1 . 0 t / h r , and t h e f lowrate was s t e a d i l y i n c r e a s e d u n t i l a f l o w r a t e of 2 . 5 t / h r w a s a t t a i n e d o n J u l y 1 5 .

1 1 - LCL 2

c

7. DESCRIPTION O F TESTS

P a g e 7

( c o n t ' d )

S i n c e t h e l a s t tes ts i n J u n e , t h e screw c o n v e y o r b e n e a t h t h e s u r g e b i n on t h e b u r n e r p l a t f o r m had b e e n r e p l a c e d w i t h a w e i g h f e e d e r . The screw c o n v e y o r had b e e n s u b j e c t t o b l o c k a g e s by w i r e b r u s h which would a r res t t h e r u b b e r flow. Dur ing t h e r u b b e r f i r i n g t e s t s c o n d u c t e d i n J u l y , t h e b e l t w e i g h f e e d e r was f o u n d t o b e immune t o t h i s p r o b l e m . T h e r e f o r e , t h e r e were less stoppages i n t h e r u b b e r f l o w t h a n i n J u n e .

N e v e r t h e l e s s , a major problem r e m a i n e d which c a u s e d f r e q u e n t i n t e r r u p t i o n s (two t o f o u r t i m e s per d a y ) i n t h e r u b b e r f low. The e x i t of t h e r o t a r y a i r l o c k a c c e p t i n g r u b b e r f rom t h e w e i g h f e e d e r was prone t o b l o c k a g e s w i t h w i r e . Ten t o f i f t e e n m i n u t e s were n e c e s s a r y t o remove t h e wire f r o m t h e i n s u f f l a t i o n p ipe .

T a b l e #l g i v e s a c h r o n o l o g y o f t h e r u b b e r f i r i n g t e s t s , as w e l l a s a n e x p l a n a t i o n of e v e n t s . T a b l e # 2 shows t h e o i l and r u b b e r c o n s u m p t i o n for per iods of s t a b l e k i l n o p e r a t i o n .

F u r t h e r d i s c u s s i o n a b o u t k i l n o p e r a t i o n c a n be f o u n d i n t h e s e c t i o n e n t i t l e d " K i l n S t a b i l i t y " .

S a m p l i n g for v o l a t i l e r e c i r c u l a t i o n was c o n d u c t e d on b o t h J u l y 1 4 a n d 1 5 , b e t w e e n 9 PM and 1 AM. D u r i n g t h e J u l y 1 4 t e s t p e r i o d , t h e r u b b e r f l o w was a p p r o x i m a t e l y 2 .0 t / h r w h i l e o n J u l y 1 5 it was 2 .5 t / h r . T h i s c o r r e s p o n d e d t o o i l s u b s t i t u t i o n s of 2 5 a n d 3 2 % r e s p e c t i v e l y . U n f o r t u n a t e l y , t h e r e was a 20 m i n u t e i n t e r r u p t i o n i n t h e r u b b e r f low d u r i n g t h e t e s t of J u l y 15 .

c

Date

1/07/8

11/07/8

11/0 7/8 :

Time

1 O : O O t o 14:O

14 :15 t o 1 5 : 2

15:26 t o 1 5 : 4 (

L5:40 t o 1 6 : 2 t

.6:28 t o 17:3E

.7 :35 t o 1 8 : 3 €

.8:38 t o 18:54

8 :54 t o 1 9 : 5 3

9:53 t o 1 9 : 5 9

TABLE #1

SUMMARY OF TESTS

& Min

4:OO

1:11

0:14

0:48

1 : 0 7

1 : 0 3

0 :16

0 :59

0 :06

P a g e 8

Comments

S a m p l i n g of k i l n fo r v o l a t i l e r e c i r c u l a t i o n s t u d y , n o r u b b e r f i r i n g . K i l n s t a b l e , s p e e d a n d p r o d u c t i o n a t maximum, no s lowdowns .

Rubber i n t r o d u c e d i n t o k i l n a t 1 . 0 t / h r , o i l f l o w c u t from 96 t o 8 5 L/M, k i l n s t a b l e , s p e e d a t maximum. B u r n i n g z o n e s lowly d e c r e a s e d i n l e n g t h , t h e f r o n t o f t h e k i l n became steamy.

R u b b e r f low s t o p p e d d u e t o b l o c k a g e of r o t a r y a i r l o c k o n b u r n e r p l a t f o r m , o i l f l o w b a c k t o 96 L/min.

K i l n speed d r o p p e d t o minimum a s k i l n was too c o l d .

K i l n r e s t a r t e d , speed b r o u g h t u p s lowly t o 1 .13 RPM.

R u b b e r f l o w r e s t a r t ed a t 1 . 0 t / h r .

K i l n s t o p p e d d u e t o e x c e s s i v e l y h i g h b a c k end t e m p e r a t u r e , a b o v e 400OC.

K i l n r e s t a r t e d , k i l n speed b r o u g h t up t o 1 . 0 RPM, r u b b e r f l o w s t a r t e d 4 m i n u t e s a f t e r s t a r t o f k i l n .

B a l l of w i r e a t e x i t o f ro ta ry a i r l o c k c a u s e s i n t e r r u p t i o n of r u b b e r f l ow.

LCL

Date

11/07/82

12/07/8 2

Time

1 9 : 5 9 t o 22:3(

22 :30 t o 0:28

0:28 t o 1 : 4 0

1 : 4 0 t o 2 :07

2:07 t o 2:15

2:15 t o 1 3 : 3 5

1 3 : 3 5 t o 16 :30

16:30 t o 18:44

18:44 t o 19:12

TABLE #1

SUMMARY OF TESTS

No.Hrs & Min.

2 : 3 1

1 : 5 8

1 : 1 2

0:27

0:08

11 :20

2:55

2:14

0 :28

Comments

Page 9

Rubber f l o w s t a r t e d a t 0 . 9 t / h r , 1 0 m i n u t e s l a t e r f low was a t 1 . 0 t / h r . K i l n speed is 1 . 3 RMP a n d s t a b l e .

K i l n s p e e d c u t t o 1 . 0 RPM as # 4 b e a r i n g temperature w a s too h i g h . Rubber f l o w l e f t a t 1 . 0 t / h r . O i l f l o w c u t t o 5 0 L/min.

Rubber f l o w s t o p p e d , b l o c k a g e a f t e r ro t a ry a i r l o c k . O i l f l o w i n c r e a s e d t o make up f o r l a c k o f r u b b e r .

R u b b e r flow re s t a r t ed a t 1 . 0 t / h r , o i l f l o w d r o p p e d , k i l n speed m a i n t a i n e d a t 1 . 0 RPW.

R u b b e r f l o w s t o p p e d a g a i n f o r same r e a s o n .

Rubber f l o w r e s t a r t e d a n d k e p t a t 1 . 0 t / h r , k i l n s p e e d b r o u g h t u p s l o w l y t o 1 . 3 5 RPM and o i l f l ow t o 8 0 L/min.

Rubber f l o w stopped as p l a n t a i r p r e s s u r e u s e d t o i n s u f f l a t e r u b b e r i n t o k i l n f e l l too l o w . A i r s u p p l y s w i t c h e d t o p o r t a b l e a i r compressor.

Rubber flow resumed a t 1 t / h r , k i l n s p e e d 1 . 3 5 RPM, t h e b u r n i n g z o n e is close and steamy.

R u b b e r f low s t o p p e d , e x i t o r r o t a r y a i r l o c k b l o c k e d w i t h l a r g e piece of r u b b e r 3" x 4" .

c

23:47 t o 24:02

00 :02 t o 4 : 1 4

4 : 1 4 t o 4 :28

4 :28 t o 5 :07

5 :07 t o 5:30

5 :30 t o 7 : 1 1

7 : 1 1 t o 7 :22

Date

0 : 1 5

4:12

0 : 1 4

0.39

0 :23

1 : 4 1

0:ll

12/07/82

13 /07 /82

7 : 3 2 t o 8 : 0 4

8 : 0 4 t o 9 :06

TABLE P1

0 :32

1 : 0 2

SUMMARY OF TESTS

Time r?o . H r s & Min.

P a g e 1 0

Comments

Rubber f l o w r e s u m e d a t 1 t / h r . F i n e c l i n k e r e x i t i n g k i l n a n d e l e v a t e d k i l n amps ( 4 4 0 ) i n d i - c a t e b u r n i n g zone i s long a n d cool.

Rubber f low s t o p p e d . E x i t of r o t a r y a i r l o c k b l o c k e d w i t h wi re .

Rubber f l o w r e s u m e d a t 1 t / h r . K i l n s p e e d 1 . 3 5 RPM, k i l n s t a b l e .

Rubber f l o w i n c r e a s e d t o 1 . 3 t / h r .

R u b b e r f l o w i n c r e a s e d t o 1 . 5 t / h r . F u e l f l o w d e c r e a s e d f r o m 8 4 t o 75 .5 L/min.

Rubber f l o w s t o p p e d d u e t o p r o b l e m w i t h a i r compressor.

R u b b e r f l o w re sumed a t 1 . 5 t / h r .

Rubber f l o w i n c r e a s e d to 1 . 8 t / h r . O i l f low c u t f r o m 7 9 . 5 t o 78 L/min.

Rubber f l o w s t o p p e d . E x i t of ro t a ry a i r l o c k b l o c k e d because a i r pressure w a s o n l y 1 2 p s i .

Rubber f l o w r e s u m e d a t 1 . 8 t / h r .

Rubber f l o w s t o p p e d , b l o c k e d r o t a r y a i r l o c k . Oil f l o w i n - c r e a s e d f r o m 7 8 L/min. t o 9 6 L/min.

LCL

Date

13 /07 /8 .

.4/07/82

T i m e

9:06 t o 9 : 4 4

9:44 t o 1o :os

10 :09 t o 10 :45

1 0 : 4 5 t o 10:52

1 0 : 5 2 t o 1 3 : 5 5

1 3 : 5 5 t o 1 5 : l O

15:lO t o 1 7 : 2 0

17:20 t o 1 7 : 4 0

17:40 t o 24:OO

1 O : O O t o 2 :50

2:50 t o 5:OO

5 : O O t o 1 0 : 4 0

0:40 t o 1 1 : l O

TABLE #1 P a g e 11

SUMMARY OF TESTS

r m . H r : & Min,

0 : 3 8

0:25

0 :36

0 :09

3 : 0 3

1:15

2 : l O

0 :20

6:20

2:50

2:PO

5:40

0:30

Comments

R u b b e r flow resumed a t 1 . 8 t / h r

R u b b e r f low stopped, same reasoi a s a b o v e . K i l n is now u n s t a b l e F r e q u e n t v a r i a t i o n s i n k i l n speed a re r e q u i r e d .

R u b b e r f l o w resumed a t 1 t / h r w i t h u n s t a b l e k i l n a t r e d u c e d s p e e d .

K i l n s t o p p e d d u e t o e lectro- f i l t e r h i g h t e m p e r a t u r e .

K i l n r e s t a r t e d a t r e d u c e d speed, R u b b e r f l o w re sumed a t 1 .5 t / h r .

K i l n s t o p p e d d u e t o h i g h back- e n d t e m p e r a t u r e .

K i l n r e s t a r t e d a t r e d u c e d s p e e d w i t h o u t r u b b e r f l o w t o s t a b i l i z e k i l n .

K i l n s t o p p e d d u e t o c o m p u t e r problem.

K i l n r e s t a r t e d a t 1 . 0 RPM b r o u g h t u p t o s p e e d slowly.

R u b b e r f low resumed a t 1 . 0 t / h r , k i l n s p e e d 1 . 2 5 RPM. K i l n un- s t a b l e .

Rubber f l o w i n c r e a s e d t o 1.5. t / h r .

R u b b e r f low i n c r e a s e d t o 2 .0 t / h r . K i l n s p e e d 1 . 3 0 t / h r .

K i l n stoppage d u e t o e l ec t r i ca l power f l u c t u a t i o n .

Date

14/07/8

.5/07/8;

Time

11:lO t o 1 5 : 5

15 :50 t o 1 8 : 4

18 :40 t o 19:O

19:20 t o 2 0 : l i

2 O : l O t o 20:3(

!0:30 t o 00:5!

