technology options for the cement industry with the use … presentation.pdf · technology options...

35
Alf-Cemind Workshop / Athen 16 th May 2007 Andreas Hand Andreas Hand Head of Head of Pyro Pyro Process Engineering Process Engineering KHD Humboldt Wedag GmbH KHD Humboldt Wedag GmbH Technology Options for the Cement Industry with the Use of Alternative Fuels

Upload: letram

Post on 01-Feb-2018

225 views

Category:

Documents


2 download

TRANSCRIPT

Page 1: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Alf-Cemind Workshop / Athen16th May 2007

Andreas HandAndreas Hand

Head of Head of PyroPyro Process Engineering Process Engineering KHD Humboldt Wedag GmbHKHD Humboldt Wedag GmbH

Technology Options for the Cement Industry with the Use of Alternative Fuels

Page 2: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 2

KHD Humboldt Wedag GmbH

1. Secondary Fuels – Challenge and OpportunityProperties and Fuel CharacteristicsInfluences on Process and Equipment

2. Technical SolutionsBurner TechnologyCalciner TechnologyKiln exit-gas extraction (Bypass Systems)

3. Case Study: Plant Comparison considering Primary and Secondary Fuels

Contents:

Page 3: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 3

KHD Humboldt Wedag GmbH

tires

Animal-meal

MunicipalWaste

Secondary Fuels – Challenge and Opportunity

RDF

Wood chips

Sewage-sludge

rubber chips

Rice husks

Page 4: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 4

KHD Humboldt Wedag GmbH

Influences of Secondary Fuel Utilisation on Pyro Process

Challenges:Challenges:

Global Goals:

Saving of natural resources

Reduction of CO2 emissions (Emission trading)

Thermal recycling

Individual Goals:

Earning of disposal fees

Reduction of fuel costs “negative fuel costs”

Stronger market position

Page 5: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 5

KHD Humboldt Wedag GmbH

However:However:

Establishment of an additional fuel management

Silos and storage facilities, dosing and transport equipment

Process influenced by:

Higher specific waste gas volume and pressure drop

Increase of specific heat demand

Increase of chlorine and sulphur input within the system

…..

Influences of Secondary Fuel Utilisation on Pyro Process

Page 6: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 6

KHD Humboldt Wedag GmbH

Typical Secondary FuelsPetcoke Tyres Fluff RDF Sewage

sludge Animal meal

Moisture [%] 0,11 1,00 17,80 6,60 3,40Volatiles [%] 10,90 61,00 65,00 45,30 68,70Hardgrove [°H] 50Cal. Value Hu [kJ/kg] 34830 29480 14650 9849 19990Ash [% wf.] 1,28 7,50 17,69 46,20 20,50Carbon [% wf.] 86,36 81,00 53,08 26,60 43,80Hydrogen [% wf.] 3,49 6,70 7,26 4,93 5,30Oxigen [% wf.] 1,85 3,00 19,50 16,00 16,90Nitrogen [% wf.] 1,61 0,30 0,47 5,73 8,90Chloride [% wf.] 0,01 0,10 1,20 0,05 0,60Sulphur [% wf.] 5,40 1,70 0,80 0,46 0,50P2O5 [% wf.] < 10,0 < 5,0Hg [ppm] < 0,01 < 0,01 < 1,0 < 5,0 < 0,1Cd + Tl [ppm] < 10,0 < 20,0 < 20,0 <10,0 < 10,0

Σ(Sb, As, Pb, Cr, Co, Cu, Mn, Ni, V)

[ppm] < 3000 < 2000 < 2000 < 5000 < 1000

Page 7: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 7

KHD Humboldt Wedag GmbH

coal

petco

kean

thrac

itetyr

e chip

sflu

ff-RDF

anim

al mea

lse

wage s

ludge

Heat valuePreparationHandlingChlorine InputSulfur InputNOx reduction potentialFuel costs

positive indifferent negative

Characteristics of some solid fuels

Page 8: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 8

KHD Humboldt Wedag GmbH

Feeding Points for Secondary FuelsKiln system without pre-calciner

Low pre-calcination rate of hot meal (app. 40%)

Fuel used for sintering and calcination in the kiln

Possible to use fuels with “delayed heat release” in the kiln burner to shift energy to the calcination zone.

Kiln burner

Inlet Chamber (max. 15% of energy)

Calcining zone Transition and Sintering zone

Page 9: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 9

KHD Humboldt Wedag GmbH

Kiln system with pre-calciner

and combustion chamber

CombustionChamber

Kiln burner

Calcining zone Transition and Sintering zone

High pre-calcination rate of hot meal (> 90%)

Fuel energy in the calciner (up to 60 %) is used for pre-calcination

Fuel energy in the kiln is used for sintering

Shifting secondary fuels with „low quality“ properties to the combustion chamber.

