Usage of Alternative Fuels & Raw Materials in Cement ... Mr AK Dembla- Humboldt...Materials in...

Usage of Alternative Fuels & Raw

Materials in Cement Industry as

Sustainable Waste Management Option

3rd International Conference on AFR in Cement Industry –

23rd & 24th March, 2017 - New Delhi

Ashok Kumar Dembla

KHD Humboldt Wedag India

Content

Introduction

KHD Pyro Equipment for Burning AFR – PYROJET® Kiln Burner

KHD Pyro Equipment for Burning AFR – PYROCLON® Calciner

AFR – Alternative Fuels and Raw Materials

Conclusion

AFR Handling Concepts

AFR – KHD‘s References [India]

RDF

Tyres

• Before exercising Alternate Fuels and

Raw Materials it is Important to know

about the waste Management system

and Amount of Waste Availability.

• Cement Industry experienced many

usages of waste materials of other

industries / Bi-Products in last few

decades.

• Waste management Hierarchy Shows

that the Most Potential band is

avoidance of Waste [as shown ].

• Co-Processing of waste falls under mid

point of the Hierarchy Cone which has

a great potential than incineration and

Landfilling or Dumping.

Introduction - Alternative Fuel Potential

RD

F

Recovery of Materials

(Recycle & Reuse)

Co-Processing

Incineration

Landfilling

Uncontrolled

Burning

or Dumping

Minimization

Hierarchy of Waste Management

Alternative Fuels and Raw Materials-Introduction

States Generated

(TPD)

Treated (TPD)

Andhra Pradesh* 4760 6402

Chhattisgarh* 1896 168

Delhi 8370 3240

Gujarat 9988 2644

Haryana 3103 188

Jammu & Kashmir* 1792 320

Jharkhand* 3570 65

Karnataka 8697 3000

West Bengal 9500 851

Madhya Pradesh 6678 -

Maharashtra 22,570 5,927

Punjab* 4105 350

Rajasthan* 5037 490

Tamil Nadu 14500 1607

Telengana 6740 3016

Uttar Pradesh 19180 5197

Other 10578 1287

Total 1,41,064 34,752

141064

34,752

Only 25 % of Generated

Waste is Treated,

(Data of CPCB Annual Report 2013-14 & 2014-15)

Waste Generation Statistics: India

Introduction - Alternative Fuel Availability in India

Introduction - Alternative Fuel Utilization Rate

5

Alternative Fuels (AF) utilization rate in the German Cement Industry.

Source: VDZ Monitoring Data

RD

F

Tyres

• Recent database analysis shows that the Green House Gases emission reduction

potential through waste utilization in cement kilns is extremely high.

• A look at international experiences supports this presumption. For example,

Japanese cement industry utilizes about 450 kg Waste / Ton of cement manufactured.

In European cement plants, thermal substitution from alternate fuels is as high as

40%.

• Netherlands is the country where highest TSR more than 80% is achieved.

• India has a Huge Potential when TSR 1% is compared to European Countries TSR

above 40% but limited due to continuous processing and supply of Alternate fuels.

Introduction - Alternative Fuel Potential

Alternative Fuels and Raw Materials (AFR)

AFR are mainly industrial, agricultural, or household wastes and by-products, which can be used

as a source of energy or as substitute for raw materials and cement additives.

AFR is identified as one opportunity to lower the fossil fuel related CO2 emissions.

Thermal substitution rate of AFR will increase on global basis.

Introduction – AFR, Alternative Fuel and Raw Materials

Sewage

Sludge

Rice Husks

Tyres Municipal

Waste

Animal-Meal Animal Meal

Rubber

Chips

RDF

Wood Chips

Alternative Fuels, examples

RDF (Residue derived

Fuels)

Agricultural wastes (Rice

Husk..)

Waste oil, solvents

Sewage sludge

Waste tyres

Impregnated saw dust,

waste wood

etc.

Type of Alternative Fuel: RDF, Fluff, Sorted Waste

Calorific Value, Hu:

Moisture:

3500 - 5000 kcal/kg, kiln ready

15 - 25 wt.-%, kiln ready

0,3 - 0,5 wt.-%

0,5 – 1,0 wt.-%

S-content:

Cl-content:

Others:

Particle Size

Kiln Burner: 2-D Material: < 10 mm 3-D Material: < 2 mm

Calciner: 2-D Material: < 20 mm (< 50 mm for Comb.