)0 :55 t o 1:15

. : 15 t o 4 :40

:40 t o 11 :20

1:20 to 14 : lO

4:lO to 15 :30

5:30 t o 1 6 : 1 5

TABLE #1

SUMMARY OF TESTS

N o . H r & t l i n

4:40

2:50

0:20

0:50

0:20

4 :25

0:20

3 :25

6 :40

2:50

1 : 2 0

0 : 4 5

P a g e 1 2

Comments

K i l n r e s t a r t e d , s p e e d b r o u g h t u p 1 . 3 0 RPM i n 2 0 m i n u t e s . K i l n p u s h e d a t 1 2 : 4 0 s p e e d c u t , b r o u g h t back t o 1 . 3 0 RPM a t 1 :40 .

R u b b e r resumed a t 2.0 t / h r .

R u b b e r f low s t o p p e d d u e t o c o l d k i l n .

R u b b e r f l o w re sumed a t 2 . 0 t / h r K i l n s p e e d 1 . 3 0 RPM.

R u b b e r f l o w stopped. R e a s o n noi n o t e d .

R u b b e r f l o w re sumed a t 2 .0 t / h r , K i l n s p e e d 1 . 3 0 RPM. V o l a t i l e r e c i r c u l a t i o n s a m p l i n g s t a r t e d a t 21:OO.

R u b b e r f l o w s t o p p e d , e x i t of r o t a r y a i r l o c k b l o c k e d w i t h meta l wi re . Vo la t i l e r e c i r c u l a - t i o n s a m p l i n g e n d e d a t 1 : O O .

R u b b e r f l o w re sumed a t 2.0 t / h r .

R u b b e r f l o w stopped, a i r compressor p rob lem.

R u b b e r f l o w re sumed a t 2 .0 t / h r . K i l n u n s t a b l e .

R u b b e r f l o w s t o p p e d , e x i t of r o t a r y a i r l o c k b l o c k e d .

R u b b e r flow resumed a t 2 . 0 t / h r .

TABLE #1

SUMNARY OF TESTS

I

No. H r s Date T ime ti Min. Comments

15 /07 /82 1 6 : 1 5 t o 19:OO 2:45 R u b b e r flow i n c r e a s e d t o 2 . 5 t / h r . K i l n s p e e d 1 . 3 0 t / h r . K i l n u n s t a b l e .

19:OO t o 1 9 : 3 0 0 :30 Rubber f low s t o p p e d , r o t a ry

19:30 t o 21:50 2 :20 Rubber f l ow resumed a t 2 . 5 t / h r . K i l n speed 1 .30 RPM. V o l a t i l e r e c i r c u l a t i o n s a m p l i n g s t a r t e d a t 2 1 : O O .

a i r l o c k b l o c k e d .

21 :50 t o 22: lO 0 :20 C a v i t a t i o n i n b i n i n p a r k i n g l o t s t o p p e d r u b b e r f l o w t o b i n o n b u r n e r plat form. T h i s b i n s u b s e q u e n t l y e m p t i e d , a r r e s t i n g r u b b e r f l o w t o k i l n .

22: lO t o 24 :55 2 :45 R u b b e r flow resumed a t 2 . 5 t / h r . K i l n s p e e d 1 . 3 0 RPM. V o l a t i l e r e c i r c u l a t i o n s a m p l i n g e n d e d a t 24:55.

16 /07/82 00 :55 t o 1:40 0 : 4 5 R u b b e r f l o w s t o p p e d , k i l n o v e r - h e a t i n g . F u e l o i l f l o w n o t i n c r e a s e d .

1 : 4 0 t o 2:OO 0 :20 Rubber f low resumed a t 2 t / h r . K i l n s p e e d 1 . 3 0 RPM.

2:OO t o 6 :45 4 :45 R u b b e r f l o w s t o p p e d , k i l n s p e e d d r o p p e d t o 1 . 0 RPM a s k i l n too c o l d . K i l n b r o u g h t back t o 1 . 3 RPM a t 5:30.

6 : 4 5 t o 1 0 : 1 5 3 :30 Rubber f low resumed a t 2 .0 t / h r .

1 0 : 1 5 t o 1 3 : 1 5 3:OO Rubber f low s t o p p e d , weigh- feeder s t o p p e d .

LCL

Page 1 3

Date

13:15 t o 14:15

14:15

16/0 7/8 2

Time

TABLE #1

SUMMARY OF TESTS

N o . H r E & Min,

1 : o o

P a g e 1 4

Comments

R u b b e r flow r e s u m e d a t 2 t / h r t o empty s u r g e b i n o n b u r n e r p l a t f o r m . K i l n speed 1 . 3 0 RPM.

R u b b e r flow s t o p p e d . End of t e s t s .

1/0 7/8 2

2/07/82

3/07/82

4/07/8 2

5/0 7/8 2

Time

1O:OO t o 14:OO

16:30 to 18:44

19:12 to 23:47

0.02 to 4:14

5:30 to 7:11

1@:52 to 13:55

2:50 to 5:OO

5:OO to 10:40

15:50 to 18:40

19:oo to 20:lO

20:30 to 0:55

1:15 to 4:40

19:30 to 21:50

22:lO to 0:55

Corrected for k i l n speed

" h r of Hrs and Min.

4:OO

2:14

4:35

4:12

1: 41

3.03

2: 10

5:40

2: 50

1: 10

4:25

3 : 25

2:20

2:45

md product ion

TAnLS #2

KILN FUEL COfJS~R1PTICXJ

Ki ln Speed RPM

1:42

1.35

1.35

1.35

1.35

1.35

1.25

1.29

1.30

1.30

1.30

1.30

1.30

1.30

Clinker Product ion

t/hr

58

55

55

55

55

55

51

53

53

53

53

53

53

53

Average O i l Consumption L/Min.

98

87

87

82

77

76

66

66

67

68

68

67

63

63

n Fuel* L/min

- 10

10

15

20

21

21

26

26

25

25

26

30

30

Fuel 8

-

10

10

15

21

22

24

28

28

27

27

28

32

32

Page 15

Ca lcu la t ed Rubber Flow t/hr

-

0.8

0.8

1.2

1.7

1.8

1.8

2.2

2 :2

2.1

2.1

2.2

2.5

2.5

Date

L/07/8 2

!/07/8 2

)/07/82

I/O 7/8 2

/07/82

Time

1O:OO to 14:OO

16:30 to 18:44

19:12 to 23:47

0:02 to 4:14

5:30 to 7:11

10:52 to 13:55

2:50 to 5:OO

5:OO to 10:40

15:50 to 18:40

19:oo to 20:lO

20:30 to 0:55

1:15 to 4:40

19:30 to 21:50

22:lO to 0:55

Number of H r s and Min.

4:OO

2: 14

4:35

4:12

1: 41

3:03

2: 10

5:40

2: 50

1:lO

4.25

3: 25

2: 20

2:45

Kiln sped mf

1.42

1.35

1.35

1.35

1.35

1.35

1.25

1.29

1.30

1.30

1.30

1.30

1.30

1.30

TABLE #3

KID1 PWIETERS

*

a

Page 16

~

Fuel L/Min. * -

10

10

15

20

21

21

26

26

25

25

26

30

30

Bhaust Fan Speed WI

529

530

535

518

522

5 27

480

493

495

501

510

512

533

547

02

1.8

1.3

1.1

1.7

1.5

2.1

2.0

1.6

1.6

1.5

2.1

2.1

2.2

2.4

Chain Inlet Gas Temp. OC

876

867

884

881

881

884

869

876

882

886

874

863

878

870

Water Spray

95

126

125

133

133

132

88

99

108

121

124

116

121

123

Corrected for k i l n speed and production

P a g e 1 7

8. KILN PROCESS PARAMETERS

T a b l e # 3 l i s t s t h e v a l u e s o f some k i l n process parameters f o r t h e p e r i o d s l i s t e d i n T a b l e # 2 . The r e s i d u a l o x y g e n , water s p r a y , and e x h a u s t f a n s p e e d w h i c h is r e l a t e d t o t h e f l o w o f g a s e s o u t o f t h e k i l n , were a l l h i g h e r t h a n n o r m a l , w i t h and w i t h o u t r u b b e r f i r i n g , d u e t o t h e b r o k e n n o s e r i n g s e a l . These t h r e e parameters are p r o p o r t i o n a l t o o n e a n o t h e r . When f i r i n g r u b b e r , t h e r e a r e g r e a t e r f l u c t u a t i o n s i n r e s i d u a l oxygen l e v e l . T h e r e f o r e , t h e a v e r a g e has to be k e p t a t a h i g h e r v a l u e t h a n when r u b b e r i s n o t f i r e d , i n o r d e r to c o u n t e r a c t l a r g e d i p s i n t h e r e s i d u a l oxygen l e v e l , which would knock o u t t h e p r e c i p i t a t o r . Due t o t h e combined e f f e c t s o f r u b b e r f i r i n g a n d a b r o k e n n o s e r i n g t h e water s p r a y s y s t e m w a s o v e r t a x e d o n s e v e r a l o c c a s s i o n s and c o u l d n o t m a i n t a i n t h e b a c k end temperature be low 4OO0C, n e c e s s i t a t i n g a k i l n shu tdown . Some p l a n t a i r n o r m a l l y u s e d f o r t h e water spray system was u s e d t o i n s u f f l a t e r u b b e r i n t o t h e k i l n . T h e r e f o r e , t h e capacity o f t h e water s p r a y s y s t e m w a s r e d u c e d .

The c h a i n i n l e t g a s temperature was n o r m a l .

9. KILN STABILITY

A s i n J u n e , m e c h a n i c a l p r o b l e m s w i t h t h e s h r e d d e d r u b b e r d e l i v e r y s y s t e m c a u s e d f r e q u e n t i n t e r r u p t i o n s i n r u b b e r f l o w t o t h e k i l n . The m o s t serious p r o b l e m w a s t h e d i s c h a r g e o f r o t a r y a i r l o c k l o c a t e d a f t e r t h e r u b b e r w e i g h f e e d e r o n t h e b u r n e r p l a t f o r m , wh ich p l u g g e d o f t e n d u e t o t h e wire i n t h e s h r e d d e d r u b b e r . Sudden i n t e r r u p t i o n s i n f u e l f l o w n e g a t i v e l y a f f e c t k i l n s t a b i l i t y . The m e c h a n i c s o f t h e r u b b e r f i r i n g system h a s t o be improved b e f o r e s t a b l e and c o n s i s t e n t k i l n o p e r a t i o n c a n be a s s u r e d .

A l s o , t h e r e were p r o b l e m s w i t h t h e k i l n i t s e l f t h a t compromised i t s o p e r a t i o n . The k i l n nose r i n g w a s b r o k e n and h i g h g e a r b e a r i n g t e m p e r a t u r e s were e x p e r i e n c e d .

LCL

9.

P a g e 1 8

K I L N STABILITY ( c o n t ' d )

Because o f t h e b r o k e n n o s e r i n g and f r e q u e n t s t o p p a g e s i n r u b b e r f l o w , t h e k i l n e x p e r i e n c e d h i g h b a c k e n d t e m p e r a t u r e s ( g r e a t e r t h a n 4 O O O C ) wh ich c o u l d no t be m o d e r a t e d b y t h e o v e r t a x e d water s p r a y s y s t e m . The k i l n had t o be s t o p p e d f o r s e v e r a l m i n u t e s .

T h e r e were p e r i o d s o f s e v e r a l h o u r s d u r a t i o n , w h i l e f i r i n g r u b b e r , when t h e k i l n was s t a b l e and n e a r f u l l s p e e d a n d p r o d u c t i o n . The s i t u a t i o n l o o k s p r o m i s i n g i f t h e p e r f o r m a n c e o f t h e s h r e d d e d r u b b e r system c a n be i m p r o v e d .

1 0 KILT1 S P E C I F I C HEAT CONSUMPTION

The k i l n s p e c i f i c h e a t c o n s u m p t i o n was c a l c u l a t e d o n t h r e e d i f f e r e n t o c c a s i o n s : J u l y 1, 1 4 , a n d 15. The m e a s u r e d q u a n t i t i e s o f f u e l and k i l n f e e d , as w e l l as t h e loss on i g n i t i o n a t 1050°C o f r u b b e r , k i l n f e e d and c l i n k e r , were used t o d e t e r m i n e t h e amount o f c l i n k e r p r o d u c e d . The h e a t v a l u e o f o i l and r u b b e r d e t e r m i n e d by c h e m i c a l a n a l y s e s a l l o w e d t h e h e a t i n p u t t o t h e k i l n t o be c a l c u l a t e d .

The s p e c i f i c h e a t c o n s u m p t i o n c a l c u l a t i o n s f o r t h e r e spec t ive days are shown i n Appendix D t o F.

