Utilization of Fluff From Reception to Burner

8/18/2019 Utilization of Fluff From Reception to Burner

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Utilization of fluff: from reception to burner

Höver Plant, Germany

39th Cement Manufacturing Conference 2006

Klaus Eichas


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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG

Index

Waste market survey

Kiln system

Fluff project survey costs

equipment specifications Quality impact

Overall results

Messages


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Industrial waste regional availability for recovery Comments

Waste market survey

Market volume (‘000t)

3 081

384

111

397

304

380

475

188

310

1 267

1 031

435

908

147675

367

Markets within ~300 km around

the plants offer enough volume

for fluff production

Due to the extremely high

volumes of 3 Mio. t NRW may

have a positive price effect on

Hoever market area

Waste spread within the total on

average:

50 % industrial waste

20 % production residue

30 % construction waste

Laegerdorf market area

Hoever market area

Holcim


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What is fluff ?

Fluff = shredded

and classified

industrial and

municipal waste

particle size

< 30 mm

net calorific value

21 – 24 MJ/kg

Chlorine < 1 %

residual moisture

content < 15 %


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Industr ial waste for co-processing in the cement industry – payment by the suppliers

price range:

€/t

Estimated Price and Volume

5 -10

2004 2005 2006 2007 2008 2009

price dumpingby landfills

10 -15 20 -30price development linked to

incineration prices25 -35

the volume available for recovery

increases by 40% between 2000

and 2006

4 main outputs for fluff

cement

power plants using steam coa

power plants using lignite

incineration

0

2'000'000

4'000'000

6'000'000

8'000'000

10'000'000

12'000'000

1995 2000 Expectation

2006

Expectation

2012

Construction and demolition waste

Production residuesIndustrial waste

5 966 600

7 523 500

10 460 50010 695 600

change in German landfill directive


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Index

Waste market survey

Kiln system

Fluff project

survey costs


Overall results

Messages


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KHD-Kiln with planetary cooler and 4 stage preheater

main burner:

- lignite (coal)

- animal meal

- fluff (shredded plastics)

kiln inlet:

- waste tires

- filter cake (AR)

- satellite cooler (10 cooler tubes 2,2 m x 22 m)

- rotary kiln 5,4 m x 80 m

- 4-stage preheater

- BDP 2850 t/d

- spec. heat consumption 3460 kJ/kgKlinker


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Index

Waste market survey

Kiln system

Fluff project

survey costs


Overall results

Messages


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Project survey

The objective was to burn solid alternative fuels like fluff

at the main burner up to 8 t/h

the average throughput at the moment is 9,5 t/h commissioning: October 2003

CAPEX: 3,3 Mio €

pay back: 1,8 years

TSR (2006) 68 %

TEE (2006) 85 %

annual savings today: 5,7 Mio €/a


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Flow sheet: fluff handling system

Storage capacity3.600 m³ / 700 t fluff


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Storage hall


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Automatic crane


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Index

Waste market survey

Kiln system



Overall results

Messages

Th l f th CEM I 52 5 h th t th 1 d


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The example of the CEM I 52.5 shows that the 1 day

