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AFR Profile 2002 - Guidelines (Version 01.06.2002)
last update: April 8, 2002
GUIDELINES FOR PREPARATION OF THE "Holcim" AFR PROFILE FOR CEMENT PLANTS
RICHTLINIEN ZUR ERSTELLUNG DES "Holcim" AFR PROFILS FR ZEMENTWERKE
DIRECTRICES PARA LA CONFECCION DEL PERFIL AFR DE PLANTAS DE CEMENTOS "Holcim"
DIRECTIVES POUR LA REDACTION DU PROFIL AFR DES USINES "Holcim"
2014
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ATR2001
2
SF
IL
OL
SL
342 ff
2.2
This report should be completed asaccurately as possible for each calendar year
and sent to HGRS/CTS not later than the
30th January of the following year. It is
imperative to use the Questionnaire, supplied
by HGRS/CTS as an EXCEL-file. Please
return the Questionnaire via Lotus Notes or
Internet to the email address
By using the supplied EXCEL-file, pleasetake note of these general remarks:
General
The bluemarked parts of the spreadsheetcontain data retrieved from the ATR
The yellowmarked parts of the spreadsheetcontain data not part of the ATR
1. ATR Questionnaire (complete file)
Section 2: specific information per kiln line
- Precalciners
2.1
Classification of precalciners:
Type of precalciner as installed. If there is no
precalciner installed, then write NA in the cell.
Espaol
General Remarks Allgemeine Bemerkungen Remarques gnrales
English Deutsch Franais
Observaciones generales
secondary firing calciners (no
tertiary air duct)
Fuel allocation in calciner for each kiln line as % of
heat consumption for clinker production:
The sum of all fuels attributed "PC" in the ATR
lines 241 - 265
(Pre-) Combustion Chambers are small cyclone-
like vessels, protected with a meal curtain at the
wall, where the calciner fuel is ignited in pure
tertiary air (e.g. Polysius CC-Chamber, RSP-
calciner).
2. Equipment for Clinker Burning
in-line (kiln gas through calciner)
off-line (only tertiary air incalciner, but kiln and calciner gas
merge after calciner)
separate-line (two strings, one for
kiln gas, one for calciner gas)
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2.3
136
2.4
226
2.5
Supplier
Pillard
Pillard
FLS
FLS
KHD
Unitherm
Greco Greco
Gross CKD production = amount of dust collected
in the exhaust filter, bypass, fall-through kiln seal &
LEPOL grate, etc. expressed as percentage of the
clinker production (during the production of the
predominant type of clinker). This applies for all
types of kilns. Dust recirculated to the kiln system
is included in this calculation.
Net CKD production = amount of dust collected
and removed from the kiln system as a percentage
of the clinker production (during the production of
the predominant type of clinker). This applies for
all types of kilns. Dust recirculated to the kiln
system is notincluded in this calculation.
Installed calciner volume (inside refracrtory),
defined as follows:From above the restriction (throat) near kiln inlet
and from the inlet of the tertiary air (e.g. off line
calciner) until the inlet to the cyclone, including pre-
combustion chambers.
Product name of the main burner installed.
- Bypass & CKD
PyroJet
Mono-Airduct-System (M.A.S.)
Productname(to be given)
Rotaflam (coal -radial air -axial air)
3-Channel (radial air -coal -axial air)
Duoflex
Centrax
CKD dumped = amount of dust removed from the
kiln system, not used in products, not sold etc. but
discarded in land filling or by other means
expressed as a percentage of the clinker
production (during the production of the
predominant type of clinker). This applies for all
types of kilns.
Kiln bypass gas percentage = amount of bypass
gas, as a percentage of total kiln gas quantity at
kiln inlet during production of the predominant type
of clinker. This applies only for DG, DS and PC
kilns. If there is no bypass then write N/A in thecell.
2.6
- Main Burners
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2.7
2.8
Type(to begiven)
EF
BF-R
BF-PJ-low
BF-PJ-high
MC
GF
HY
SNCR
SCR
Lime-Inj
Lime-Add
Bicar-Inj
Scrub-wet
Scrub-semi
Scrub-dry
ACF
ACI
FA
CFBA
RTO
2.9
Type of kiln gas dedusting (filter), indicated withone of the following abbreviations:
Bag Filter (Pulse Jet, high
pressure)
Multicyclone
Gravel Bed Filter
Electro-Filter
Bag Filter (Reverse Gas)
Bag Filter (Pulse Jet, low
pressure)
Description
Installednominal capacity of primary air fanin
Nm3/h. For burners with separate blowers andventilators for axial and radial air, the sum of both
units is asked for. Transport air blowers of any
kinds are excluded.