The k i l n s p e c i f i c h e a t c o n s u m p t i o n s a r e shown i n T a b l e 4 . The S . H . C . c a l c u l a t e d f o r J u l y 1 was h i g h e r t h a n n o r m a l b e c a u s e t h e n o s e r i n g s e a l was b r o k e n on t h a t d a y . T h i s i n c r e a s e d t h e S.H.C by a l l o w i n g a n e x c e s s i v e amount o f c o l d a i r t o e n t e r t h e k i l n , r e d u c i n g s e c o n d a r y a i r f l o w and h e a t r e c o v e r y f rom t h e cooler, l o w e r i n g t h e f l a n e temperature and a f f e c t i n g h e a t t r a n s f e r i n t h e k i l n .

The S.H.C. o n J u l y 1 4 was 3 . 5 % h i g h e r t h a n o n J u l y 1, w h i l e t h e S . H . C . for J u l y 1 5 was 1 . 7 % g r e a t e r . The i n c r e a s e i n S.H.C. can b e a t t r i b u t e d t o s e v e r a l f a c t o r s : a n i n c r e a s e i n t h e amount of c o l d a i r i n p u t i n t o t h e k i l n a s i n s u f f l a t i o n a i r f o r t h e s h r e d d e d r u b b e r , a p p r o x i m a t e l y 4 0 0 CFM; f l u c t u a t i n g r e s i d u a l o x y g e n l e v e l s d u e t o v a r i a b l e s h r e d d e d r u b b e r f l o w , w h i c h

- LCL A

D a t e

J u l y 1

J u l y 1 4

J u l y 1 5

% of S .H.C .

Page 1 9

H e a t I n p u t of Rubber 3 of

M J / t C k S . H . C .

T A B L E #4

K I L N S P E C I F I C HEAT CONSUMPTIOM

1 0 0

74

67

H e a t I n p u t of O i l MJ/t C k

0

1 0 8 3 25

1 3 6 1 3 2

- 4127

3 1 9 0

2836

S . H . C . ( L . H . V . )

M J / t C k

4127

4273

4197

. P a g e 2 0

1 0 KILN SPECIFIC HEAT CONSUMPTION ( c o n t I d )

a f f ec t flame t e m p e r a t u r e and h e a t t r a n s f e r i n t h e k i l n ; a n d t h e r e d u c e d k i l n s p e e d and p r o d u c t i o n o n J u l y 1 4 a n d 15 .

11. CONBUSTION O F RUBBER

N o C o m b u s t i o n o f r u b b e r a p p e a r e d t o be complete. r u b b e r r e s i d u e o r wire was found . i n t h e c l i n k e r samples t a k e n .

The a u x i l i a r y b l a s t p i p e c o n v e y i n g r u b b e r i n t o t h e k i l n w a s a n g l e d toward t h e f l a m e . The p i e c e s of r u b b e r c a u g h t f i r e s h o r t l y a f t e r e n t e r i n g t h e k i l n . However, a s h o w e r o f f l a m i n g pieces was s e e n t o impact o n t h e w a l l of t h e k i l n o p p o s i t e t o t h e l o a d . T h e s e would t h e n accumulate a t t h e b a s e o f t h e k i l n . I t is c l e a r t h a t c o m p l e t e c o m b u s t i o n o f a l a r g e number of pieces of r u b b e r ( n o t a b l y t h e l a r g e r o n e s ) d o e s n o t occur i n s u s p e n s i o n i n t h e k i l n g a s .

I d e a l l y no f u e l s h o u l d c o n t a c t t h e load. A r e d u c i n g a t m o s p h e r e ( o x y g e n p o o r ) e x i s t s a t p o i n t s of i m p i n g e m e n t o f f u e l o n t h e l o a d . T h i s p r o m o t e s v o l a t i l i z a t i o n of s u l p h u r and o t h e r v o l a t i l e e l e m e n t s t h a t c a n l e a d t o k i l n c y c l i n g i f t h e v o l a t i l e e l e m e n t s a r e p r e s e n t i n a p p r e c i a b l e a m o u n t s i n t h e raw mix . W h e t h e r r u b b e r b u r n i n g a t t h e b o t t o m o f t h e k i l n p r o v e s d e t r i m e n t a l t o r e f r a c t o r y l i f e r e m a i n s t o be s e e n .

The a i r p r e s s u r e i n t h e f l e x i b l e h o s e c o n v e y i n g r u b b e r t o t h e k i l n a p p e a r e d t o be adequate as t h e r u b b e r was i n s u f f l a t e d w e l l i n t o t h e b u r n i n g zone ( a b o u t 30'), e n s u r i n g i t would b u r n i n t h e k i l n and n o t i n t h e cooler.

LCL

. P a g e 2 1

12. SHREDDED RUBBER CHARACTERISTICS

The mater ia l i s t h e r e s u l t o f s h r e d d i n g s t e e l b e l t e d r a d i a l t i r e s . Along w i t h t h e p i e c e s o f s h r e d d e d r u b b e r , t h e r e a r e a p p r e c i a b l e q u a n t i t i e s o f metal w i r e and c l o t h f i b r e , When t h e i n i t i a l r u b b e r f i r i n g t e s t s were c a r r i e d o u t i n J u n e 1 9 8 0 , t h e r e was no metal wire p r e s e n t a s s h r e d d e d b i a s - p l y t i res were u s e d .

Composites of i n d i v i d u a l r u b b e r samples, c o l l e c t e d h o u r l y o v e r f o u r - h o u r p e r i o d s d u r i n g t h e r u b b e r f i r i n g t e s t s of J u n e and J u l y , were s e n t t o B e l l e v i l l e , w h e r e a s i e v e a n d proximate a n a l y s e s on t h e s h r e d d e d r u b b e r , and a c h e m i c a l a n a l y s i s on t h e r e s i d u a l a s h a f t e r c o m b u s t i o n , were p e r f o r m e d . The r e s u l t s are l i s t e d i n t h e t ab l e s i n Appendix I .

V i r t u a l l y a l l r u b b e r p i e c e s were less t h a n 1" i n s i z e . The pieces of s h r e d d e d r u b b e r f i r e d on J u n e 3 a n d 4, a s w e l l a s o n J u l y 1 4 a n d 15 , were a lmos t a l l less t h a n 5/8" i n s i z e . The rubber f i r e d on J u n e 1 a n d 2 , was n o t i c e a b l y coarser.

The p r o x i m a t e a n a l y s e s of t h e s h r e d d e d r u b b e r showed t h a t t h e a s h c o n t e n t v a r i e d f r o m 1 2 . 0 0 t o 1 9 . 5 6 % w h i l e s u l p h u r c o n t e n t v a r i e d f rom 1 . 0 9 t o 1 . 6 9 % . The s u l p h u r c o n t e n t i n t h e Bunker C o i l i n t h e two samples t a k e n i n J u n e and J u l y r e s p e c t i v e l y , v a r i e d f r o m 1 . 1 2 t o 0 . 9 4 % . The s u l p h u r c o n t e n t on t h e k i l n c a n t h e r e f o r e be e x p e c t e d t o i n c r e a s e s l i g h t l y when f i r i n g r u b b e r . The a v e r a g e lower h e a t v a l u e of t h e r u b b e r was 7 6 4 7 k c a l / k g , compared t o t h e a v e r a g e lower h e a t v a l u e o f t h e o i l a t 1 0 , 0 9 5 k c a l / k g .

The c h e m i c a l a n a l y s e s o f t h e a s h r e v e a l e d s i g n i f i c a n t q u a n t i t i e s o f z i n c o x i d e , r a n g i n g f r o m 5.75 t o 22.78%.

1 3 . CLINKER AFJALYSES

S e v e n t e e n c l i n k e r s a m p l e s were c o l l e c t e d d u r i n g t h e m o n t h s of J u n e and J u l y . T h e s e samples w e r e s e n t t o B e l l e v i l l e f o r c h e m i c a l a n a l y s e s , s i e v e a n a l y s e s , a n d g r i n d a b i l i t y , m i n e r a l o g y and s t r e n g t h d e t e r m i n a t i o n . The l a s t t h r e e samples were t a k e n d u r i n g t h e c o u r s e o f a f o u r h o u r s a m p l i n g p e r i o d t o d e t e r m i n e v o l a t i l e r e c i r c u l a t i o n i n t h e k i l n . One sample was t a k e n w h i l e n o t f i r i n g r u b b e r t o s e r v e as a c o m p a r i s o n t o t h e samples t a k e n w h i l e f i r i n g r u b b e r .

All samples a r e composites of i n d i v i d u a l s a m p l e s t a k e n o n t h e h o u r d u r i n g t h e p e r i o d s i n d i c a t e d .

. -.

\ I P a g e 2 2

The r e s u l t s of t h e a n a l y s e s a t B e l l e v i l l e a r e d e s c r i b e d below. T h e d a t a is i n c l u d e d i n Append ix B .

. C h e m i c a l A n a l y s e s

All c l i n k e r samples were q u i t e u n i f o r m i n c h e m i c a l c o m p o s i t i o n . T h e f r e e l ime of t h e c l i n k e r samples r a n g e d f r o m 0 . 2 5 % t o 0 . 7 0 % . A l l samples a r e e v i d e n t l y w e l l b u r n e d c l i n k e r . Due t o t h e p r e s e n c e o f z i n c i n t h e metal f i l a m e n t s i n t h e r u b b e r , z i n c o x i d e was f o u n d i n t h e samples of c l i n k e r made when f i r i n g r u b b e r i n c o n c e n - t r a t i o n s v a r y i n g f rom 0 . 0 2 t o 0 . 0 7 % . The c o n c e n t r a t i o n of z i n c o x i d e i n t h e c l i n k e r made w i t h o u t r u b b e r f i r i n g was 0 . 0 0 5 % .

G r a n u l o m e t r y

Some c l i n k e r samples were f o u n d t o be c o a r s e . The r e m a i n d e r were f i n e . T h i s i s p r o b a b l y d u e t o t h e c o n d i t i o n of t h e b u r n i n g z o n e t h a t e x i s t e d a t t h e t i m e t h e r e s p e c t i v e c l i n k e r s were produced. T h e coarser c l i n k e r samples have lower f r e e l i m e c o n t e n t s i n d i c a t i n g t h a t a r e l a t i v e l y h o t t e r b u r n i n g z o n e e x i s t e d when t h e coarse c l i n k e r was made. F i n e c l i n k e r is assoc ia ted w i t h a cooler b u r n i n g z o n e .

G r i n d a b i 1 i t y

All c l i n k e r samples were f o u n d to be as easy or eas ie r t o g r i n d t h a n t h e c l i n k e r made w i t h o u t f i r i n g r u b b e r . T h e g r i n d a b i l i t y c u r v e s of t h e c l i n k e r made w i t h o u t r u b b e r f i r i n g a n d t h e eas ies t c l i n k e r t o g r i n d a r e i l l u s t r a t e d i n F i g u r e 111. T h e s e were p l o t t e d from d a t a i n T a b l e #5 i n A p p e n d i x B. F o r a B l a i n e of 3 4 5 0 , t h e a p p r o x i m a t e f i n e n e s s t o which S t . C o n s t a n t g r i n d s i t s c l i n k e r s , t h e a p p r o x i m a t e e n e r g y r e q u i r e d wou ld be 53 .9 a n d 4 7 . 6 kwh/t f o r t h e t w o c l i n k e r s , r e spec t ive ly . T h i s is a s s u m i n g a BBlO e n e r g y t o r e v o l u t i o n r a t i o o f 1 4 kwh/t pe r 1 0 0 0 r e v o l u t i o n s . The g r i n d a b i l i t y of a l l o t h e r c l i n k e r samples were f o u n d t o be b e t w e e n t h e s e t w o v a l u e s .

5

.... ,..... ...... ...

..... ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....

0 c3 h 3 ‘3 T

1000,

4000

3000

.... ...

- - - - c

. i

... . . . . . . . . . . . . . . .... _... . . . -. . . . . . . . . . ._...

