Usage of Alternative Fuels & Raw Materials in Cement Industry as Sustainable Waste Management Option

Transcription

1 Usage of Alternative Fuels & Raw Materials in Cement Industry as Sustainable Waste Management Option 3rd International Conference on AFR in Cement Industry 23 rd & 24 th March, New Delhi Ashok Kumar Dembla KHD Humboldt Wedag India

2 Content Introduction AFR Handling Concepts KHD Pyro Equipment for Burning AFR PYROJET Kiln Burner KHD Pyro Equipment for Burning AFR PYROCLON Calciner AFR Alternative Fuels and Raw Materials AFR KHD s References [India] Conclusion

3 Introduction - Alternative Fuel Potential 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. Hierarchy of Waste Management Minimization Recovery of Materials (Recycle & Reuse) Co-Processing Incineration Landfilling Uncontrolled RDF Burning or Dumping Tyres RD F

4 Introduction - Alternative Fuel Availability in India Waste Alternative Generation Fuels Statistics: and Raw India Materials-Introduction States Generated Treated (TPD) (TPD) Andhra Pradesh* Chhattisgarh* Delhi Gujarat Haryana Jammu & Kashmir* Jharkhand* Karnataka West Bengal Madhya Pradesh Maharashtra 22,570 5,927 Punjab* Rajasthan* Tamil Nadu Telengana Uttar Pradesh Other Total 1,41,064 34,752 34, Only 25 % of Generated Waste is Treated, (Data of CPCB Annual Report & )

5 Introduction - Alternative Fuel Utilization Rate Alternative Fuels (AF) utilization rate in the German Cement Industry. Source: VDZ Monitoring Data 5

6 Introduction - Alternative Fuel Potential 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. RD F Tyres

7 Introduction AFR, Alternative Fuel and Raw Materials 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 CO 2 emissions. Thermal substitution rate of AFR will increase on global basis. Alternative Fuels, examples Municipal Waste Tyres RDF (Residue derived Fuels) Agricultural wastes (Rice Husk..) Waste oil, solvents Sewage sludge Waste tyres Impregnated saw dust, waste wood etc. Animal-Meal Animal Meal Sewage Sludge Rice Husks RDF Rubber Chips Wood Chips

8 Introduction - Alternative Fuels Type of Alternative Fuel: RDF, Fluff, Sorted Waste Calorific Value, Hu: Moisture: S-content: Cl-content: Others: Particle Size Kiln Burner: Calciner: kcal/kg, kiln ready wt.-%, kiln ready 0,3-0,5 wt.-% 0,5 1,0 wt.-% 2-D Material: < 10 mm 3-D Material: < 2 mm 2-D Material: < 20 mm (< 50 mm for Comb. Chamber) 3-D Material: < 5 mm (< 20 mm for Comb. Chamber) Type of Alternative Fuel: Dried Sewage Sludge General: Calorific Value Moisture: S-content: Cl-content: Particle Size: Kiln Burner: Calciner: Physical and chemical properties of sewage sludge are strong dependent on treatment of sludge (P2O5 elimination, digestion rest amount of organic substance..) kcal/kg, kiln ready Raw ~ % / Mech. dried ~ % / Therm. dried 5 15% 0,9-1,6 wt.-% 0,1-0,2 wt.-% < 1 mm < 4 mm Fluff / RDF Dried Sewage Sludge

9 w Introduction Materials - Alternative Raw 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 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

10 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.

11 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.

12 Introduction Feed points for Alternative Fuels and Raw Materials Cement Mill: FGD Gypsum Gran. Blast Furn. Slag Fly Ash. Kiln Burner: Sorted municipal and industrial waste (RDF) Dried sewage sludge Liquid hazardous wastes, Solvents. Kiln Inlet: Whole Tires Pasty sludge Calciner: Sorted municipal and industrial waste, low Quality Sewage Sludge Tire Chips. Raw Mill: Slag Fly Ash. 12

13 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.

14 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.