Installednominal pressure of primary air faninmbar. For burners with separate blowers and
ventilators for axial and radial air, the nominal
pressure of the axial air blower is asked for.
Electro & Bag Filter (Hybrid)
- Exhaust Gas Cleaning
Regenerative Thermal Oxidizer
Circulating Fluidized Bed
Absorber
SO2-Scrubber (dry)
Activated Carbon Filter
Activated Carbon Injection
Fluegas Absorber
SO2-Scrubber (wet)
SO2-Scrubber (semi-dry)
Slaked Lime Injection for SO2
reduction
Slaked Lime Addition for SO2
reduction
Selective Catalytic Reaction for
NOx reduction
Natrium Bicarbonate Injection for
SO2 reduction
Selective Non Catalytic Reaction
for NOx reduction
2.10
Indicate the installed type of kiln gas cleaning
system, if no such system is available type NA.
Classification of systems:
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RCO
3.1 - 3.2
SP/PC kilns
LEPOl kilns
long dry / wet
kilns
3.3 - 3.7
Average LEPOL fall-through dust
(LOI, SO3, K2O, Na2O, Cl)
Average hot meal analysis (LOI,
SO3, K2O, Na2O, Cl)
Average filter dust analysis (LOI,
SO3, K2O, Na2O, Cl)
- Process Data
Information relevant for Chlorine and Sulfur flows.
Average can be average of spot samples or
composite samples during production of normal
clinker and stable operation.
Indicate the average kiln gas composition (O2, CO)
at the kiln inlet, measured with the kiln inlet gas
probe during normal operation. The tip of the probe
must reach into the rotating part of the k iln and
must notbe close to the kiln seal.
3. Key Operating Data (ATR and process data)
Regenerative Catalytic Oxidizer
Precalcined Material Addition
others...
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5, 35, 112, 315
7,114
Raw Material
Fuel
ls
g
v
p
m
4.3
at feed point
as fired
Moisture content of the raw
materials, when dumped into thefirst crusher or unloading hopper
(in case these values should not
be measured periodically, one
can indicate approximate mean
values and estimated
minimum/maximum values)
Moisture content of preparedfuels (e.g. ground coal, sludge's
after co-grinding) as present in
the firing system for kiln and
precalciner.
substituting traditional fuels (AF)
Moisture as received at the plant gate, given as
weight percentage of the wet material
What is the substitution purpose of the material
4. AFR Properties relevant for Process
4.1
4.4
substituting raw materials (AR)
Classification of possibilities:
Industry of origin of industrial material. For biofuels
(e.g. rice husks, pea nut shells, etc) industry of
origin is "agriculture"
Locally used name of the product
viscous: high viscosity but no
solids content, normally reduced
by heating the material4.2
liquid state
muddy: liquified mix of fine solids
with liquid, pumpable (e.g. slurry,
wet sludge)
gaseous state
Physical state of the material:
solid state
pasty material, mix of fine solids
with some liquid (e.g. concrete,
sludge), pumpaple only with
pumps similar to concrete pumps
Moisture given as weight percentage of the
material as present at the respective location.
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4.5 - 4.17
4.18
4.19
4.20
4.21
1 kp*s/m2
1 kp*h/m2
1 g/cm*s
1 lb/(ft*hr)
1 kg/(ft*hr)
1 lb/(ft*s)
4.23
5
5.1
5.2
= 0.41338 cP
= 1488.2 cP
= 100 cP
= 0.91134 cP
Solids contents of the AFR, expressed in % weight
fraction of dry solids per total weight of liquid asfired.
Section 5: specific information per AFRinstallation. This section refers to each individualinstallation for handling and feeding of AFR. Later
in section 7, for each type of AFR the assigned
handling installation is identified. Section 5 asks
from the installation point of view, and NOTfromthe AFR stream point of view.
pH value as fired
Dynamic viscosity at feed temperature in cP
[centi Poise = 0.01 g/(cm*s) = 0.001 kg/(m*s)]
- liquid, visquous, pasty & muddy Alternative Fuels
Transformation of dynamic viscosity units into cP
Bulk density of solid AFR as delivered. It issufficient to give the figures as on the truck: "tons
loaded divided by volume of the truck load"
Local name and HAC code of the installations for
AFR handling, storage and feeding.