2000 t , I, / I I I I I I I I

I I I I

1000

0 10000 2000 3000 4000 5000 6000

P a g e 2 4

13 . CLINKER ANALYSES

( d ) S t r e n g t h

E a r l y , medium and l o n g - t e r m s t r e n g t h s o n c e m e n t made w i t h t h e c l i n k e r g r o u n d i n t h e B B l O m i l l were d e t e r m i n e d by e v a l u a t i n g s t r e n g t h s a t 3, 7 and 28 d a y s The c l i n k e r was g r o u n d f i n e r i n t h e B B l O m i l l t h a n it is a t t h e p l a n t (4000 B l a i n e v e r s u s 3450 a t t h e p l a n t ) . C o n s e q u e n t l y , t h e B e l l e v i l l e r e s u l t s shown i n T a b l e #6 i n Appen- d i x B c a n n o t be i n t e r p r e t e d a s a b s o l u t e v a l u e s . N e v e r t h e l e s s , a c o m p a r i s o n c a n be made b e t w e e n t h e c l i n k e r s a m p l e made w h i l e n o t f i r i n g r u b b e r , and t h e r e m a i n i n g samples. O n l y f o u r of t h e o t h e r 1 6 samples h a v e s i g n i f i c a n t l y lower s t r e n g t h a t 3 , 7 and 28 d a y s . The r e a s o n s f o r t h e d i f f e r e n c e s a r e n o t e v i d e n t a s t h e r e appear t o b e n o s t r o n g c o r r e l a t i o n of s t r e n g t h w i t h f r e e l i m e o r C3s c o n t e n t .

O v e r a l l t h e r e s u l t s a r e p r o m i s i n g , b u t more tests s h o u l d b e c o n d u c t e d b e f o r e it c a n b e d e f i n i t i v e l y s t a t e d t h a t f i r i n g r u b b e r h a s no a d v e r s e e f f e c t s on c e m e n t s t r e n g t h .

1 4 . VOLATILE FLOW CALCULATIONS

The c n e m i c a i a n a l y s e s of t h e r u b b e r , c l i n k e r , k i l n feed and k i l n m a t e r i a l samples were u s e d t o d e t e r m i n e v o l a t i l e f l o w s i n t o , o u t o f , and w i t h i n t h e pyroprocess. The a n a l y t i c a l r e s u l t s f o r v o l a t i l e e l e m e n t s are shown i n Tables # 5 t h r o u g h # 7 .

The f l u x of v o l a t i l e e l e m e n t s a t v a r i o u s p o i n t s i n t h e pyroprocess = f l u x of mater ia l x p e r c e n t c o n c e n t r a t i o n of v o l a t i l e e l e m e n t s i n mater ia l s a m p l e d .

F i g u r e s 4 t h r o u g h 1 5 i l l u s t r a t e t h e f l u x e s o f e a c h v o l a t i l e e l e m e n t . The f l u x e s i n t h e k i l n g a s were c a l c u l a t e d by d i f f e r e n c e of t h e mater ia l f l o w s i n t h e k i l n l o a d .

t

C = C l i n k e r

F = K i l n Feed

KM = K i l n Material

VOLATILE ELEPIEPITS

% L . O . I . 105OOC s o 3 c1 K20 Na 2 0

0.94 0 .28 1 .29* - 0.50

0.68 0.20 0.69 0.008 35 .15

1 . 7 6 0 .32 3 .50 0 .048 20 .29

P a g e 2 5

TABLE # 5

ST. CONSTAP7T KILP? # 2

J u l y 1, 1 9 8 2

PERC EMT COPJC EMTRAT I OM

* Calcu la t ed from v o l a t i l e b a l a n c e . Data s u p p l i e d by B e l l e v i l l e i n a c c u r a t e .

LEI

t

K20

0 . 5 0

0 . 7 2

2 .32

TABLE #6

Ela 2 0 so3

0 .22 0.70

0 . 1 4 0 .73

0 .26 5 .10

ST. CONSTANT KILN # 2

VOLATILE ELEMENTS

PERC EEJT COEJC ENTRATI OfJ

C = C l i n k e r

F = Kiln F e e d

KM = Kiln E l a t e r i a l

J u l y 1 4 , 1 9 8 2

c1

-

0 . 0 0 3

0 . 1 3

P a g e 26

% L.O.I . 1 0 5 O O C

0 . 3 3

35.. 2 9

2 1 . 0 1

VOLATILE ELEMENTS

C = C l i n k e r

F = K i l n Feed

KM = K i l n Material

P a g e 27

K20 Na20

1.09* 0.30

0.70 0.16

2.18 0.26

TABLE #7

ST. COI’JSTANT KILN # 2

J u l y 15, 1982

so3

1.41*

0.73

4.22

* C a l c u l a t e d from v o l a t i l e balance. Data s u p p l i e d by B e l l e v i l l e i naccura t e .

c1

-

0.002

0.16

3 L.O.I. 1 0 5 O O C

0.35

35.26

19.67

Page 28

14. VOLATILE FLOW CALCULATIONS (cont 'd )

In some cases, due to sampling, analytical error, and kiln instability, the sum of the fluxes of a volatile element into the kiln does not equal the sum of the fluxes out of the kiln. Where such an inequality exists two values for flux of that element in the kiln gas are presented. The loss in the stack gases was used to close the balance for sulphur and chlorine, but this is not applicable to K20 or Na20 as it is generally accepted that all of these volatile elements are trapped in the dust.

The calculation of material flows and fluxes of volatile elements for July 1, 14 and 15, are included in Appendices D to F.

The calculated fluxes were used to determine the coefficients of volatilization and recirculation. The volatilization coefficient is a measure of the degree of volatilization of a particular volatile element and is defined by the following rates:

Vol. flux in kiln - vol. flux in clinker flux in kiln

Another ratio characterizing volatile recirculation in a kiln is the recirculation factor defined as follows:

-- iii LIIC: k i l f i l l l d ter I ai LL- nl ..-. r A u A

Volatile flux in the kiln feed

The values of these parameters for July 1, 14 and 15 are illustrated in Figures 4 through 15.

The port hole furthest down the kiln, that is, closest to the burning zone was sampled to determine the flow of volatile elements in the kiln.

15. VOLATILE RECIRCULATION ANALYSES

The volatilization and recirculation factors for kiln #2 on July 1, 14 and 15, 1982, are shown in Table #8. The values for November 9, 1976, determined in a volatile recirculation test conducted by Patrice Chaurand of LCL are included in table 4 for comparison.

15. VOLATILE RECIRCULATION AlaALYSES

Page 2 9

( cont 'd )

On rJovembes9 and July 1, the kiln was not fired with rubber. The -fue'Z--uWin November was natural gas while bunker C was used in July. The volatilization and recirculation factors of the respective volatile elements were similar on these two days with the following exceptions:'

(a) The volatilization and recirculation for SO3 appeared high on July 1. This may be due to the use of bunker C Oil, which contains sulphur while natural gas does not.

(b) The recirculation of chlorine on July 1 appeared low. The reason for this is not obvious. It is most probably due to an error in the chemical analyses.

On July 14, the volatilization and recirculation of ~ 2 0 and SO3 were the highest. K20 volatilization can be considered high at 84%, while 91% for sulphur is very high. Kiln stability plays an important role in volatilization of volatile elements. Disturbances to fuel flow is one factor that can elevate the volatilization in the kiln. by several interruptions in rubber flow before the start of kiln sampling. On July 15, volatilization of K20 and So3 were similar to that on July 1, indicating that_ the kiln iinc-+c -r---- experienced befare ar;d di;ri i ig the test period were less severe than on July 14.

The kiln operation was marked

The concentrations of potassium and sulphur in the kiln are significant, but do not seem to be a major factor in promoting kiln instability as the kiln is normally stable. However, no two kilns are alike. The kilns at Brookfield suffer serious instability with the concentrations of volatile elements found at St. Constant.

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5

c 0 0

a a, Q) cr

-.

rl rl

rl .

..

-.

. . ..

! I

N 03 m rl .

t i I I I

oc) rl

0

0 .rl

d

o\

0

m

_L

rl N

0

.

0 d

I

I

N m P

I m 0

t-

n

N d

rl

*

3 [3 H Lc

dip' .O w

# " a

cn rl m u- .. Ii

0 CJ 0

rl rl

_ .

I

I 'I I

I

. c n rl

- 0

W cn rl

0

d N

cn rl

0

I-- cn r i

0

r C C

C

v) 0 0

0

d

'dp In

3 0 N m w -

I1 ..

N 0 0-l rl .

N *

N rl

'I

I

m r4

"

m rl

d

. .

a3 m a, tn a PI

..

a, u

a a, c, (d 4 5 u rl

dp 0 CD

3 c3 H * c r c

N Ln a. rl z it ..

2 ;

N 03 m rl . In rip: w

I 3

0 0

m rl.

0 rl

0

m 0

0

. . .

... . . . .

... - - . ." .. _ .

m . m Q) tr rd PI

a aJ c, rd

'W m m

0 u3 ul v)

..

3 [3 H

. E r

w rl

2 ;

W rl

Ln

d m u3 .. .

I

r

r

m rl

rl

0 w * a, bl Id PI

..

a, u G Q, k a,

4-1 4-1 -rl a

a a, c, Id rl I u d Id V

. . . . . .

3 u H

. k 4

L n rl

I

I

0-l m hl

0

rl

a,

fn m cv 0

fi m N

0

a a, a,

m 0 0

0

,

TABLE #8 Page 42

ST. CONSTANT VOLATILE RECIRCULATION STUDY

November 9, 1976

Volatile Element Volatilization % Recirculation Factors %

K20 60 220

1Ja 2 0 32 150

so3 61 300

c1 99 9100

K20

Na20

so3

c1

Na20

so3

c1

July 1, 1982

6 5

42

76

99

J u l y 14, 1982

84

46

91

99

July 15, 1982

67

23

78

96

252

155

497

600

317

185

654

3940

305

156

563

8000

Page 4 3

16. CONCLUSION

To d e t e r m i n e d e f i n i t i v e l y t h e s u i t a b i l i t y of r u b b e r f i r i n g a t S t . C o n s t a n t , f u r t h e r t es t s w i l l h a v e t o b e performed. To d a t e , r u b b e r f i r i n g h a s promoted k i l n i n s t a b i l i t y and f r e q u e n t k i l n s lowdowns d u e t o f l o w i n c o n s i s t e n c y . The m e c h a n i c s o f t h e s h r e d d e d r u b b e r d e l i v e r y s y s t e m , i n p a r t i c u l a r t h e r o t a r y a i r l o c k o n t h e b u r n e r p l a t f o r m , h a v e t o be improved .

The c h e m i c a l a n a l y s e s d o n e a t B e l l e v i l l e i n d i c a t e d that a l l c l i n k e r w a s o f good q u a l i t y . However, most of t h i s c l i n k e r was p r o d u c e d u n d e r c o n d i t i o n s o f f r e q u e n t i n t e r r u p t i o n s i n r u b b e r f l o w . T h e r e f o r e , s t a b l e t e s t r u n s of l o n g e r d u r a t i o n a t 3 0 % l e v e l of k i l n f u e l s u b s t i t u t i o n w i l l h a v e t o be a c h i e v e d b e f o r e it c a n b e s a i d w i t h o u t d o u b t t h a t r u b b e r f i r i n g h a s no a d v e r s e e f f e c t s o n c l i n k e r q u a l i t y .

I t is n o t c e r t a i n w h e t h e r t h e r e l a t i v e l y h i g h v o l a - t i l i z a t i o n o f s u l p h u r e x p e r i e n c e d d u r i n g r u b b e r f i r i n g was d u e t o k i l n i n s t a b i l i t y o r t h e c r e a t i o n of re- d u c i n g zone c o n d i t i o n s c a u s e d by r u b b e r b u r n i n g o n t h e l o a d .

APPENDIX A

BELLEVI LLE ANALYSES

ON RUBBER SAMPLES

TABLE #1

Sample #

1 2

4 5 6

8

3

7

REFERENCE FOR RUBBER I D E N T I F I C A T I O N

Reference Date

4 A M - 8 A M 1/6/82 12 PM - 4 PM 1/6/82

9 PM - 12 PM 2/6/82 a PPI - 12 PM 3/6\82 AM- a m 4/6/82

9 PM - 1 PM i5/7/a 2

5 PM - a PM 2/6/82

9 PM - 1 PM 14/7/82

LCL

TABLE # 2

Rubber #

1 2 3 4 5 7 8

S C R E E N A N A L Y S I S O F THE SHREDDED RUBBER ( & P A S S I P J G )

1" 3/4 I' 5/8"

97.5 88.2 74.9 98.7 80.0 64.8 95.5 84.3 78.5 98.3 96 .2 79.0

1 0 0 99.8 96.6 1 0 0 95.8 92.4 1 0 0 96.7 92.6

LCL

TABLE # 3

_ - -_ . I_ -

' Proximate analysis of the shredded r u b b e r (unless noted, r e s u l s are in % ) ...................................................................... Rubber # Volatile Fixed C Ash Su lphur BTU/lb. Kcal/kg.