15 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. Global KHD Presence

16 Content Introduction AFR Handling Concepts KHD Pyro Equipment for Burning AFR PYROJET Kiln Burner KHD Pyro Equipment for Burning AFR PYROCLON Calciner AFR Alternative Fuels and Raw Materials AFR KHD s References [India] Conclusion

17 AFR Handling Concepts Feed Bin Drum Screen Optional: Manual Sep. Magn. Sep. Shredding Concept consists of the following modules: Reception Storage Screening Long Distance Conveying Dosing Preparation Plant Concept:

18 AFR Handling Concepts 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

19 AFR Handling Concepts 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

20 Content Introduction AFR Handling Concepts KHD Pyro Equipment for Burning AFR PYROJET Kiln Burner KHD Pyro Equipment for Burning AFR PYROCLON Calciner AFR Alternative Fuels and Raw Materials AFR KHD s References [India] Conclusion

21 KHD Pyro Equipment for Burning AFR PYROJET Kiln Burner Refractory Jet-Air Nozzles Coal Dust Nozzle Primary Air Amount: Depending on fuel scenario Lower for primary fuels ( Low NOx Burner) Higher for alternative fuels Swirl Element Inner Tubes for Alt. Fuels

22 KHD Pyro Equipment for Burning AFR PYROJET Kiln Burner 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

23 KHD Pyro Equipment for Burning AFR PYROJET Kiln Burner AFR Swirl element in front position Poor AFR distribution AFR Swirl element in back position Good AFR distribution into the flame

24 KHD Pyro Equipment for Burning AFR PYROJET Kiln Burner Reference List for Burner Modification with newly developed AFR Nozzle Plant Company Clinker Production [t/d] Burglengenfel d, D Heidelberger Cement AFR Rate Kiln Burner [%] AFR Fuel Type Plastic and paper foils Outão, PT SECIL RDF, Sawdust, Wood Chips Erwitte, D Lampang, Thailand Spenner Zement Siam Cement Commissioning started Future intention to burn AFR Project Existing Burner, retrofit with AFR Nozzle Existing Burner, retrofit with AFR Nozzle Existing Burner, retrofit with AFR Nozzle New Burner

25 Content Introduction AFR Handling Concepts KHD Pyro Equipment for Burning AFR PYROJET Kiln Burner KHD Pyro Equipment for Burning AFR PYROCLON Calciner AFR Alternative Fuels and Raw Materials AFR KHD s References [India] Conclusion

26 KHD Pyro Equipment for Burning AFR - PYROCLON Calciner KHD PYROCLON Calciner Technology Overview PYROTOP Mixing Chamber for complete fuel burn-out Design of Calciner length to reach suitable residence time (6-10 sec) for complete burn-out High velocity to ensure lifting of coarse fuels, avoidance of thick coatings 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

27 KHD Pyro Equipment for Burning AFR - PYROCLON Calciner PYROCLON R PYROCLON R Extended PYROCLON R + Combustion Chamber 2D: < 40 mm 2D: < 50 mm 2D: < 100 mm

28 KHD Pyro Equipment for Burning AFR - PYROCLON Calciner 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 NO x reduction via staged combustion (Top Air Duct). Lower demand on fuel quality and preparation efforts. Saving of alternative fuel costs.

29 KHD Pyro Equipment for Burning AFR - PYROCLON Calciner KHD PYROCLON Combustion Chamber Working Principle Meal is fed from 2 nd lowest cyclone to tertiary air. Hot center flame (~ 1200 C) 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.

30 KHD Pyro Equipment for Burning AFR PYROCLON Calciner KHD PYROCLON Combustion Chamber Characteristics Attributes Combustion Chamber Start-up With burner. Mechanical Design Less weight No moving parts in the combustion area. Design for 100% Calciner fuel. Wear Operation No moving parts. Protected by a curtain of cold meal. Fully oxidizing burning 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].

31 KHD Pyro Equipment for Burning AFR - PYROCLON Calciner KHD PYROCLON Combustion Chamber Norway, tpd 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. In 2014, after 10 years in operation Calculation Example: 16 t waste/h 384 t/d assumed plant run time of 310 d/y t/y t waste in 10 years. Waste Density: Waste Volume: 0,3 t/m³ m³ (in 10 years) In Other Numbers Storage Height: 5 m Storage Area: 891 m x 891 m!!!! Result = Stable feeding of approx. 90 th-% of alternative fuels to the calciner.