The total storage capacity of the equipment,
including reception storage, intermediate storage
of pretreatment (if available) and storage of the
feeding installation (e.g. feed bin) in metric tons.
Indicate the mean chemical composition of the rawmaterials, as well as that of fuel ash and the ash of
other materials used in the burning process.
Concentrations are based on dry material, ash on
loss free basis.
Give the maximum particle size of the solid AF in
mm. For AF prepared in a mill, give % residue on
200mm sieve as follows: R200 = ...%
Temperature of the liquid close to the burner
- Raw Material and Ash Composition
- solid Alternative Fuels
- AFR installation
4.22
= 9806.65 cP
5. AFR Installations, Handling and Feeding
= 0.3532 cP
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5.3
Class
activated floor
mechanicalconveyor
loader / crane
pump
Class
volumetric flow
mass flow
mass flow
mass flow
mass flow
mass flow
mass flowmass flow
Classmechanical
transport
pneumatic
transport
liquid, sludge
transport
Poldos
e.g. front loader, automated
crane
Example of dosing equipment
weighing screw
Type(to be given & supplier)5.6
Example of transport equipment
e.g. redler, belt conveyor, ..
e.g. centrifugal pump, concrete
pump
rotary valve
more....
belt scale
rotating disk feeder
Equipment used for flow control of the AFR.
Provide the specific type and add the suppliers
name.
5.5
Type(to be given & supplier)
apron feeder
loss in weight measurement
5.4 e.g. screw, apron feeder
Examples of storage extraction equipment:
Main equipment used to transport the material to
the mill or the kiln. Provide the specific type and
add the suppliers name.
Main equipment used for storage extraction.
Provide the specific type and add the suppliers
name.
e.g. walking floor
Type(to be given & supplier)
The designedmaximum feed rate of the equip-
ment in t/h. Note the difference between the designfeed rate and the feed rate during normal
operation.
e.g. centrifugal pump, screw
pump
pneumatic transport
coriolis flow meter
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CR
PB
RM
SEP
KF
HM
MF
SFPC
MidK
C
more....
feed hopper
feed shute
bucket elevator
feed bin
cyclone
hot meal duct
raiser duct
kiln inlet
calciner bottom
Clinker Cooler
near restiction
introduction into the lowest hot
meal duct (feeding into kiln inlet)
of the preheater
introduction into cyclones, e.g.
raw mill dedusting or preheater
cyclones
introduction into the bucketelevator, e.g. bucket elevator of
mill separator or of kiln feed
main feed hopper for crusher,
mills, etc
5.8
Classification of locations:
direct introduction into the feed
shute (e.g. raw mill), bypassing
the main feed hopper.
introduction into the feed bin of
existing dosing equipment, e.g. of
raw meal additives or kiln feed
Mid kiln
Precalciner
Main firing
Hot meal
Kiln feed
Raw mill
5.7
Classification of main feed points:
Pre-blending bed
Raw mill separator
Exact location of the feed point mentionned in 5.7
from the equipment point of view.
In case that below pre-defined locations do not
match the respective situation, enter your ownlocation into the questionnaire and provide
explanation by adding a comment to the cell
Secondary firing
Raw material crusher
introduction into the raiser duct
Feed point of the material from the process point
of view.
introduction into the kiln inlet
chamber
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calciner top
hot spot
teriary air duct
pre-combustion
chamber
flame center
on top of burner
kiln hood
more....
dumping
actuated gate
rotary valve
pneumatic
mechanic
controlled hot spot near thecalciner bottom (requires two
feed points of the meal, control-
led by an activated splitter gate)
injection into the TA duct
near cyclone
5.9
Used method to move, transport, force or let pass
the material into the process.
Classification of possible injection methods:
applicable only, where there is no
further mechanism between the
material discharge and the target
location (e.g. truck dis-charge
into feed hopper). Dumping into
the kiln would require an open
door without any air lock.
applicable only if the rotary valve
discharges directly to the target
location (e.g. rotary valve
dischages onto the feed shute of
the raw mill). If another transport
follows the valve (e.g. a
pneumatic transport or a belt),
then see below "pneumatic" or"mechanic"
actuated gates (singe, double,
tripple) are normally used forlump or coarse material at mills
or kiln preheater
pneumatic transport with open
end to the target location
mechanic transport with open
end to the target location
(normally feed circuits for liquids
or sludgy and viscous products)
see explanation to 2.2
injection through a pipe which is
fixed on top of the main burner
injection into the secondary air at
the kiln hood/cooler hood.
injection through the burner
central axis into the flame center
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more....