1 6 3 . 09 2 2 . 6 9 1 4 . 2 2 1 . 4 9 1 4 , 4 9 9 8 , 056 2 6 4 . 1 6 2 2 . 6 8 1 3 . 1 6 1 . 5 0 1 4 , 5 6 8 8 , 094

2 3 . 6 6 1 2 . 3 6 1 . 6 3 1 4 , 5 1 7 8 , 0 6 6 3 6 3 . 9 8 4 6 4 . 0 5 2 3 . 9 5 1 2 . 0 0 1 . 6 8 1 4 , 4 1 7 8 , 010 5 6 4 . 0 8 2 3 . 8 7 1 2 . 0 5

......................................................................

1 . 6 9 1 4 , 5 8 9 8 , 1 0 6 6 6 4 . 2 0 2 1 . 9 8 1 3 . 8 2 1 . 5 2 1 4 , 4 1 5 8 , 0 0 9

8 6 4 . 2 8 1 6 . ;L6 i s . 56 1 . 1 4 1 3 , 2 3 8 - 7 ,355 7 6 4 . 2 1 1 8 . 6 2 1 7 . 1 7 1 . 0 9 13', 2 7 5 7 , 3 7 6

TABLE # 4

Chemical analysis of the ashes

Rubber # SiOa A 1 2 0 3 Fe203 CaO MgO Na20 K20 SO3 Z n O Loss

: 1 1 8 . 3 2 1 2 . 9 0 3 9 . 1 4 8 . 4 0 1 . 2 0 0 .60 0 . 4 7 6 . 0 0 1 3 . 0 0 0 .62 2 2 4 . 7 6 1 2 . 1 0 24.010 1 2 . 8 0 1 .31 0 . 7 6 0 . 5 6 7.09 1 7 . 8 1 0 . 3 5 3 8 . 2 8 1 4 . 4 1 62.210 4 . 4 3 2 .89 0 . 8 8 0 .44 1 . 3 7 5 . 7 5 0 . 3 5 4 9 . 0 0 1 7 . 7 3 5 2 . 9 1 3 .69 5 . 6 9 0 .36 0 .38 2 . 6 0 8 . 8 5 0 .29 5 1 5 . 4 6 1 6 . 6 1 35.9!5 5.35 5 . 2 2 0 . 6 7 0.54 5.50 1 5 . 0 6 0 . 3 7 6 1 2 . 1 2 2 2 . 4 7 42.414 3 . 6 9 0 . 6 4 0 .74 0 . 4 2 3 . 4 0 1 4 . 2 0 0..19 7 1 0 . 0 8 11.87 59.513 4.97 0 .44 0 . 4 3 0 . 3 0 3 r 9 8 8 . 5 9 0 . 3 1 8 1 1 . 8 2 2 1 . 8 1 21.813 9 . 1 7 1 .73 0 .68 0 .52 8 . 6 4 2 2 . 7 8 0 . 8 9

...................................................................... Tota l

1 0 0 . 7 0 1 0 1 . 5 4 1 0 1 . 0 0 101, . 5 0 1 0 0 . 7 3 100.31. 1 0 0 . 5 6

9 9 . 9 2

------

I

APPENDIX B

BELLEVILLE ANALYSES

ON CLINKER SAMPLES

Y

TABLE #1

CLINKER SAMPLE IDEMTIFICATIOM

Sample #

1 2 3 4 5 6 7 8 9

1 0 11 1 2 1 3 1 4 1 5 1 6 1 7

R e f e re n c e

Rubber I1

I1

I1

11

11

11

11

11

11

I1

II

I1

I1

No r u b b e r 11

W

f i r i n g : 5 AM - 8 AM : 9 AM - 1 2 PM

" : 1 PM - 4 PPI I' : 5 PM - 8 PPI I' : 9 PM - 1 2 Plil " : 5 A M - 8 A M

: 5 PM - 8 PM : 9 PM - 1 2 AM

'I : l A M - 4 A M : 5 A M - 8 A M : 9 PM - 1 2 All

" : 5 AM - 8 AN I' :12 PM - 3 PEI I' :12 PM - 3 PM

f i r i n g : l O AM - 2 PM : 9 PPI - 1 zul

'I : 9 PM - 1 AEI

Date

1 /6 /82 1 /6 /8 2 1 /6 /8 2 1 /6 /82 1 /6 /82 2/6/82 2/6/82 2/6/8 2 3/6/8 2 3/6/8 2 3/6/82 4 /6 /82 4/6/82

11 /6 /8 2 1 /7 /8 2

14 /7 /82 15 /7 /82

,

1

I TABLE # 2

i

- - i C l i n k e r , C h e m i c a l a n a l y s i s .......................................................................................... ------------------------------------------------------------------------------'------------

. C l i n k e r # Si02 A 1 2 0 3 T i 0 2 P205 Fe203 CaO MgO SO3 Na20 K 2 0 Loss F-CaO T o t a l

1 2 1 . 3 3 4 .80 - 2 1 .17 3 .49 6 3 . 9 4 2 . 9 5 1 . 2 3 . 2 4 0 . 9 4 . 1 4 . 5 6 9 9 . 44- 2 2 1 . 3 2 4 .77 . 2 0 .17 3 . 3 4 64 .10 2 . 8 3 1 . 4 3 .24 1.05 - 2 6 -53 9 9 7 1 3 2 1 . 1 2 4 .68 - 2 0 .17 3 .40 64 .30 2 . 9 4 1 . 3 4 . 2 6 1 . 0 2 .24 . 7 0 99 .66 4 21 .02 4 . 5 5 - 1 9 .18 3.38 6 4 . 1 5 2 . 9 1 1 . 8 0 . 2 5 1 . 0 9 . 1 6 . 4 8 9 9 . 67 5 2 1 . 4 9 4 .66 .20 - 1 9 3 .47 6 4 . 9 4 2 . 9 1 0 . 6 1 . 2 3 0 . 5 9 . 2 0 . 5 0 9 9 . 4 8

7 2 0 . 8 6 4 . 8 2 . 2 0 -18 3 .44 64 .40 2 .94 1 . 2 0 . 2 5 1 . 0 0 - 0 9 - 5 6 9 9 . 38 8. 2 0 . 8 6 4 . 4 1 .19 .17 3 . 2 8 63 .54 2 . 8 3 2 . 3 1 . 2 9 1 . 6 3 . 1 6 . 6 4 ' 99 .66

6 21 .24 4 . 6 3 . 2 0 - 1 7 3 .37 6 5 . 6 1 2 .97 0 . 7 1 . 2 2 0 . 6 5 .33 . 4 2 9 9 . 1 0

9 2 0 . 9 9 4 . 5 5 . 2 0 .18 3 . 2 5 6 3 . 9 4 2 .84 2 . 0 9 . 2 7 1 . 4 8 . 1 6 .50 i99 . 94 1 0 21 .14 4 .70 - 2 0 .18 3 .30 6 4 . 5 1 2 .90 1 . 1 8 . 2 4 0 . 9 2 . 1 6 . 2 2 9 9 . 4 3

13 21 .04 4 . 6 1 . 1 9 . 1 7 3 . 3 6 63 .68 3 . 0 2 2 . 0 6 . 3 2 1 . 2 7 . 2 0 .28 ' 9 9 . 9 1 1 4 2 0 . 7 3 4 . 8 3 . 1 9 . 1 6 3.58 6 3 . 4 5 3 . 1 7 2 . 0 5 . 3 3 1 . 2 6 . 2 5 . 3 4 99 .99 15 2 1 . 5 2 4 .74 . 1 9 . 1 7 2 . 7 6 64 .49 2 .54 1 . 6 4 . 2 8 0 .94 . 5 0 . 2 5 9 9 . 7 7

11 2 1 . 6 9 4 . 8 1 - 2 0 . 1 9 3 . 2 6 6 5 . 3 1 3.11 0 .48 . 2 1 0 . 5 1 - 2 5 . 2 2 1 0 0 . 0 2 1 2 2 1 . 2 9 4 .86 . 2 0 .18 3 . 2 8 6 4 . 0 8 3 . 0 0 1 . 7 5 . 2 4 1.11 . 2 6 - 5 0 1 0 0 . 2 5 .

1 6 2 1 . 6 1 4 .84 . 1 9 .16 3 .00 6 5 . 1 7 3 .26 0 . 7 0 . 2 2 0 . 5 8 .33 . 3 6 1 0 0 . 0 4 1 7 20 .75 4 . 6 5 -18 .15 2 . 9 5 63 .49 2 . 6 9 2 . 7 2 . 3 0 2 .06 .35 . 5 6 1 0 0 . 2 9

Note: % ZnO i n c l i n k e r wi th ,out rubber ; 0,005, i n c l i n k e r w i t h rubber from 0.02 t o 0 .07

TA8LE # 3

Bogue P o t e n t i a l Compounds ( % I .

C l i n k e r # C$AF ................................................

C3A c3s c25 ................................................

1 1 0 . 6 7 . 8 5 6 . 1 18.8 2 1 0 . 1 8 . 0 5 7 . 5 1 7 . 8 3 1 0 . 3 7 .6 59 .6 1 5 . 6 4 1 0 . 3 7 . 3 61.6 1 3 . 8 5 1 0 . 6 7 .5 6 0 . 1 1 6 . 3

: 6 1 0 . 3 7 .5 65 .6 1 1 . 4 7 1 0 . 5 8 . 0 6 1 . 5 13 .4

i 8 1 0 . 0 7 . 1 60.8 1 3 . 9 ' 9 9.9 7 .6 61.0 1 4 . 2 j 1 0 1 0 . 0 7.9 62.2 1 3 . 7 I 11 9.9 8.3 6 0 . 5 1 6 . 5 j 1 2 1 0 . 0 8 . 3 5 7 . 1 1 7 . 9 i 13 1 0 . 2 7 . 5 60 .0 15 .1 ' 1 4 1 0 . 9 7 . 7 5 9 . 5 1 4 . 6

8 . 4 8.8 59 .8 1 6 . 6 i6 9 . 1 8 . 7 60.4 1 6 . 4

i

I i 15

1 7 9 . 0 8.2 6 0 . 8 1 3 . 6 Note: T i 0 2 a n d P205 v a l u e s are i n c l u d e d i n A 1 2 0 3

TABLE # 4

__ Sieve analysis, as received - % passing; ......................................................................................... Clinker# 1' 3/4 ' 1/2 ' 3/8 ' 4 mesh 8 mesh 16 mesh 30 mesh 50 mesh 1 0 0 m ___-___-_---_-----L---------------------------------------------------------------------~

99.3 87.9 51.0 32.6 26.1 22.9 15.1 99.8 86.1 49.6 35.0 29.1 24.5 14.6 99.9 89.8 59.6 44.3 36.5 31.8 22.7

12.2 100 10 0 83.5 43.7 29.8 22.0 17.6

63.6 53.4 36.8 23.2 17.7 12.1 6.6 3.2

1 100 100 100 2 100 100 100 3 100 100 100 4 100 100 5 100 100 .6 96.3 83.9 7 100 100 8 9 100 100 100 10 100 100 11 100 100 12 100 100 13 100 91.7 71.8 14 100 86.9 76,l 15 98.7 86.3 62.1 16 97.8 89.9 70.6 17 94.8 91.1 78.6

100 99.6 81.2 42.5 28.1 21.5 16.6 11.2

100 99.3 81.6 40.1 24.5 17.7 13.9 9.0 100 100 100 99.6 0 3 . 2 50.8 36.5 28.5 19.1 11.0

99.4 74.6 37.5 25.1 18.5 14.3 9.3 L O O 99.8 84.1 46.1 28.9 22.3 18.6 11.4 100 99.6 85.1 42.8 27.2 20.9 16.0 10.4 100 99.8 86.7 50.3 35.5 27.1 22.7 14.7

67.2 48.6 23.3 6.1 2.9 2.3 1.3 47.5 26.9 20.2 18.0 17.3 15.0 7.0 53.4 23.3 10.2 6.2 5.0 4.1 2.7

52.4 21.6 6.9 2.6 1.9 1.6 1.0

66.0 47.2 34.0 23.6 17.0 13.8 7.9

TABLE #5

_ _ - BBlO T e s t ..........................................................................................

1000 revs. 2000 r evs . 3000 r evs . 4000 revs. 5000 revs. C l i n k e r # B l a i n e Log.Bl . B1. Log.Bl . B1 . Log .B l . B l . Log.Bl . B1. Log.Bl . ..........................................................................................