=> Increased Flexibility

Page 10: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 10

KHD Humboldt Wedag GmbH

Max. 70 x 70 mm

Max. 40 x 40 mm

-~ 32Tyre Chips/Rubber residues

0 – 50 mm0 – 5 mm0 – 4 mm~ 27Hard Plastics

0 – 50 mm0 – 5 mm0 – 4 mm~ 15Biomass/Sewage Sludge

0 – 100 mm0 – 30 mm0 – 10 mm~ 18Fluff-RDF

Max. 10% R 90µm

Max. 5% R 90µm

Max. 5% R 90µm

~ 33PetrolcokeAnthrazite

++

+ +

++

~ 33 ~ 17

Waste OilAnimal Meal

PYROCLON R +Combustion Chamber

PYROCLON R LNCalciner

PYROSTREAMKiln burner

Heat Value[MJ/kg]

Technical Solutions - Burning TechnologyExamples for typical secondary fuels

Page 11: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 11

KHD Humboldt Wedag GmbH

The PYRO-JET Burner

A typical multi-channel burner for various fuels. To achieve highest substitution rates, the burner can fire different combustibles in mixed rates: Sewage sludge, animal meal, coal, used oil, solvents and contaminated water

central channels

swirl air nozzle

sewage sludge / AM nozzle

coal nozzleJet nozzles Oil / solvent / water nozzles

Technical Solutions - Burner Technology

Page 12: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 12

KHD Humboldt Wedag GmbH

Technical Solutions - Burner TechnologyPYROJET®-Burner in a German cement plant

inner coal dust nozzlemain swirl air slots

slots for secondary fuel atomizationsecondary fuel channel

Page 13: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 13

KHD Humboldt Wedag GmbH

Technical Solutions - Burner Technology►PYROSTREAM®-Burner for improved adjustment of

flame shape and intensity

Page 14: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 14

KHD Humboldt Wedag GmbH

Fuel mix, thermal input, for two KHD burners

►PYRO-JET Burner (Swiss)► 25% Coal► 19% Oil► 13% Solvents► 34% Plastics (<10 mm)► 9% Sewage Sludge

►PYROSTREAM Burner (France)► 36% Coal► 35% Animal Meal► 23% Fluff (<25 mm)► 6% Solvents

Technical Solutions - Burner Technology

Page 15: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 15

KHD Humboldt Wedag GmbH

Fuels: suspended in air and easy to ignite lumpy and difficult to ignite

PYROCLON® LowNOx Calciner : primary fuels like lignite, coal, oil, gasalternative fuels like liquids or animal meal

Technical Solutions - Calciner Technology

Page 16: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 16

KHD Humboldt Wedag GmbH

Extended PYROCLON® LowNOx Calciner :fine anthracite & petcoke (< 5% R 90µm)Fluff - RDF / sewage sludge / shredded tyres

Fuels: suspended in air and easy to ignite lumpy and difficult to ignite

Technical Solutions - Calciner Technology

Page 17: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 17

KHD Humboldt Wedag GmbH

PYROCLON® LowNOx Calciner with ignition module: coarse anthracite & petcoke (5-8% R90µm)

Fuels: suspended in air and easy to ignite lumpy and difficult to ignite

Technical Solutions - Calciner Technology

Page 18: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 18

KHD Humboldt Wedag GmbH

regular extended Ignition module Combustion chamber

Fuels: suspended in air and easy to ignite lumpy and difficult to ignite

Technical Solutions - Calciner Technology

Page 19: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 19

KHD Humboldt Wedag GmbH

PYROTOP®

compact

CO

O2

NOX

LowNOx-burner

PYROCLON®-burner

PYROCLON®-R LowNOxStaged combustionLow cost NOx - reduction without additives (SNCR process)

High efficiency and flexibility

> 30 references

BAT „Best Available Technique“

Emission level: < 500 mg NO2/Nm³

Technical Solutions - Calciner Technology

Page 20: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 20

KHD Humboldt Wedag GmbH

PYROTOP®

compact swirl chamber

Feeding level fordiaper & tyre chips

(max. 40% / 50 x 50 mm²)

PYROCLON® LowNOx CalcinerHolnam, Devil‘s Slide Plant

Page 21: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 21

KHD Humboldt Wedag GmbH

tertiary air

combustion air

Meal from seccond

last cyclone

secondary fuel

gas

burner -swirl air

coal / petcokebypass

air

PYROCLON®-R Calciner with Combustion Chamber

swirl airswirl air

Page 22: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 22

KHD Humboldt Wedag GmbH

Combustion Chamber

AdvantagesHigh flexibility and efficiency.

Lower demand on fuel quality and preparation

saving of treatment costs

Ignition and start of combustion in pure air at high temperatures (T ~ 1200°C).

Raw meal feeding to the swirl air leads to meal fogging at the wall and thereby protecting it against overheating.

Winning of additional retention time. Final burnout in pre-calciner.

