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Pretreatment of Waste Fuels for the Cement Industry

ECRA – Seminar Retznei - Austria 2011, September 16th Hubert Baier Vecoplan FuelTrack GmbH A company of ThyssenKrupp Polysius AG and Vecoplan AG Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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ThyssenKrupp Polysius and Vecoplan established the joint venture “Vecoplan FuelTrack GmbH” a Company dedicated to the environmental technology in Cement and Lime Industry

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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Table of Content

1. Initial position 2. Mechanical processing for the use at the calciner 3. Use of alternative fuels in a main burner 4. Optimised clinkering zone firing system at the rotary kiln

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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Cost cake and Development of the Thermal Substitution Rate*

Thermal Substitution Rate (TSR) of Engineered Fuels + Biomass 70% 60%

Cost cake of cement production

TSR

50%

Germany EU 27

40%

Emerging Countries 30%

Industrial Countries global

20% 10% 0% 2006

2009

2030 Period

*Source: VDZ 2010 Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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2050

Seeking + Sourcing

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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Waste-Assessment food

textile

• Identify feasible waste compounds + shares • Identify chemical and process benefits or obstacles • Define capabilities and requirements for coprocessing

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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high calorific fraction

glass

paper

leather, rubber metal

polymeric pack

wood construction waste

stones

Technical Assessment

• Exploring capabilities and the best options for co-processing • Detect technical defaults and process faults • Define basic conditions for dimensioning pro-processing and handling and dosage

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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From Waste to Engineered Energy

cv ~ 14.000 kJ/kg

Pre-Processing

Sourcing + Identification

< 250 mm

< 80 mm

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Calciner

cv ~ 16.000 kJ/kg

< 25 mm cv ~22.000kJ/kg

Mainburner < 3 mm cv ~24.000kJ/kg

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

PREPOL SC

Impacts of Missing Quality Assurance alkaline corrosion

ring creation

chlorine corrosion

reductive burn Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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Fundamental Principles of Fuel Conversion

Useful heat

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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Table of Content

1. Initial position 2. Mechanical processing for the use at the calciner 3. Use of alternative fuels in a main burner 4. Optimised clinkering zone firing system at the rotary kiln

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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Preparation: High Calorific Fraction (HCF < 300 mm) HCF < 300 mm Pre-sorting

< 300 mm

Sieving Residues, Wastes & Biomass

Classifier Drop out

QM HCF < 300 mm

Screening

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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HCF-handling to feed the PREPOL Step-Combustor HCF < 300 mm

Step-Combustor & Calciner

HCF < 300 mm

MS - Calciner

Tertiary air Rotary kiln Step combustor

HCF < 300 mm

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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PREPOL StepCombustor tertiary air with meal

suspending coke and ash fraction

Calciner ~12 min Ignition/ conversion Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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2-3 min Drying/ pyrolisis

HCF < 300 mm

No mechanical installations – only fixed shockblowers separate light from heavy unburnt fractions and feeds the material into the calciner by controlled steps.

RDF-handling to feed the Calciner

Calciner RDF < 80 mm

RDF < 80 mm

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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Dust-proof Fuel Transport for RDF and SRF


closed system

= no dust and air emission


air cushion effect

= low energy consumption


no track wheels

= low maintenance efforts

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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Type of Calciner as a function of retention time

Air-Separate (AS)

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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Multi-Stage (MSC) AS + CombustionChamber (CC)

MSC + CC

Tire chips RDF 80 mm Biomass coal/ petcoke

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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Table of Content

1. Initial position 2. Mechanical processing for the use at the calciner 3. Use of alternative fuels in a main burner 4. Optimised clinkering zone firing system at the rotary kiln

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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Preparation: Solid Recovered Fuel (SRF < 30 mm)

RDF < 80 mm Classifier

SRF < 30 mm QM

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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RDF < 80 mm

Table of Content

1. Initial position 2. Mechanical processing for the use at the calciner 3. Use of alternative fuels in a main burner 4. Optimised clinkering zone firing system at the rotary kiln

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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SRF-Feeding to Main Burner

Pretreatment of waste fuels for the Cement Industry Dr. Hubert Baier 16.09.2011

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The Main Burner POLFLAME©

SRF < 30 mm

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RDF-Mill to feed the Sinter Zone Burner

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Pre-Processing for a Customized Co-Processing… Solid Waste

1. Level: High Calorific Fraction (250 – 80 mm)

PREPOL SC™

2. Level: RDF (< 80 mm)

PREPOL™

3. Level: SRF (30 - < 20mm)

RDF-Mill 100% < 3 mm

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POLFLAME™

POLFLAME™

Contact

to fit your process right … www.vecoplan-fueltrack.com Vecoplan FuelTrack GmbH Vor der Bitz 10 D - 56470 Bad Marienberg Fon: +49 2661 6267-871 [email protected]

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