Chamber) 3-D Material: < 5 mm (< 20 mm for

Comb. Chamber)

Fluff / RDF

Introduction - Alternative Fuels

Type of Alternative Fuel: Dried Sewage Sludge

General: Physical and chemical properties of sewage

sludge are strong dependent on treatment of

sludge (P2O5 elimination, digestion rest amount

of organic substance..).

2000 - 4000 kcal/kg, kiln ready

Raw ~ 90 – 95 % / Mech. dried ~ 60 – 85 % /

Therm. dried 5 – 15%

Calorific Value

Moisture:

0,9 - 1,6 wt.-%

0,1 -0,2 wt.-%

S-content:

Cl-content:

Particle Size:

Kiln Burner: < 1 mm

Dried Sewage Sludge Calciner: < 4 mm

w Materials

Alternative Raw Materials

• Ca -

• Si -

• Fe -

• Al -

• Si-Al-Ca -

etc.

• S

Lime from waste water treatment

Foundry sands

Steel mill dust, pyrite cinders

Aluminium recycling sludge Fly ash,

ground slag

Gypsum from Desulphurization

Iron Dust

Introduction - Alternative Raw Materials

Alternative Materials to substitue Clinker in

Cement

• Fly ash (power generation)

• Artificial gypsum (flue gas cleaning)

• Ground slag (steel industry)

• Natural Pozzolan

• Limestone

Coarse Slag

Introduction - Alternative Fuel - Goals and Challenges

Global Goals:

Saving of natural resources

Reduction of CO2 emissions (Emission trading)

Thermal Recycling

Material Recycling

Individual Goals:

Earning of disposal fees

Reduction of fuel costs “negative fuel costs”

Stronger market position

Challenges:

Identifying of new (fuel) sources.

Preparing of waste to alternative fuel.

Installation of AFR handling equipment.

Plant up-grade.

Introduction - Alternative Fuel co-processing in the clinker process

Why is the Cement Plant the optimal solution for burning Wastes?

• Highest temperatures and residence time.

• High excess of oxygen for improved and

complete combustion.

• Complete destruction of organic

compounds.

• Basic kiln atmosphere (CaO) and therefore

highest scrubbing effect (Counter Current

Flow) for acid fuel components (Cl, S,

F,…).

• Stable embedding of heavy metals in

crystalline structure of clinker.

• No formation of by-products (e.g. ash, slag,

liquids, residues from gas cleaning…).

Complete recovery of waste fuel energy and mineral content.

Introduction – Feed points for Alternative Fuels and Raw Materials

12

Cement Mill:

• FGD Gypsum

• Gran. Blast Furn. Slag

• Fly Ash

• …….

Raw Mill:

• Slag

• Fly Ash

• …….

Kiln Inlet:

• Whole Tires

• Pasty sludge

• ……

Kiln Burner:

• Sorted municipal

and industrial

waste (RDF)

• Dried sewage

sludge

• Liquid hazardous

wastes, Solvents

• …….

Calciner:

• Sorted municipal

and industrial

waste, low Quality

• Sewage Sludge

• Tire Chips

• …….

Introduction – AFR Influence on Clinker Burning Process

Influence on energy balance, increase of specific heat consumption.

Increased waste gas volumes (higher fuel moisture, fuel chemical composition, higher excess air

demand, more fuel to maintain hot sintering zone).

Higher amount of primary air (transport air) and leakage air, decrease of recuperation air from clinker

cooler.

Increased heat losses by radiation (shifting temperature profile of kiln to kiln inlet chamber).

In case of Bypass System losses due to bypass gas extraction.

Influence on plant operation stability

High demands on fuel dosing equipment, continuous fuel feed.

Formation of build-ups in case of Cl- and S-rich alternative fuels in the area kiln inlet, riser duct,

bottommost cyclone. More manual cleaning efforts or Bypass System necessary

Influence on clinker quality

“Raining” of unburnt fuel out of the kiln flame to the clinker bed => reduced burning conditions.

Cooling down of the sintering zone.

Possible enrichment of harmful elements in clinker, e.g. MgO, P2O5 (depending on Alternative Fuel ash

composition).

Adaption of raw mix, e.g. high Fe-content in Alternative Fuel.

Influence on emissions

Positive influence on avoiding NOx formation and / or NOx reduction.

CO formation in case of inadequate calciner technology or unsuitable secondary fuels.

Saving of primary fuel related CO2 emissions.

Introduction – AFR Influence on Clinker Burning Process

Influence on Process

Just to add some AFR without deeper analysis and knowledge of process

related impacts can cause big problems!

