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ALTERNATIVE FUELS

I Waste-to-flame processby BMH Technology Oy,Finland With the right know-how, waste is a valuable resource for the cementindustry. The TYRANNOSAURUs$ Waste-ta-Flame Process by BMHTechnology offers aproven turnkey solution for the introduction of SolidRecovered Fuel as a substitute fuel for the cement production process.

T v R A N N O S A U R U 5 ~SRF processThe process typically involvesa large feeder which puts rawmaterial into the TYRANNOSAURUSShredder, where the material isshredded into an 80mm particlesize. T Y R A N N O S A U R U S ~ 9900series shredders are in fact theworld's largest waste reducers,claim BMH, and are fullyprotected against unshreddablemetals by the patented MIPSTMSecurity System (Massive ImpactProtection System).

Ferrous metals are separatedfrom the shredded material by

Waste to Flame Waste to Flame now from one source Tumkey plant deliverles Highest capadty Best fuel quality Lowest production costs Tru ly heavy-duty Industrial solution

via BMH's T Y R A N N O S A U R U S ~ Process andProcess Optimisation Technology.

TVRANNOSAURUS units are capable ofautomatically processing 3000 tyres anhour into 70mm Tyre Derived Fuel (TDF)

In a single pass. The process is alsounaffected by entrapped metaland occasional rims.

.... oF- Co:;:)._ .- .CI . . . . . ' '- e-ur'I .:::- ..,....

a tonne of coal very cost-effectively.Annual averages of up to 90 per centthermal substitution rates (TSR) can beexpected via themain burner and calcinerand 30 per cent in a gas riser/AT calciner,

Pt \"': l.....-----

4 I "." J I") ,"" I ' : ". ll ' ':.

V irtually any type of combustiblewaste - from municipal,commerclal, and industrial wasteto scrap tyres, textiles, big bags, plasticfilm, and waste paper - can be convertedinto Sol-d Recovered Fuel (SRF). In theshredding and sorting process harmfulsubstances and recyclable materials,such as ferrous and nonferrous metals.sand, and stones are separated out fromthe waste stream for onward use. Theend product - SRF - is fight fluff, whichpredominantly consists of two-dimensionalmaterial, such as plasfc foils, paper,cardboard and textiles.Not only is the w e l l ~ p r o c e s s e d SRf

a cheap fuel available, it is locallyproduced and not subject to globalprice fluctuations. Its application alsoenables cement producers to benefit fromC02 credits/trading. SRF represents anIdeal substitute for the more expensivetraditional fuels at the same time as

r ~ d u d n g NO K With a typ'cal heating valueof 20MJ/kg compared to approximately25MJ/kg for coal, 1.3t of SRF can replace

SEPTEMBER 2011 ICR 101

ALTERNATIVE FUELS

I Waste-to-flame processby BMH Technology Oy,Finland With the right know-how, waste is a valuable resource for the cementindustry. The TYRANNOSAURUs$ Waste-ta-Flame Process by BMHTechnology offers aproven turnkey solution for the introduction of SolidRecovered Fuel as a substitute fuel for the cement production process.

T v R A N N O S A U R U 5 ~SRF processThe process typically involvesa large feeder which puts rawmaterial into the TYRANNOSAURUSShredder, where the material isshredded into an 80mm particlesize. T Y R A N N O S A U R U S ~ 9900series shredders are in fact theworld's largest waste reducers,claim BMH, and are fullyprotected against unshreddablemetals by the patented MIPSTMSecurity System (Massive ImpactProtection System).

Ferrous metals are separatedfrom the shredded material by

Waste to Flame Waste to Flame now from one source Tumkey plant deliverles Highest capadty Best fuel quality Lowest production costs Tru ly heavy-duty Industrial solution

via BMH's T Y R A N N O S A U R U S ~ Process andProcess Optimisation Technology.

TVRANNOSAURUS units are capable ofautomatically processing 3000 tyres anhour into 70mm Tyre Derived Fuel (TDF)

In a single pass. The process is alsounaffected by entrapped metaland occasional rims.

.... oF- Co:;:)._ .- .CI . . . . . ' '- e-ur'I .:::- ..,....

a tonne of coal very cost-effectively.Annual averages of up to 90 per centthermal substitution rates (TSR) can beexpected via themain burner and calcinerand 30 per cent in a gas riser/AT calciner,

Pt \"': l.....-----

4 I "." J I") ,"" I ' : ". ll ' ':.

V irtually any type of combustiblewaste - from municipal,commerclal, and industrial wasteto scrap tyres, textiles, big bags, plasticfilm, and waste paper - can be convertedinto Sol-d Recovered Fuel (SRF). In theshredding and sorting process harmfulsubstances and recyclable materials,such as ferrous and nonferrous metals.sand, and stones are separated out fromthe waste stream for onward use. Theend product - SRF - is fight fluff, whichpredominantly consists of two-dimensionalmaterial, such as plasfc foils, paper,cardboard and textiles.Not only is the w e l l ~ p r o c e s s e d SRf

a cheap fuel available, it is locallyproduced and not subject to globalprice fluctuations. Its application alsoenables cement producers to benefit fromC02 credits/trading. SRF represents anIdeal substitute for the more expensivetraditional fuels at the same time as

r ~ d u d n g NO K With a typ'cal heating valueof 20MJ/kg compared to approximately25MJ/kg for coal, 1.3t of SRF can replace