3560 3 ,5514 4060 3.6085 1 1 3 8 0 3 .1399 2280 3.3679 2920 3 .4653 2 1460 3.1643 2310 3.3636 3010 . 3 .4786 3500 3.5440 3990 3.6010

3820 3 . 5 8 2 1 4260 3.6294 3 1500 3 .1761 2370 3.3747 3210 3 .5065 4 1400 3 .1461 2250 3.3522 2990 3.4757 3620 3 .5587 4110 3.6138 5 1510 3.1790 2440 3.3874 3180 3.5024 3720 3 .5705 4230 3 .6263 6 ' _ 1420 3.1523 2330 3.3674 3060 3.4857 3650 3.5622 4190 3 .6222 7 1480 3 .1703 2400 3.3802 3090 3.4900 3710 3.5694 4190 3.6222

3040 3.4829 3630 3.5599 4160 3 .6191 8 1340 3 , 1 2 7 1 2230 3.3483 2360 3.3729 3060 3 .4857 3650 3 .5623 4150 3 .6180 9 1440 3.1584

1 0 1410 3 .1492 2300 3.3617 3030 3.4814 3640 3 .5611 4130 3.6160 3010 3 .4785 3580 3 .5539 4060 3 .6085 11 1470 3 .1673 2530 3 . 4 0 3 1

1 2 1280 3.1072 2120 3 .3263 2830 3..4518 3410 3 .5328 4300 3 ,6334 2980 3 .4742 3560 3.5514 4060 3 .6085 1 3 1420 3 .1523 2270 3.3560

4180 3.6212 1 4 1350 3 .1303 2250 3 .3521 2980 3 .4742 3630 3.5599 1 5 1420 3 .1523 2170 3 .3365 2890 3.4609 3520 3 .5465 4040 3.6064

3710 3 .5694 4180 3.6212 1 6 1560 3 .1931 2390 3.3784 3130 3 .4955 3790 3 .5786 4260 3.6294 1 7 1530 3.1847 2460 3 .3909 3170 3 .5011

TABLE 6

2 3 4 5 6 . 7 8 9 1 0 11 1 2 1 3 1 4 1 5 1 6 1 7

48.5 48 .5 48 .5 48.5 48 .5 48.5

1 3 7 1 3 5 1 3 6 1 2 4 1 2 6 1 3 0

48.5 1 2 3 48.5 1 3 2 48.5 1 2 6 48 .5 1 3 0 48.5 1 3 0 48.5 1 2 9 48 .5 1 2 2 48.5 134 48.5 - 1 2 6 48 .5 110

24 .4 24.8 25 .4 23.0 2 4 . 5 24 .5 21 .6 23 .7 2 4 . 1 23 .9 24 .9 2 3 . 5 22 .2 24.2 24 .0 2 2 . 1

29 .2 31 .4 31.1 3 0 . 1 32 .2 31 .2 2 6 . 5 30.2 31 .3 32 .0 32.9 29 .6 28 .8 31 .9 32 .8 2 7 . 9

36 .5 38 .7 35 .9 35.7 3 8 . 3 37.4 3 3 . 5 36 .6

Note: t e s t material from BBlO p roduc t s , see 'Sable 3 f o r B l a i n e (under co- lumn 5 0 0 0 revs.) Gypsum w a s added t o b r i n g t h e SO3 t o 2.80 %.

37.7 37 .9 37 .4 33 .9 32 .4 36 .6 3 8 . 5 3 1 . 3

APPENDIX C

EXPLATJATIOH OF VOLATILE

FLOW CALCULATIONS

.

APPENDIX C

EXPLAMATION OF VOLATILE FLOW CALCULATIOMS

The calculation of material fluxes in the kiln were determined by mass balance. The principle of conservation of loss-free material flow applies:

x (kiln feed) + x (fuel) = x (clinker) where x = loss - free material flow. Therefore: ukf (1-L) kf +pI(l-L) = uck (1-L) ck, ‘where ukf = kiln feed, pI=rubber, uck = clinker, where p = total material flow, and L = loss fraction (105OOC).

Setting flows on a per loss free clinker basis:

UCk (1-L) ck = 1

The l o s s on ignition of fuel oil is 100% and so does not appear in the equation. However, the flow of oil into the kiln is measured in C.O.P. and from a chemical analysis of the oil the flux of volatile elements from the oil into the kiln can be determined.

The flux of volatile elements at various points in the pyroprocess = flux of material x percent concentration of volatile elements in material sampled.

. The flux of kiln material was not directly measurable. According to simulation by computer model of kiln #2 in a volatile recirculation study done by Patrice Chaurand in 1976, the loss-free kiln material flow is 120% of the flow of clinker on a loss free basis. This value is the same as that adopted in the volatile recirculation studies on the long dry kilns at the Brookfield plant, so it is a good assumption for purposes of comparison.

APPENDIX D

VOLATILE RECIRCULATION

KILN P2, JULY 1, 1982

APPENDIX D

ST. CONSTAWT CEMENT PLANT

VOLATILE RECIRCULATICN K I L N #2, JULY 1, 1982

Kiln I n p u t G t p u t IXlring I n t e r v a l (10 AM to 2 PM)

Y = total material flow X = loss-free material flow L = loss f r a c t i o n (105OOC)

Conservation of loss-free material flow (i.e. no s t a c k loss or material accumulated )

X ( r a w mix) = X(c1inker)

Therefore : Ym (1 - L) = Yck (-1 - L) ck

S e t t i n g flaws on a per loss-free clinker bas is :

Yck (1 - L)ck = 1

F’ran chemical na lyses (L.O.I. a t 105OOC)

Lck = 0.0005 Lrm = 0.3515 LKiln = 0.2029

Solving: Yrm = 1.5420 Yck = 1.0005

Specific Heat Consumption

S . H . C . = 98 L x 42,261 raS x 0.9673 t - t -3

- min . x m3* x 1.5420 kg RM x h r

997.41; 1.0005 kg ck 90 t RM

X 60 min. = 4127 M J (L.H.V. ) hr t clinker

Oil Consumption = 98 L x 0.9673 t mj

- min.

m3* x 1.5420 kg RM x hr 997.4L 1.0005 kg ck 90 t

- X

x 60 min. = 9.77 t oil - hr 100 t clinker

* Iknsity of water at a standard temperature, i.e. 68'F.

NOTE: Lower heat value ard density of oil taken from Table #1 in this Appendix.

Volatile Recirculation

The volatile recirculation flows per loss-free clinker are obtained directly frun the total mass flows calculated above and the relevant volatile chemical analysis shown in Table # 5 in the body of the report. m e total mss flows within the kiln can be obtained only by estimating the loss-free recirculation above the particular point in the kiln load under consideration. The loss-free recirculation between the chains and the burning zone w a s taken to be 0.2 per clinker.

Thus, within the kiln:

Y = 1.2 = 1.2 = 1.5055 (1 - L) (1 - .2029)

?he volatilization coefficient for each volatile is defined as:

Vi = flow kiln - flow clinker flow kiln

The volatile flows are shown in Figues 4 to 7.

c

TABLE 1

BUNKER C O I L CHARACTERISTICS

Date Sample Taken : J u l y 1 2 , 1 9 8 2

A n a l y s e s by C a l e b Bre t t Canada L i m i t e d , M o n t r e a l

S p e c i f i c G r a v i t y a t 71OC : 0.9673

L o w e r Heat V a l u e 4 2 , 2 6 1 MJ/tonne

SO3 c o n t e n t ( % ) 2.34

NOTE: 71OC is t h e t e m p e r a t u r e of t h e o i l a t t h e l o c a t i o n where it is m e t e r e d b e f o r e e n t e r i n g t h e k i l n .

APPENDIX E


KILN #2, JULY 14, 1982

c

APPENDIX E

ST. CONSTANT CEMENT PLANT

VOLATILE RECIRCULATICN KID1 #2, JULY 1 4 , 1982

Tonnages During Hours ( 9 PM to 1 AM)

Raw Mix:

. Average M'IFH based on all hourly readings during in t e rva l :

Shredded Rubber:

. Average MTPH based on readings during in te rva l :

82.5 MTPH'

1.95 EITPH

Kiln Input-Output During In t e rva l ( 9 PM to 1 AM)

Y = total material flow X = loss-free material flaw L = loss f r a c t i o n (105OOC)

Conservation of loss-free material flaw (i.e. no s tack loss or material accumulation) :

X (raw mix) + X ( f u e l ) = X ( c l i n k e r )

Therefore :

YKKI (1 - L)rm = Y f ( 1 - L ) f = Yck (1 - L)ck

Se t t i ng flows on a per loss-free c l i n k e r basis :

Yck (1 - L)ck = 1

F" chemical analyses , (L.O.I. a t 105OOC):

Lck = 0.0033 Lrm = 0.3529 Lf = 1 - ash - 1 0.1717 Lkiln = 0.2101

F m tonnages: Yf = 1.95 Yrm 82.5 -

Solving : Yrm = 1.5357 Yf = 0.03630 Yck = 1.0033

LCL

SPeci f ic Heat Consumtion

S .H.C.

= 1) 67 L x 42,261 M J x 0.9673 t mj

- - min. t

X m3* x 1.5357 kg RM x h r x 60 min. 997.4L 1.0033 kg ck 82.5 t IF.I h r

= 3190 MJ for bunker C o i l t c l inke r

+ 2) 1.95 t x 7376 Kcal HHV x 0.97 LHV x 1000 kg x 4.186 x M J - - - h r kg HHV t KcaL

x 1.5357 kg RM x h r - 1.0033 Kg ck 82.5 t IFI

= 1083.0 M J f o r shredded rubber t clinker

Tota l S.H.C. = 3190 + 1083 = 4273 M J (L.H.V) t c l inke r

O i l Consumption = 67 L x 0.9673 t min . 7

x 1 m3* x 1.5357 kg €+I x h r 997.4L i.0033 kg ck 825 t m

x 60 min. = 7.23 t o i l h r 10.0 t clinker

Rubber flow is 25% of total hea t input to k i l n . S.H.C. has increased by 3.5%. B e l l e v i l l e are H.H.V. as t h a t of coal, was assmed.

Relative to July 1, Heat values for rubber reported by

To convert to L.H.V., a ratio of 0.97, the same

* Density of water a t a standard temperature,i.e. 68OF

MOTE: Lower hea t value and density of oil taken frcm Table #1 i n Appendix D. i n m n d i x A.

Lmer hea t value of rubber taken from Table #3

*

Volatile Recirculat ion

The volatile flows per loss-free c l inke r are obtained d i r e c t l y frm the total mss flows calculated above and the re levant v o l a t i l e chemical analyses shown i n Table #6. The total mss flows within the k i l n Can be obtained only by est imat ing the loss-free r ec i r cu la t ion above t h e p a r t i c u l a r p i n t i n the k i l n load under consideration. ?he loss-free rec i r cu la t ion between the chains and the burning zone was taken to be 0.2 per c l inke r .

Thus, within the ki ln:

Y = 1.2 = 1.2 = 1.5192 (1 - L) (1 - .2101)

The v o l a t i l i z a t i o n c o e f f i c i e n t f o r each v o l a t i l e is defined as:

V i = f l o w k i l n - flow c l i n k e r flm k i l n .

The v o l a t i l e flows are shown in Figures 8 to 11.

- LCL

APPEflDIX F


KILN #2, JULY 15, 1982

I PI

. APPENDIX F

ST. CONSTANT CEME2?T PLANT

VOLATILE RECIRCULATION K I L N #2, JULY 15, 1982

Tbnnages Curing Hours ( 9 PM to 1 AM)

Raw Mix:

Average MTPH based on a l l hourly readings during i n t e r v a l :

Shredded Rubber :

. Average MTPH based on readings during i n t e w a l :

Kiln Input-Output Ihr ing I n t e r v a l ( 9 PM - 1 AM)

Y = total material flow X = loss-free material flow L = loss f r ac t ion (105OOC)

82.0 MTPH

2.45 MTPH

Conservation of loss-free material flow (i.e. no s t a c k loss or material accumulation).

X (raw n i x ) + X(fue1) = X(c1inker)

merefere : Ym (1 - L) IXI + Y f ( 1 -L)f = Yck (1 - L)ck

Se t t i ng flows on a per loss-free clinker basis :

Yck (1 - L)ck = 1

From chemical analyses (L.O.I. a t 105OOC):

Lck = 0.0035 Lrm = 0.3526 LE = 1 - ash = 1 - 0.1956 Lkiln = 0.1967

F m tonnages:

Solving:

Y f = 2.45 Ym 82.0 - -

Ym = 1.5308 Yf = 0.04574 Yck = 1.0035

Specific Heat Consmption

S.H.C.