KHD with his over 160 years of industrial history has the

experience and process knowledge to identify and to solve these

challenges to reach high and stable AFR firing rates.

Global KHD Presence

Introduction – AFR Services by KHD

• Analysis of fuels and raw materials.

• Plant Audit as basis for process

design.

• Process design and selection of

components.

• Integration of the full AFR concept into

the cement plant.

• Basic and detail Engineering.

• Project execution.

• Supervision of erection and

commissioning.

• Training.

• After sales service.

Content

Introduction




Conclusion




Concept consists of the following modules:

• Reception

• Storage

• Screening

• Long Distance Conveying

• Dosing

Feed Bin Optional: Manual Sep. Magn. Sep. Shredding

Preparation Plant Concept:

Drum Screen


Solid Alternative Fuels - Calciner

Pneumatic Transport • Feed bin

• Dosing

• Injector Rotary Valve

• Blower + Pipeline

• Direct injection into Calciner

Suitable for fine and medium sized solid fuels, e.g.: • Shredded agricultural wastes and biomass

• Pre-treated industrial and municipal waste, RDF, Fluff


Solid Alternative Fuels - Calciner

Mechanical Transport • Feed bin

• Belt Elevator, Bucket Elevator etc.

• Dosing bin

• Belt Scale

• Chute

Double Pendulum Flap (Protected by Slide Gate) • Gravimetric transport into Calciner

Suitable for fine and medium sized solid fuels, e.g.: • Shredded agricultural wastes and biomass

• Pre-treated industrial and municipal waste, RDF, Fluff

• Shredded tyres

Belt Scale (in front of Combustion Chamber) Double Pend. Flap for shredded Tires, Mordow Cement

Content

Introduction






Conclusion

Primary Air Amount:

Depending on fuel scenario

– Lower for primary fuels ( Low NOx Burner)

– Higher for alternative fuels


Refractory

Swirl Element

Coal Dust Nozzle

Jet-Air Nozzles

Inner Tubes for Alt.

Fuels


AFR Swirl Nozzle – Special Feature for higher AFR rates

Retractable swirl element.

No additional primary air necessary for

AFR nozzle.

Adjustable during operation.

Fracturing, mixing of the AF flow shortly

before entering the kiln (spraying angle).

Improving the mixture within the flame

core and with oxygen.

Oxygen enrichment is also possible.

Increase of alternative fuel firing rate

AF Channel with retractable

Swirl Nozzle


AFR Swirl element in front position Poor AFR distribution

AFR Swirl element in back position Good AFR distribution into

the flame


Reference List for Burner Modification with newly developed AFR Nozzle

Plant Company Clinker

Production

[t/d]

AFR Rate Kiln

Burner [%]

AFR Fuel

Type

Project

Burglengenfel

d, D

Heidelberger

Cement

2000 50-60 Plastic and

paper foils

Existing

Burner,

retrofit with

AFR Nozzle

Outão, PT SECIL 3500 40-50 RDF,

Sawdust,

Wood Chips

Existing

Burner,

retrofit with

AFR Nozzle

Erwitte, D Spenner

Zement

2000

Commissioning started

Existing

Burner,

retrofit with

AFR Nozzle

Lampang,

Thailand

Siam

Cement

5500 Future intention to burn AFR New Burner

Content

Introduction




Conclusion



KHD Pyro Equipment for Burning AFR - PYROCLON® Calciner

KHD PYROCLON® Calciner Technology – Overview

PYROTOP® Mixing Chamber for complete fuel burn-out

High velocity to ensure lifting of coarse fuels, avoidance

of thick coatings

Design of Calciner length to reach suitable residence time

(6-10 sec) for complete burn-out

Orifice to maintain gas balance and avoidance of coarse

fuel fall through

Tertiary Air Duct with Dust Settling Chamber or extended

Kiln Hood to reduce clinker dust recirculation


PYROCLON® R PYROCLON® R Extended PYROCLON® R + Combustion Chamber

2D: < 40 mm 2D: < 50 mm

2D: < 100 mm


KHD PYROCLON® Calciner Technology – Combustion Chamber

• Utilization of coarse fuels with extremely poor ignition and

burning properties like coarse anthracite, petcoke and coarse

secondary fuels or waste derived fuels.

• Ignition and start of combustion in pure air at high

temperature (T > 1200°C).

• Calciner retention time > 7 sec.

• High efficiency and flexibility.

• Possibility for primary low NOx reduction via staged

combustion (Top Air Duct).

• Lower demand on fuel quality and preparation efforts.

Saving of alternative fuel costs.