5.10
5.11
5.12
e.g. 25 m/s
"free fall"
"N/A"
more....
none
mechanical
air
steam
more....
5.14
The used method for atomizing liquids and sludgy
or viscous products is asked
liquids are merely pumped intothe system with an open end of
the circuit
atomization with air in dual or
multi-fluid nozzles (generally
used for solvents)
Classification of atomization methods:
Not Applicable when using
atomizers for liquids
5.13
Injection velocity based on the equipment design
Classification of options:
calculated velocity, expressed in
meters per second, for pneumatic
transports
"free fall" describes all those
applications where the injection
velocity is governed by gravity
Designed fuel load in transport air expressed in kg
fuel per Nm3transport air. The number is
calculated automatically in the spreadsheet by
dividing line 5.3 by line 5.11
Type "yes" or "no"
Designedair flow, espressed in Nm3/h, forpneumatic injection systems identified in 5.9
- AF Injection & Atomization
mechanical atomization applies
for all single-fluid nozzles working
at high pressures (e.g. water
sprays in conditionning towers or
heavy oil atomizers)
atomization with steam in dual or
multi-fluid nozzles (a variant of air
nozzles, also used for high
viscosity oil atomization)
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5.15
6.1 - 6.26
6.27 - 6.30
7.1 - 7.10
7.11
7.13
7.14
6. AFR Properties relevant for Environment
The maximum sustainable feed rate in tons per
hour of the material (regardless of the reason) is
asked for during stable process conditions. For
alternative raw materials, type "N/A".
Describe all set point changes compared to
operation without this particular AFR that are
necessary to maintain correct operation (e.g. LSF
+2%, O2kiln inlet +1.5%, kiln feed - 2t/h)
Normal operating pressure of atomizers for liquidsand sludgy or viscous products. For dual fluid
nozzles give the pressure of the auxiliary media
(air or steam).
- Experiences with AFR materials
For each AFR, the name or HAC-code of the
installation (from line 5.1) handling and feeding the
material is asked for.
7. Combustion, Impacts and Limits of AFR / Experience- Process limits as defined by the plant
For each kiln line, the locally defined process limits
for the use of AFR's are asked for. The defaultsubjects (e.g. chlorine limit) are only hints. The
plant is asked to provide its own process relatedcriterias and limits (see default subjects, e.g. feed
rate limits due to unsufficient storage capacity or
logistics is NOTprocess related and especiallyasked for in 7.15).
Classification of the materials according to
- physico-chemical properties
- hazards classification
- toxicological properties
- selected other characteristics
The mean concentration of the respective
elements/substances in alternative fuels and raw
materials, refered to the condition as received
(= on wet basis as received).
- Organic Compounds, Halogenes & Heavy Metals
- Hazards Identification
7.12
For alternative fuels: give all kiln numbers, in which
the fuel is actually burned (e.g. #1 & #3)
For alternative raw materials: give all names of the
different raw mixes in which the respective AR is
used (e.g. "normal", "sulfur resistant").
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AFR market
logistics
on site storage
handling
feeding
installation
process (e. g.
CO formation)
emissions
permit
more....
7.16 - 7.19
7.15
The main limiting factor governing the use of each
AFR.In case that below pre-defined factors do not
match the respective situation, enter your own
words into the questionnaire and provide
explanation by adding a comment to the cell
Classification of possible limiting factors:
AFR feeding installation running
at maximum rate (e.g. manual
feed of tires)
uncertain intervalls of delivery
forcing to reduce the rate in ordernot to run out of material
limited availability of the product
on the market
Describe in your words specific experiences made
with each product in the fields of
- handling and dosing
- equipment operation (kiln, mill , crusher, ..)
- quality of products (clinker, cement)
- emissions
limited on-site storage capacity
forcing to reduce the rate
between delivery (e.g. on
weekends)
process reasons / limits (as
defined in 7.1 - 7.10)
permit dictating the feed rate
emission values limiting the feed
rate of AFR (e.g. organic content
in AR, increased SO2 emissions
in wet plants for combustion
reasons)
limited feed rate due to handling
or transport difficulties (e.g. sticky
material, blockage of pneumatic
transports)
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