compressive strength deteriorated over the last years

22

23

24

2526

27

28

29

30

31

32

1997 1998 1999 2000 2001 2002 2003 2004 2005

1 d a y s

t r e n g t h N / m

m ²

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

s u p h a

t i z a t i o n g r a d e

1 day strength sulphatization grade

Lo n g - t e r m t r e n d


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Avoid double flame

Decreasing grade of sulphatization by long main flame

Double flame was created by using lignite (brown coal) and fluff

This has to be avoided by right burner settings and adequate

waste fuels like solvents or fossil fuels like steam coal

Burner t ip

Burner

3.5 m

unstable

coating

7.5 m

stable

coating

30 m

stable

coating

Burner t ip

Burner

3.5 m

unstable

coating

7.5 m

stable

coating

30 m

stable

coating


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Index

Waste market survey

Kiln system



Overall results

Messages


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0.0

10.0

20.0

30.0

40.0

50.0

60.0

s u

b s t i t u t i o n

r a t e

%

black carbon 0.0 0.0 1.5 0.8 0.0 0.0

animal meal 0.0 8.4 18.1 9.5 4.0 1.4

fluff 0.0 0.0 4.8 11.6 31.5 44.5

waste tires 6.8 5.7 1.8 4.8 5.9 6.3

2000 2001 2002 2003 2004 2005

Step change in use of AFR 2000 - 2005


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The fluff installation at the plant works very successful

and reliable with an average throughput of 9,5 t/h

The kiln has a BDP of 2850 t/h and works now at a rate

of 2450 t/h

The maximum applicable throughput of fluff without

creating clinker reactivity problems is to be found yet.

Optimization measures are in progress.

The GAV is 5.7 Mio. in 2006

Overall results


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Index

Waste market survey

Kiln and burner



Overall results

Messages


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Messages

Waste markets around the plant must offer enough

volume.

The fluff quality must fulfill all quality requirements.

The installation for using fluff has to be very reliable.

Appropriate safety installations are necessary !!!

High momentum main burner is a prerequisite.

Fluff in conjunction with lignite leads to poor burning

conditions with negative impact on the clinker rectivity.

The kiln performance is decreasing by 10 – 15% with a

TSR > 50%.


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Annex


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High momentum burner

animal meal

oil,

waste oil ,add. waste

liquids or

solids

ignition

lance

fluff

coal

swirl air

axial air


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Equipment specification

The plant covers a closed storage hall with truck tippingplace, automatic grab-crane, dosing box, weighing belt,

dedusting filter and conveying system to the kiln burner.

designed throughput: 1,0 - 8,0 t/h

bulk density fluff: 0,1 - 0,2 t/m³

closed storage hall: length 40 mwidth 18 m

height 18 m

storage capacity: 3.600 m³ / 700 t fluff

2 truck tipping places

explosion protected dedusting filter: 50.000 m³/h

activated carbon smell filter

fire protection system


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Crane specification

automatic crane with hydraulic grab load-carrying capacity: 11,0 t

grab capacity: 8,0 m³

grab weight: 4,7 t automatic evacuation of the trucks tipping-place

automatic feeding into the dosing box

automatic material relocation/blending


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Feeder specification

dosing box (installation of a 2nd box in Oct. 2004) capacity: 35,0 m³

bottom: 4 speed adjustable screws, diameter 630 mm

1 collector screw, speed adjustable, diameter 800 mm radar level switch


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Equipment specification

2 Debris screens wide x length 1.200 x 2.500 mm

screen

- feeding area: rods, distance 60 mm- other: Mesh 70 mm

2 Weighing belts


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Conveyor specification

conveyor to burner platform length 67,0 m

belt width 800 mm

rotary feeder diameter 630 mm

pneumatic transport

pipeline length 50 m

Impact on quality: At Höver plant the increasing TSR goes


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p q y p g g

along with decreasing early strength behavior

24

25

26

27

28

29

30

1997 1998 1999 2000 2001 2002 2003 2004 2005

N / m

m ²

1 day strength development CEM I 52,5R

Note: at the moment Höver is carrying out a comprehensive quality

improvement program; The maximum applicable throughput of fluff withoutcreating clinker reactivity problems is to be found yet by the ongoing

optimization measures.

0.0

20.0

40.0

60.0

s u b s t i t u t i o n r a t e

%

black carbon 0.0 0.0 1.5 0.8 0.0 0.0

animal meal 0.0 8.4 18.1 9.5 4.0 1.4

fluff 0.0 0.0 4.8 11.6 31.5 44.5

waste tires 6.8 5.7 1.8 4.8 5.9 6.3

2000 2001 2002 2003 2004 2005

Documents

Utilization of Fluff From Reception to Burner