KHD PYROCLON® Combustion Chamber – Working Principle

• Meal is fed from 2nd lowest cyclone to tertiary air.

• Tertiary air duct is connected tangentially to the combustion

chamber.

• Due to tangential tertiary air inlet, the main amount of meal is

forced into the direction of the chamber wall.

• This results in a thermal protection of the refractory lining by this

meal curtain.

• Therefore the meal concentration in the center part of the

combustion chamber is very low.

• The low meal concentration in the center results in high flame

temperatures (no absorption of heat by de-carbonisation

reaction).

Improved ignition and start of AF burn-out.

Chamber refractory

protected by meal

curtain.

Hot center flame (~ 1200°C)

Attributes Combustion Chamber

Start-up With burner.

Mechanical Design

Less weight

No moving parts in the combustion area.

Design for 100% Calciner fuel.

Wear

No moving parts.

Protected by a curtain of “cold”

meal. Fully oxidizing burning

Operation

Temperature control by fuel feed and

tertiary air to the top of the combustion

chamber. Very fastcontrol of temperature.

No additional burner is necessary. Very intensive contact of fuel and oxygen.

Separation of meal (due to tangentially

inlet at chamber wall) and fuel (in the

center of chamber).

Hazardous Fuel Can be Burnt [ high temperature and

intensive contact with oxygen].


KHD PYROCLON® Combustion Chamber – Characteristics


KHD Combustion Chamber: 60 % of total fuel (thermal)

• Coal / Petcoke / Animal Meal mix: 10 th-%

• Solid Hazardous Waste: 27 th-%

• Fluff RDF: 63 th-%

Typically 16 to 18 t/h of solid hazardous waste and Fluff RDF

are fed into the KHD Combustion Chamber.

Result = Stable feeding of approx. 90 th-% of alternative fuels to the calciner.

KHD PYROCLON® Combustion Chamber – Norway, 3 500 tpd

In 2014, after 10 years in operation

Calculation Example:

16 t waste/h 384 t/d assumed plant run time of 310 d/y

119 040 t/y 1 190 400 t waste in 10 years.

Waste Density: 0,3 t/m³

Waste Volume: 3 968 000 m³ (in 10 years)

In Other Numbers

Storage Height: 5 m

Storage Area: 891 m x 891 m !!!!


KHD PYROCLON® Combustion Chamber – Latvia, 4 000 tpd

Result = Stable feeding of approx. 68 th-% of Alternative Fuels to the kiln / calciner.

Main burner: 40 % of total fuel (thermal)

Coal: 78 th-%

Solid Residue Fuel, fine: 22 th-% (= 2,5 t/h)

KHD Combustion Chamber: 60 % of total fuel (thermal)

Coal (as stand-by for fast response): 3 th-%

Solid Residue Fuel: 70 th-%

Waste Wood Chips: 2 th-%

Tyre Chips and Fluff: 15 th.-%

Neutralized Sulphuric Acid Tar: 10 th.-%

Typically 20 t/h of Alternative Fuels are fed to the KHD

Combustion Chamber.

Cemex Rüdersdorf, Germany – 6.000 tcli./d

Core equipment 5 Stage Cyclone Preheater WT PRZ 7648/3

PYROCLON R® Low NOx Calciner w. PYROTOP

2-Pier Rotary Kiln, PYRORAPID® Ø 5,2 x 61 m

15% Bypass

3-Grate Cooler (CP) with hammer crusher

Worlwide unique Plant Concept Clinker Pyroline combined with

CFBR

Circulating Fluidized Bed Reactor

Result Since 1995 in operation

Capacity proven for up to 6.500 t/d

AFR ratio up to 85%

CFBR

WHR in connection with powerplant

A gasifyer operating on the principle of circulating

fluidized bed to extent the options for using a wide

range of different secondary materials.

The produced lean gas is burned in the calciner

firing system while the reaction residues are

discharged at the reactor floor and finally used in

the raw mill.

Heidelberger Cement Teutonia, Germany – 2.500 tcli./d

Core equipment

1-String Pre-Heater, 4-stage. Type 7346/4

PYROCLON® R LowNOx with PYROTOP®

Tertiary Air Duct with Dust Setting Chamber

Bypasssystem, design for 14 %

2-Station Rotary Kiln PYRORAPID® 4,2 x 50 m

Kiln Burner PYROJET® HPJ/230

Clinker Cooler IKN 3000/52/56/5/3 P, Grate Area

55 m²

Result Since 1996 in operation

Capacity proven for up to 2.500 t/d

AFR ratio up to 50 %

Alternative Fuel

Rate

Alternative Fuel Fossil Fuel

Kiln 15 % Animal Meal 85 % Coal

LowNOx Calciner 70 % RDF 30 % Coal

Total 48 % Alt. Fuel 52 % Foss.

