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Watch Out – You Might Be Getting What You Are After…
• AF can reduce your fuel costs down to zero – or even below!
• At ~30-40% fuel cost contribution to OPEX this can really raise PROFIT!
• …and you can do something good for the environment and society too!
• … so where is the catch??
Effort must be spent on: • Equipment • Process adaptation Mistakes can be made… … but can be avoided by expert advice !
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1. Step: 0-25% TSR in Kiln Riser Duct
Preheater kiln:
Fluff
• no TAD
• short riser duct
Possible limitations: • Insufficient burn-out • Cyclical loading & fall out of suspended
meal and fuel • Fall through into inlet chamber
Necessary modifications: Fluff storage & handling
Injection System
Sluice, flaps, chutes, pneumatic pipes etc.
Adaptation of process conditions
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Kiln bypass system:
2. Step: Bypass for Removal of Cl & S
Limitations/Considerations: • optimal tapping position • efficient quenching to reduce gas volume • Bypass dust handling and utilization
Necessary modifications: • Bypass extraction pipe • Qenching chamber • Dedusting & fans
Necessity: Cl and S-components need to be removed from the kiln gas to allow smooth and efficient operation
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3. Step: 25-60% Total TSR (additionally 25-85% of Calciner Fuel)
Calciner extension
duct length extension
tertiary air duct
Possible limitations: • Fall through into inlet chamber • Unstable calcination • Unstable kiln process • Ring & ball formation
Necessary modifications: Fluff storage & handling
Calciner modification
Optimization of injection ports
Optimization of process conditions
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3. Step: 25-60% Total TSR (additionally 25-85% of Calciner Fuel)
Rocket mill instead of Calciner extension:
LQ-Fluff
Possible limitations: • Insufficient burn-out • Cyclical loading & fall out of suspended
meal and fuel • Fall through into inlet chamber • Ring & ball formation
Necessary modifications: RDF storage & handling
Rocket Mill
Optimization of injection ports
Optimization of process conditions
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3. Step: 25-60% Total TSR (additionally 25-85% of Calciner Fuel)
Combustion Chamber:
Necessary modifications: Fluff storage & handling
Combustion chamber
Optimization of process conditions
Possible limitations: • Insufficient burn-out • Cyclical loading & fall out of suspended
meal and fuel • Fall through into inlet chamber • Ring & ball formation
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3. Step: 25-60% Total TSR (additionally 25-85% of Calciner Fuel)
Mixing Chamber:
Necessary modifications: Fluff storage & handling
Mixing Chamber
Optimization of injection ports
Optimization of process conditions
Possible limitations: • High temperatures in lowest stage
cyclone • Temperature peaks in mixing chamber
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4. Step: 45 – 90% Total TSR (Increase 20-80% TSR at Main Burner)
Main Burner & Rocket Mill:
L
Q-F
luff
Advantages of AF-burner or satellite burner: • High oxygen availability • High temperature field • Long retention of AF-particles „in flight“
Advantages of Rocket Mill: • Smaller particle size • Less humid particles • Ignition facilitating particle surface structure
Necessary modifications: Rocket Mill: Storage, Handling, Dosing, Silos…. High AF-Burner or Satellite Burner