32 KHD Pyro Equipment for Burning AFR - PYROCLON Calciner KHD PYROCLON Combustion Chamber Latvia, tpd 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. Main burner: 40 % of total fuel (thermal) Coal: Solid Residue Fuel, fine: 78 th-% 22 th-% (= 2,5 t/h) Result = Stable feeding of approx. 68 th-% of Alternative Fuels to the kiln / calciner.

33 Cemex Rüdersdorf, Germany tcli./d Worlwide unique Plant Concept Clinker Pyroline combined with CFBR Circulating Fluidized Bed Reactor 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. 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 Result Since 1995 in operation Capacity proven for up to t/d AFR ratio up to 85% CFBR WHR in connection with powerplant

34 Heidelberger Cement Teutonia, Germany 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 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 Result Since 1996 in operation Capacity proven for up to t/d AFR ratio up to 50 %

35 KHD Pyro Equipment for Burning AFR - PYROCLON Calciner KHD Combustion Chamber Reference List Customer Country Year [t/d] Preheater / Dimensions Kiln Fuel Cimentos Liz S.A. Brazil PR 9067 / 5, PYROCLON R Maras II Turkey PR 8864 / 5,PYROCLON R Sengelejewski Russia PR 7950 / 4,PYROCLON R 5,0 x 69 PYRORAPID 4,6 x 54 PYRORAPID 4,4 x 52 PYRORAPID Coal Coal Gas Cimpor Yibitas Hasanoglan Plant Turkey PR 7648 / 5,PYROCLON R 4,2 x 50 PYRORAPID Petcoke, Local Waste Derived Fuels OAO Mordowzement, Komsomolski MORDOW 3 Russia PRZ 7950 / 5,PYROCLON R 5,2 x 65 Gas Holcim Campulung Cement Romania 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 Cimenterie National S.A.L. Latvia PR 7650 / 4,PYROCLON R Lebanon PRZ 6442 / 4,PYROCLON R 4,6 x 54 PYRORAPID 4,4 x 64 Coal / Petrol Coke, Local Waste Fuels, Wood, Shredded tyres Oil Petrol Coke Alternative Fuels Guangzhou Heidelberg Yuexiu Cement PR China PRZ 7950/5,PYROCLON R 5,2 x 70 Pyrorapid Hard Coal, Anthrazite, Sewage Sludge Norcem A.S., Brevik Dalen plant Line VI Norway PRZ 5635/4,PYROCLON R Bypass 4,4 x 68 Coal Alternative Fuels, Waste Fuel

36 KHD Pyro Equipment for Burning AFR - PYROCLON Calciner KHD PYROCLON Combustion Chamber Global Cemfuel Award 6 th Global Cemfuels Conference 2012, in Aachen, Germany. KHD Combustion Chamber KHD wins the award for the most innovative technology for alternative fuel use.

37 KHD Pyro Equipment for Burning AFR - PYROCLON Calciner KHD PYROCLON Combustion Chamber Impressions

38 Content Introduction AFR Handling Concepts KHD Pyro Equipment for Burning AFR PYROJET Kiln Burner KHD Pyro Equipment for Burning AFR PYROCLON Calciner AFR Alternative Fuels and Raw Materials AFR KHD s References [India] Conclusion

39 AFR Alternative Fuels and Raw Materials Use of Alternative Raw Materials Novotroizk, Russia, 2 x t cli./d Special Feature: Up to 30% of raw material: Blast Furnace Slag Fe-corrective component: Siemens Martin Slag Slag Dump as raw material source Source: Slag dump from nearby steel works Result: Spec. Heat Consumption only ~ 600 kcal/kg cli. A successful project as an example of using Alternative Raw Materials.

40 Content Introduction AFR Handling Concepts KHD Pyro Equipment for Burning AFR PYROJET Kiln Burner KHD Pyro Equipment for Burning AFR PYROCLON Calciner KHD Pyro Equipment for Burning AFR Kiln Gas Bypass AFR Alternative Fuels and Raw Materials AFR KHD s References [India] Conclusion

41 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

42 Content Introduction AFR Handling Concepts KHD Pyro Equipment for Burning AFR PYROJET Kiln Burner KHD Pyro Equipment for Burning AFR PYROCLON Calciner KHD Pyro Equipment for Burning AFR Kiln Gas Bypass AFR Alternative Fuels and Raw Materials AFR KHD s References [India] Conclusion

43 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 CO 2 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.

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