Fuel

RDF


KHD Combustion Chamber – Reference List

Customer Country Year

[t/d] Preheater / Dimensions Kiln Fuel

Cimentos Liz S.A. Brazil 2011 5000 PR 9067 / 5, PYROCLON R 5,0 x 69

PYRORAPID Coal

Maras II Turkey 2011 4500 PR 8864 / 5,PYROCLON R 4,6 x 54

PYRORAPID Coal

Sengelejewski Russia 2007 3000 PR 7950 / 4,PYROCLON R 4,4 x 52

PYRORAPID Gas

Cimpor Yibitas

Hasanoglan Plant Turkey 2007 2500 PR 7648 / 5,PYROCLON R

4,2 x 50

PYRORAPID

Petcoke, Local Waste

Derived Fuels

OAO Mordowzement,

Komsomolski

MORDOW 3

Russia 2006 6000 PRZ 7950 / 5,PYROCLON R 5,2 x 65 Gas

Holcim Campulung

Cement Romania 2006 4000 PR 8861 / 5,PYROCLON R 4,8 x 66

Coal / Petrol Coke

Natural Gas, Oil

Sludge, Fluff RDF

Cemex Broceni

Latvia plant, Broceni

Line V

Latvia 2006 3500 PR 7650 / 4,PYROCLON R 4,6 x 54

PYRORAPID

Coal / Petrol Coke, Local

Waste Fuels, Wood,

Shredded tyres

Cimenterie National

S.A.L. Lebanon 2005 3800

PRZ 6442 / 4,PYROCLON R

4,4 x 64

Oil

Petrol Coke

Alternative Fuels

Guangzhou Heidelberg

Yuexiu Cement PR China 2003 6000 PRZ 7950/5,PYROCLON R

5,2 x 70

Pyrorapid

Hard Coal, Anthrazite,

Sewage Sludge

Norcem A.S., Brevik

Dalen plant Line VI Norway 2003 3500

PRZ 5635/4,PYROCLON R

Bypass 4,4 x 68

Coal

Alternative Fuels, Waste

Fuel


KHD PYROCLON® Combustion Chamber – Global Cemfuel Award

6th Global Cemfuels Conference 2012, in

Aachen, Germany.

KHD Combustion Chamber

KHD wins the award for the most

innovative technology for alternative fuel

use.


KHD PYROCLON® Combustion Chamber – Impressions

Content

Introduction




Conclusion




Use of Alternative Raw Materials

Novotroizk, Russia, 2 x 3 000 tcli./d

Special Feature:

Up to 30% of raw material: Blast Furnace Slag

Fe-corrective component: Siemens Martin Slag

Source:

Slag dump from nearby steel works

Result:

Spec. Heat Consumption only ~ 600 kcal/kgcli.

A successful project as an example of

using Alternative Raw Materials.

Slag Dump as raw material source

Content

Introduction



KHD Pyro Equipment for Burning AFR – Kiln Gas Bypass


Conclusion



AFR - KHD‘s Reference in India

Plant Type of Fuel

UTCL Reddipalayam Tyre Chips, Municipal Waste, Paint

Sludge, Agro Waste

UTCL Vikram Cement Tyre Chips, Municipal Waste, Agro

Waste

UTCL Tadipatri Pharmaceutical Waste

Lafarge Sonadih Agricultural Waste, Municipal & Industrial

Waste

UTCL Aditya Cement Paint Sludge

Content

Introduction



KHD Pyro Equipment for Burning AFR – Kiln Gas Bypass


Conclusion



Conclusion

AFR - Alternative Fuels and Raw Materials

Utilization of alternative fuels is a state-of-the-art technology for cement plants.

Alternative fuels reduce the plant’s CO2 footprint.

Broad variance in alternative fuels leads to many influences on the clinker process which

have to be known and taken into account.

Different technical solutions exists for the utilization of secondary fuels in cement plants.

Due to steadily rising prices for primary fuels, the utilization of alternative fuels will

become more and more a possibility for decreasing or maintaining the operational costs.

KHD’s 160 years of industrial history and experience helps our customers to

implement alternative fuel projects into their process.

To get more out of

your plant, visit

www.khd.com

http://www.khd.com/

http://www.khd.com/

http://www.khd.com/

http://www.khd.com/

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