= 1) 62 L x 42,261 NJ x 0.9673 t - - min. t s

x m3 x 1.5308 kg RM x h r x 60 min. 997.4 L 1.0035 kg ck 82.0 t RPI h r

= 2836 W for bunker C oil - t

+ 2) 2.45 t x 7355 Kcal x 0.97 LHV 1000 kg x 4.186 x 10-3 M J - - - - h r kg H H V t K c a l

x 1.5308 kg RM x 1.0035 kg ck

h r 82.0 t €$I

= 1361 ru for shredded rubber t clinker

Tbtal S.H.C. = 2836 + 1361 = 4197 M J (L.H.V. ) t clinker

O i l Consumption = 62 L x 0.9673 t rnin. ii7

x m3* x 1.5308 kg RM x h r 997.4L 1.0035 kg ck 82.0 t RM

x 60 min. = 6.71 t oil h r 100 t clinker

R u b b e r flow is 32% of total hea t input to k i l n . S.H.C. has increased by 1.7%. Belleville are H.H.V. same on that of coal was assumed.

Relat ive to J u l y 1, Heat values for rubber reported by

Tb convert to L.H.V., a ratio of 0.97, the

* Density of water a t a standard temperature, i.e. 68OF

f$GTE: mer h e a t value and dens i ty of oil taken from Table #1 i n Appendix D. i n Appndix A.

Heat value of rubber taken frm Table #3

. Volatile Recirculat ion

The volatile flows per loss-free c l inker are obtained d i r e c t l y frm the total mass flows calculated above a d the re levant v o l a t i l e chemical analyses shown i n Table #7. k i l n can be obtained only by estimtirq t h e loss-free r e c i r c u l a t i o n above the p a r t i c u l a r p i n t i n the k i l n load under considerat ion. loss-free r e c i r c u l a t i o n between the chains and the burning zone was taken to be 0.2 per cl inker .

The total mss flows wi th in the

The

Thus, within t h e k i ln :

Y = 1.2 = 1.2 = 1.4938 (1 - L) (1 - .1967)

The v o l a t i l i z a t i o n coe f f i c i en t f o r each v o l a t i l e is defined as:

V i = flow k i l n - flow c l i n k e r flow k i l n .

The v o l a t i l e flows are shown in Figure 12 t o 15.

COMBUSTION OF SHREDDED TIRES

AT ST. CONSTANT, KILN NO. 2

MAY 31 TO JUNE 4, 1982

S. Stashin Process Department Lafarge Consultants Ltd. June 30, 1982

TABLE OF CONTENTS

1. INTRODUCTION

2. OBJECTIVES OF PROCESS TESTS

3. TEST DURATION

4. SHREDDED RUBBER CHARACTERISTICS

5. DESCRIPTION OF TESTS

6. COMBUSTION OF RUBBER

7. KILN CALORIFIC CONSUMPTION

8. KILN STABILITY

9. KILN PROCESS PARAMETERS

10. CLINKER ANALYSIS

11. CONCLUSION

CMBUSTION OF SHREDDED TIRES P a g e 1

1. INTRODUCTION

D u r i n g t h e period of May 3 1 t o J u n e 4, t e s t s were con- d u c t e d u s i n g s h r e d d e d r u b b e r as a p a r t i a l f u e l s u p p l e - ment f o r k i l n No. 2 a t S t . C o n s t a n t . K i l n N o . 2 was f i r e d w i t h b u n k e r C f u e l o i l . A s u b s t i t u t i o n o f 21% o f t h e f u e l o i l w i t h s h r e d d e d r u b b e r was o b t a i n e d .

S t e v e S t a s h i n of LCL w a s on hand a t t h e p l a n t to manage t h e process a s p e c t s of t h e tests. Michel Beaupr6 , t h e p l a n t process e n g i n e e r a t S t . C o n s t a n t , a s s i s t e d w i t h t h e process a s p e c t s . Samples o f r u b b e r used and c l i n - k e r p r o d u c e d d u r i n g t h e week h a v e been s e n t to B e l l e - v i l l e f o r a n a l y s i s . The r e su l t s are n o t a v a i l a b l e a t t h e t i m e of w r i t i n g o f t h i s report. The same c l i n k e r samples however , were a n a l y z e d a t t h e p l a n t and are d i s c u s s e d i n t h i s report . The e f f e c t s o f r u b b e r f i r i n g o n t h e pyroprocess and t h e d i f f e r e n t p rob lems encoun- t e r e d are a l so d i s c u s s e d .

2 . OBJECTIVES OF PROCESS TESTS

f o l l o w i n g were t h e major o b j e c t i v e s of t h e t e s t s :

D e t e r m i n e t h e e f f e c t s o f r u b b e r f i r i n g o n t h e o p e r a t i o n of t h e k i l n , n o t i n g any c h a n g e s i n process parameters.

D e t e r m i n e t h e s p e c i f i c h e a t consumpt ion o f t h e k i l n f o r v a r i o u s f l o w r a t e s of r u b b e r .

A s c e r t a i n any e f f e c t s o n c l i n k e r q u a l i t y .

D e t e r m i n e v o l a t i l e r e c i r c u l a t i o n w i t h i n t h e k i l n w i t h d i f f e r e n t l e v e l s o f r u b b e r f l o w .

T h r e e l e v e l s of k i l n f u e l s u b s t i t u t i o n w i t h r u b b e r were to be s t u d i e d :

0 15% s u b s t i t u t i o n ;

0 23% s u b s t i t u t i o n ;

. 30% s u b s t i t u t i o n .

U n f o r t u n a t e l y mater ia l h a n d l i n g p rob lems p r e v e n t e d o b j e c t i v e s 2 , 4 a n d 5 f r o m b e i n g m e t .

,

I

L

COMBUSTION OF SHREDDED TIRES P a g e 2

3 .

4 .

5.

TEST DURATION

T h e c l i n k e r p r o d u c e d w h i l e f i r i n g r u b b e r had t o be iso- l a t e d u n t i l i t s q u a l i t y c o u l d b e a s s u r e d . The c l i n k e r was s e n t t o t h e raw material s t o r a g e h a l l , where t h e r e w a s space a v a i l a b l e f o r o n l y 5 days p r o d u c t i o n . The k i l n was t h e r e f o r e f i r e d fo r 5 d a y s .

SHREDDED RUBBER CHARACTERISTICS

The mater ia l i s t h e r e s u l t of s h r e d d i n g s t e e l b e l t e d r a d i a l t i res. Along w i t h t h e pieces of s h r e d d e d rub - ber, t h e r e are a p p r e c i a b l e q u a n t i t i e s of metal w i r e a n d c l o t h f i b r e . When t h e i n i t i a l r u b b e r f i r i n g tests o c c u r r e d i n J u n e 1 9 8 0 , t h e r e was no metal wire p r e s e n t a s s h r e d d e d bias-ply t ires were u s e d . I t was s p e c i f i e d t h a t t h e maximum d i m e n s i o n o f a l l p ieces o f s h r e d d e d r u b b e r w a s t o be smaller t h a n 5 /8 " , b u t t h e r e were many pieces l a r g e r t h a n t h i s s i z e .

The lower h e a t v a l u e o f t h e r u b b e r h a s b e e n e s t i m a t e d a t a n a v e r a g e o f 1 3 , 5 0 0 B T U / l b , b a s e d o n l i t e r a t u r e from t h e s u p p l i e r . The lower h e a t v a l u e o f t h e b u n k e r C o i l u s e d a t S t . C o n s t a n t is a b o u t 1 7 , 7 0 0 BTU/lb.

Samples of r u b b e r were t a k e n f rom t h e s u r g e b i n on t h e b u r n e r platform d u r i n g t h e r u b b e r f i r i n g tests. T h e s e h a v e b e e n s e n t t o B e l l e v i l l e f o r a p r o x i m a t e a n a l y s i s and a d e t e r m i n a t i o n of t h e s i z e d i s t r i b u t i o n o f t h e s h r e d d e d r u b b e r and w e i g h t p e r c e n t s of r u b b e r , f i b r e and metal i n a sample.

DESCRIPTION O F TESTS

A t 15 :45 , May 31 , t h e i n s u f f l a t i o n o f r u b b e r i n t o k i l n 2 commenced. The q u a n t i t y of r u b b e r f l o w was set f o r a p p r o x i m a t e l y 1 5 % o f t h e o i l f low i n t o t h e k i l n wh ich is n o r m a l l y 9 0 l i t e r s / m i n w i t h a k i l n s p e e d of 1 .42 rpm a n d a p r o d u c t i o n of 58 t o n s / h r of c l i n k e r . The k i l n n o r m a l l y r u n s a t maximum s p e e d (1 .42 rpm). The o i l f l o w r a t e w a s r e d u c e d by 15% t h e moment t h e r u b b e r flow s t a r t e d .

COMBUSTION OF SHREDDED TIRES P a g e 3

The f l o w o f r u b b e r had been c a l i b r a t e d w i t h t h e s p e e d of t h e screw c o n v e y o r b e n e a t h t h e r u b b e r f e e d b i n o n t h e b u r n e r p l a t f o r m e a r l i e r i n t h e d a y . The p rogram was to t e s t 1 5 , 2 3 and t h e n a 30% r e p l a c e m e n t o f b u n k e r C w i t h r u b b e r on s u b s e q u e n t d a y s . The r e q u i r e d r u b b e r f l o w r a t e was d e t e r m i n e d a s suming a lower h e a t v a l u e of 1 3 , 5 0 0 BTU/lb and 1 7 , 7 1 7 BTU/lb f o r b u n k e r C. The re- s i d u a l oxygen was t o be m a i n t a i n e d c o n s t a n t i f p o s s i b l e so as n o t t o i n c r e a s e t h e s p e c i f i c h e a t consumpt ion o f t h e k i l n o r upset k i l n o p e r a t i o n .

U n f o r t u n a t e l y , t h e f l o w a b i l i t y o f t h e s h r e d d e d s t ee l b e l t e d r a d i a l t i r e s was found to be q u i t e poor. Metal wire and f i b r e i n t h e r u b b e r would a c c u m u l a t e i n t h e feed screw c o n v e y o r on t h e b u r n e r p l a t f o r m , b l o c k i n g t h e f l o w o f t h e pieces o f s h r e d d e d r u b b e r i n t o t h e r o t a r y a i r lock f rom which t h e r u b b e r would flow t o t h e k i l n . The r u b b e r f l o w was a t b e s t u n s t e a d y and incon- s i s t e n t and a t worst n o n e x i s t a n t . T h i s s i t u a t i o n had a d e s t a b i l i z i n g e f f e c t on t h e p y r o p r o c e s s .

The maximum l e v e l o f r u b b e r s u b s t i t u t i o n t h a t c o u l d be o b t a i n e d f o r a p e r i o d 4 h o u r s or more w a s 21%. A summary o f t h e causes o f r u b b e r f l o w i n t e r r u p t i o n is p r e - s e n t e d i n T a b l e 1. I n t e r r u p t i o n s of l e s s t h a n 1 5 min- u t e s were n o t n o t e d .

T a b l e 2 g i v e s t h e o i l and r u b b e r consumpt ion d u r i n g p e r i o d s o f maximum k i l n speed, t h e no rma l mode o f operation. ine d u r a t i o n of tnese p e r i o d s is i n d i c a t e d i n t h e t a b l e . The f l o w of r u b b e r was c a l c u l a t e d a s suming t h e same k i l n s p e c i f i c h e a t consumpt ion w i t h r u b b e r f i r i n g . The a p p a r e n t maximum r e d u c t i o n i n o i l f l o w a t t a i n e d was 25% f o r a p e r i o d o f 1 h o u r and 35 m i n u t e s . The k i l n s u b s e q u e n t l y pushed . I t is d o u b t f u l w h e t h e r t h e f l o w o f r u b b e r i n t o t h e k i l n w a s a c t u a l l y e q u i v a - l e n t t o 25% of t h e o i l flow. The p rac t i ca l maximum r a t e o f o i l s u b s t i t u t i o n appears t o h a v e b e e n 2 1 % .

m,. -

6. COMBUSTION OF RUBBER

Combust ion o f r u b b e r a p p e a r e d to be complete. N o rub- b e r r e s i d u e o r w i r e w a s found i n t h e c l i n k e r samples taken-.