Technical Solutions - Calciner Technology

Page 23: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 23

KHD Humboldt Wedag GmbH

NorcemNorcem A.S. / A.S. / DalenDalenModification of PYROCLON Modification of PYROCLON -- CalcinerCalciner

with Combustion Chamberwith Combustion Chamber

Page 24: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 24

KHD Humboldt Wedag GmbH

ModernisationModernisation StepsSteps of of KilnKiln Line 6Line 6

1966: 1966: ““BasisBasis”” 1600 t/d1600 t/d

PH: 3556/4Kiln: 4,4 x 68 mCooler: 54 m2

2002:2002: ““Secondary FuelsSecondary Fuels”” 3500 3500 t/dt/d

PR calciner with combustion chambermax. increase of secondary fuels

First PYROCLON® LowNOx Calciner Norcem plant / Norway

1988:1988: ““Prod. IncreaseProd. Increase”” 3500 t/d3500 t/d

PH + Calc.: PR-LowNOx5356 / 5635/4

Cooler: 70 m2

Page 25: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 25

KHD Humboldt Wedag GmbH

PYROCLON® Calciner with Combustion Chamber:Norcem Plant / Norway

Main burner: 40 Main burner: 40 thth--% of total fuel% of total fuel

Coal / Petcoke mix: 34 th-%Liquid hazardous waste; 4 th-%Animal meal: 2 th-%

• Successfully in operation since December 2004• 90% of the calciner fuel is substituted by secondary fuels• CO at stack, dry at 11%: < 0,1 %

Calciner (combustion chamber): 60 Calciner (combustion chamber): 60 thth--% of total fuel% of total fuel

Coal / Petcoke / Animal Meal mix: 6 th-%Solid hazardous waste: 16 th-%Fluff RDF: 38 th-%

Typically:16 to 18 t/h of solid haz. waste and heterogenous RDFfed to the combustion chamber

Page 26: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 26

KHD Humboldt Wedag GmbH

HolcimCampulung / RomaniaNew Kiln Line 4000 t/d

Top Air Duct

Combustion Chamber

Static Orifice

Page 27: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 27

KHD Humboldt Wedag GmbH

KHD Bypass System

• Efficient mixing of gas streams

• Rapid cooling of the bypass gases

• Homogenous mixing gas temperature

• Patented water injection system

Technical Solutions - Bypass Systems

Page 28: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 28

KHD Humboldt Wedag GmbH

Technical Solutions - Bypass Systems

0

1

2

3

4

0 1 2 3 4 5 6SO3 [%]

Cl

[%]

Heavy build-up‘s

Minorbuild-up‘s

Acceptablebuild-up‘s

Situation without bypass

Situation with bypass

Influence of sulphur and chlorides on preheater operation

Page 29: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 29

KHD Humboldt Wedag GmbH

Typical Arrangement for Bypass Extraction

Bypass gas to dedusting

Mixing chamber

Cooling air

Kiln inlet chamber

Tertiary air duct

Page 30: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 30

KHD Humboldt Wedag GmbH

Case study:Conventional Plant for Primary Fuels

Plant AProduction 3500 t/d

Coal 27,8 MJ/kg

Specific heat consumption 2956 kJ/kg cli

Specific waste gas amount at fan inlet 1,4 Nm³/kg

Pressure drop at fan inlet - 47 mbar

Page 31: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 31

KHD Humboldt Wedag GmbH

Production 3500 t/d

Primary-Secondary Fuel Mix 16,8 MJ/kg(~ 40% coal, ~ 60% altern. fuel mix)

Specific heat consumption 3274 kJ/kg cli

Specific waste gas amount at fan inlet 1,6 Nm³/kgPressure drop at fan inlet - 68 mbar

Case study:Plant for Primary and Secondary Fuels

Plant B

Page 32: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 32

KHD Humboldt Wedag GmbH

Case Study:

Comparison

Pressure drop at fan inlet

Specific exhaust gas amount

Specific heat demand

+ 45 %- 68 mbar- 47 mbar

+ 14 %1,6 Nm³/kg cli.1,4 Nm³/kg cli.

+ 10 %3274 kJ/kg cli.2956 kJ/kg cli.

Primary and Secondary FuelsPlant with combustion chamber,

bypass and extended calciner

Primary FuelPlant without combustion

chamber, bypass and extended calciner

Plant A Plant B

Page 33: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 33

KHD Humboldt Wedag GmbH

Case study: 10% more in specific heat demand shared to …

40 % 39 %

12 %

8 %

1 %0

5

10

15

20

25

30

35

40

Exhaust Gas Bypass Radiation:Kiln

Radiation:Preheater,Calciner

Dust

Plant with combustion chamber, extended calciner and bypass

Primary Fuels

Primary and Secondary Fuels

Page 34: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 34

KHD Humboldt Wedag GmbH

Challenge of Using Secondary FuelsC

osts

/ t cl

inke

r

Target

Animal MealSec. Raw MaterialSec. Fuels

WoodBottom AshNatural Gas

LigniteCoal + Pet Coke

Profit

Costs

Development of costs absolut

- x%

100 %

KHD-Symposium Cologne 05 / 2001

0 %

Time

Page 35: Technology Options for the Cement Industry with the Use … presentation.pdf · Technology Options for the Cement Industry with the Use of Alternative Fuels. Thursday, May 17, 2007

Thursday, May 17, 2007 35

KHD Humboldt Wedag GmbH

KHD Humboldt “150 Years Leadership in Technology”

and Cement Plant Engineering

• Innovative, reliable technology

• High availability and flexibility

• Low specific energy demand

• Low emission levels

• Customised solutions

Summary