COMBUSTION OF SHREDDED TIRES

10. OF 4INUTES

TABLE 1

~~

INTERRUPTION

Page 4 ii

DATE

51/05/82

51/05/82

5 1/05/8i

11/05/8i

11/06/81

11 /06/ 82

11/06/82

11/06/82

12/06/82

12/06/82

12/06/82

12/06/82

12/06/82

13/06/82

)3/06/ 82

14/06/82

TIME

15:45

17:20 t o 17:40

19:lO t o 19:30

20:oo t o 21:DO

D6:50 t o 07:lO

13:05 t o 13:30

16:50 t o 17:05

17:15 t o 19:45

02:OO t o 04:05

38:15 t o C8:30

10:30 t o 11:15

21:50 t o 22:05

23:OO t o 23:15

37:40 t o 09:05

10:25 t o 22:45

19 : 00

I

- 20

20

60

20

25

15

150

125

*c 1 2

45

15

.I5

145

740

BEGINNING OF TEST

K i l n push, speed cut, rubber f low stopped

No rubber f l o w , Screw blocked with w i r e and f i b r e

No rubber f l o w , Screw blocked w i t h wi re and f i b r e

No rubber flow, Screw blocked with w i r e and f i b r e

Larger hole cut i n manifold around screw t o a id rubber f low

No rubber flow, Screw blocked with w i re and f i b r e

No rubber f l o w , screw blocked with wi re and f i b r e

Problem w i t h canputer

nuvuer held up i n r o t a r y a i r iock, canpressed a i r l eak ing around blades

No rubber f l o w , screw blocked w i t h wi re and f i b r e

Wire removed fran screw

Wire removed from screw

n L L

Rubber he ld up i n ro ta ry a i r lock, canpressed a i r leak ing around blades

K i ln down m t i l 14:35 t o change broken r o l l e r i n c l i n k e r cooler drag chain, rubber s ta r ted a f t e r subsequent preheat o f k i l n

END OF TEST

COMBUSTION OF SHREDDED TIRES / I

P a g e 5

TABLE 2

FUEL CONSUMPTION AT MAXIMUM KILN SPEED (1.42 RPM)

DATE

3 1/05/82

31/05/82

01/06/82

01/06/82

02/06/82

02/06/82

02/06/82

03/06/82

START TIME

01 :oo

15:45

04 : 00

19:40

4 :05

18:OO

23:50

22:45

NUMBER OF HRS AND MIN.

~~

14:45

1 :35

12:50

6:20

6:25

3:50

7:50

9:45

AVERAGE OIL CONSUMPTION

90 l / m

68 l / m

83 l / m

80 l / m

75 l / m

75 l / m

71 l / m

79 l / m

FUEL

-

22 l / m

7 U m

10 l / m

15 l / m

15 l / m

19 l / m

1 1 l / m

~

a FUEL %

- 25%

8%

11%

17%

17%

21%

1 2%

CALCULATED FLOW OF RUBBER

-

26.55 kg/min

8.45 kg/min

12.07 kg/min

18.10 kg/min

18.10 kg/min

22.93 kg/min

13.28 kg/min

COMBUSTION OF SHREDDED T I R E S P a g e 6

The a u x i l i a r y b l a s t p i p e c o n v e y i n g r u b b e r i n t o t h e k i l n was a n g l e d t o w a r d t h e f l a m e . The pieces of r u b b e r c a u g h t f i r e s h o r t l y a f t e r e n t e r i n g t h e k i l n . However , a s h o w e r o f f l a m i n g pieces was s e e n t o impact o n t h e w a l l o f t h e k i l n o p p o s i t e t o t h e load. T h e s e would t h e n a c c u m u l a t e a t t h e b a s e o f t h e k i l n . I t is c l e a r t h a t complete c o m b u s t i o n of a l a r g e number of pieces of r u b b e r ( n o t a b l y t h e l a r g e r o n e s ) d o e s n o t occur i n s u s - p e n s i o n i n t h e k i l n g a s .

I d e a l l y no f u e l s h o u l d c o n t a c t t h e l o a d . A r e d u c i n g a t m o s p h e r e ( o x y g e n p o o r ) e x i s t s a t p o i n t s of impinge - men t of f u e l on t h e load. T h i s promotes v o l a t i l i z a t i o n of s u l p h u r and o t h e r v o l a t i l e e l e m e n t s t h a t can l e a d t o k i l n c y c l i n g i f t h e v o l a t i l e e l e m e n t s are p r e s e n t i n a p p r e c i a b l e amoun t s i n t h e raw m i x . Whether r u b b e r b u r n i n g a t t h e b o t t o m o f t h e k i l n p r o v e s d e t r i m e n t a l t o r e f r a c t o r y l i f e r e m a i n s t o be s e e n .

The a i r p r e s s u r e i n t h e f l e x i b l e h o s e c o n v e y i n g r u b b e r t o t h e k i l n a p p e a r e d to be a d q u a t e as t h e r u b b e r w a s i n s u f f l a t e d w e l l i n t o t h e b u r n i n g zone ( a b o u t 30’ 1, en- s u r i n g it would b u r n i n t h e k i l n and n o t i n t h e cooler.

7 . K I L N CALORIFIC CONSUMPTION

I t was i m p o s s i b l e t o d e t e r m i n e i f t h e r e were a n y chan- g e s i n t h e k i l n s p e c i f i c h e a t consumpt ion . The flow rate of tubber w a s c a l i b r a t e d w i t h the speed of t h e screw below t h e r u b b e r b i n on t h e b u r n e r f loor before t h e s t a r t of t h e tes ts , b u t s h o r t l y a f t e r commencement o f f i r i n g t h e k i l n w i t h r u b b e r , t h e f l o w o f r u b b e r no l o n g e r matched t h e c a l i b r a t i o n . I t w a s e v i d e n t by o b s e r v i n g t h e k i l n b u r n i n g zone and t h e q u a n t i t y of r u b b e r e n t e r i n g t h e r o t a r y a i r l o c k a f t e r t h e screw t h a t t h e r u b b e r f l o w was i n s u f f i c i e n t . T h i s was due t o w i r e and f i b r e a c c u m u l a t i n g i n t h e screw and impeding t h e f l o w of r u b b e r . The s p e e d o f t h e screw had to be i n - c r e a s e d t o o b t a i n t h e d e s i r e d f l o w rate .

Also, t h e r e s i d u a l oxygen t rack on t h e r e c o r d i n g c h a r t i n C.O.P. began t o f l u c t u a t e w i d e l y upon i n s u f f l a t i n g r u b b e r i n t o t h e k i l n , i n d i c a t i n g t h a t t h e r u b b e r f l o w was u n s t e a d y . Whereas b e f o r e f i r i n g r u b b e r , t h e 0 2 v a r i e d mostly be tween l e v e l s of 1 and 2 % , a f t e r s t a r t - i n g t h e t e s t it f l u c t u a t e d be tween l e v e l s o f 1 t o 4 % .

,

COt4BUSTION OF SHREDDED TIRES Page 7

I f t h e oxygen l e v e l s were s i m i l a r b e f o r e and d u r i n g t h e f i r i n g o f r u b b e r and t h e amount of r u b b e r e n t e r i n g t h e k i l n was p r e c i s e l y known, t h e n t h e k i l n s p e c i f i c h e a t c o n s u m p t i o n c o u l d be d e t e r m i n e d . However due to t h e i r r e g u l a r i t y o f r u b b e r f l o w i n t o t h e k i l n it c o u l d n o t b e a s c e r t a i n e d .

8.

9.

1 0 .

KILN STABILITY

K i l n s t a b i l i t y was compromised when f i r i n g r u b b e r . Due t o t h e poor f l o w a b i l i t y of t h e s h r e d d e d r u b b e r , t h e k i l n was " s t a r v e d " of f u e l . R e p e a t e d k i l n slowdowns were r e q u i r e d t o h a n d l e raw l o a d s . I r r e g u l a r v a r i a - t i o n s i n k i l n amperage were e v i d e n t t h r o u g h o u t m o s t of t h e week.

K I L N PROCESS PARAMETERS

T a b l e 3 l i s t s t h e c h a n g e s i n k i l n process p a r a m e t e r s fo r t h e same p e r i o d s shown i n Table 2. R e s i d u a l oxy- g e n , water s p r a y and e x h a u s t f a n s p e e d which i s r e l a t e d t o t h e f l o w o f e x h a u s t g a s e s i n t h e k i l n , were a l l h i g h e r when f i r i n g r u b b e r . T h e s e t h r e e parameters are p r o p o r t i o n a l t o o n e a n o t h e r . S i n c e t h e k i l n was oper- a t e d w i t h a h i g h e r t h a n normal oxygen l e v e l , p r o b a b l y t o c o u n t e r d i p s i n t h e u n s t a b l e r e s i d u a l oxygen l e v e l which would knock o u t t h e p r e c i p i t a t o r , t h e amount of gases flowing tiiroiigh the k i l n w a s g r e a t e r . increased water s p r a y w a s n e c e s s a r y to m a i n t a i n t h e back end t e m p e r a t u r e a t t h e s e t p o i n t of 360OC.

The c h a i n i n l e t g a s t e m p e r a t u r e r e m a i n e d e s s e n t i a l l y t h e same.

CLINKER ANALYSIS

The c l i n k e r p r o d u c e d d u r i n g t h e test p e r i o d was ana- l y z e d by t h e p l a n t l a b . Samples were o b t a i n e d e v e r y 4 h o u r s .

Wi th t h e e x c e p t i o n of some s a m p l e s which c o n t a i n e d c l i n k e r w i t h a h i g h free l i m e , most samples i n d i c a t e d good q u a l i t y c l i n k e r w i t h no u n u s u a l c o n c e n t r a t i o n s o f s u l p h u r or a l k a l i e s .

COMBUSTION OF SHREDDED T I R E S

- 22 l / m

DATE

*464 r p m

+5 r p m

TABLE 3

10 l / m

15 l / m

15 l / m

19 l / m

11 l / m

K I L N PARAMETERS AT MAXIMUM K I L N S P E E D ( 1 . 4 2 RPM)

+I2 r p m

+I5 r p m

+21 r p m

+20 r p m

+38 r p m

Page 8

31/05/82

31/05/82

01/06/82

01/06/82

02/06/82

02/06/82

02/06/82

03/06/82

START T I M E

01 :OD

15:45

04:OO

19:40

4:05

18:OO

23:50

22:45

NUMBER OF HRS AND MIN.

14:45

1 :35

12:SO

6:20

6:25

3:50

7: 50

9:15

A EXHAUST AFUEL 1 FAN SPEED

* Before f i r i n g r u b b e r , a c t u a l v a l u e s

C H A I N INLET

I *I . 3

2.7

2.2

1.5

2.3

2.4

2.5

2.2

*877OC

877°C

868°C

874°C

870°C

873°C

863'C

881 O C

A n. s.

*53 l / m

+4 l / m

+3 l / m

+43 l / m

4 1 l/m

4 0 l / m

+47 l/n!

+74 l / m

i

eWBUSTION OF SHREDDED TIRES P a g e 9

P r e s e n t l y , t h e B e l l e v i l l e l a b is d e t e r m i n i n g t h e mine- r a l o g y and g r i n d a b i l i t y o f t h e c l i n k e r s a m p l e s . They w i l l t h e n be r e t u r n e d t o t h e p l a n t so p h y s i c a l t e s t s on cement made w i t h t h e c l i n k e r c a n be done .

Two samples o f c l i n k e r made w i t h o u t f i r i n g r u b b e r h a v e b e e n i n c l u d e d w i t h t h e set o f s a m p l e s s e n t to B e l l e - v i l l e f o r p u r p o s e s o f c o m p a r i s o n .

11. CONCLUSION

The screw c o n v e y o r b e n e a t h t h e s u r g e b i n on t h e b u r n e r plat form is u n s u i t a b l e t o convey s h r e d d e d r u b b e r w i t h a p p r e c i a b l e q u a n t i t y o f wire and f i b r e . The f l o w o f r u b b e r t o t h e k i l n is i n c o n s i s t . e n t and v a r i a b l e , pro- m o t i n g k i l n i n s t a b i l i t y .

The screw c o n v e y o r is b e i n g r e p l a c e d w i t h a we ighfeed - e r , which w i l l e n s u r e a s t e a d y flow of r u b b e r i n t o t h e k i l n .

The process tests w i l l be r e p e a t e d .

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