SEPTEMBER 2011 ICR 101

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ALTERNATIVE FUELS

magnets, while eddy current separatorsseparate the non-ferrous metals. In somecases, the very fine fraction (sand, soil, etc)is screened out from the fuel to fu rtherimprove the fuel quality.The TVRANNOSAURUSI8l Air Classifier

eliminates materials that are unsuitablefor suspended combustion. These includerest metals, glass, minerals and other inertmaterials, as well as wet organic materialsand hard plastics containing PVc. Finally,the light fraction is further sized down toapproximately 25mm particle size in theTVRANNOSAURUS tllI Fine Shredder and at thispoint the fuel is ready for use.

For calciners the size can be relaxed to50mm depending on the AFR market andwet and hard plastics included, howeverinert materials need to be controlled to30 per cent are sought.

The entire TVRANNOSAURUS process isVirtually unmanned during operation.SRF fuel propertiesSRF is a homogeneous and standard sedhigh-quality fuel, similar in many aspectsto a primary fuel.The typical net calorific value of SRF is

18-24MJ/kg, equalling 4300-5730kcallkg.As such, it is suitable both for the calciner,gas riser and the main burner, only thepreparation process may be slightlydifferent depending on the use.

With well-processed SRF, 90 per centTSR is possible with optimised processoperation.SRF logisticsIf the SRF production plant is positionedclose to the kiln, the fuel can be

102 leR SEPTEMBER 2011

transported dIrectlyto the kiln by chainor tubular beltconveyors.

In cases oflonger distances,the SRF fuel isusually transportedby trucks. TheT'l'RANNOSAURUSprocess can be fittedwith fully automatictruck docking

stations or alternatively intermediatestorage bunkers.

Furthermore, the SRF fuel can becompacted into plastic wrapped EnergyCubes which are highly efficient duringtransportation. These are also a long-termstorage solution.SRF storage andconveying at the kilnThe most straightforward solution is to usetruck trailers as an intermediate storagefor the fuel. The truck leaves its trailer atthe kiln for controlled discharge directlyinto the kiln through a mechanical orpneumatic system.

In addition, silos with automaticdischarge can be built at the kiln. Anystorage volumes required can be achievedby building a multiple silo complex, or astorage hall and front loader.

Tubular belt and chain conveyors areused for transportation, while bucketelevators are available for verticaltransport. Furthermore, in some casesscrew conveyors are ideal.

All conveyor types are designed in anentirely enclosed manner to eliminatematerial spillage.

Dosing and feedingBoth pneumatic and mechanical feedingsystems are available.The pneumatic system includes a dosing

hopper with accurate discharge control.SRF fuel is fed into a rotary valve fromwhere it is injected into the pneumaticsystem and further into the process.

The mechanical systems includereceiving bunkers, silos, dosing andflow monitoring. They are designed anddimensioned so that the process canreceive a wide range of substitute fuels.

Special attentionis paid to ensuringthat the f ow of fuelis undisturbed andcontrolled.For the calciner, theSRF can be supplied tomore than one location,with the injectionsystem supplementedwith a Jet Air MiXIngSleeve to ensure anoptimum mixing andcombustion of the $RFwith the tertiary air andkiln gases.

Impad of SRF on theprocess, emissions andclinker qualityOver the years the use of alternative fuelshas had a mixed success due to adverseimpact on output, buildup, emissions andclinker quality.

BMH via its TVRANNOSAURUS processand Process Optimisation Technology,seeks to minimise the impact on output,produce a beneficial environmental impactwithout impacting clinker quality, by tailormaking the SRF and its implementationto the plant's process and chemicalcharacteristics.

Care has to be taken to ensure thatSRF is injected into a burner that has theappropriate momentum for the kiln outputand is optimally set up to avoid SRF beingdumped into the burning zone, producingreduced clinker and increased build-upissues, otherwise high TSR's will not beachievable.

For a typical operation, costs and valueof lost clinker for both types of AFR, theSRF is worth 30/t more in a market whichis not sold out and 75/t more in a sold outmarket, due to its much lower impact onoutput.

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For the calciner it is more complicateddue the most plants being different andthe injection locations. They also need tohave their modes adjusted when fed withSRF to achieve higher T5Rs.

Where would you put the SRF tomaximise TSR and avoid increased COor unburnts in the hot meal that increase503 cycles, build up and lost output? BMHoffers advises for all types of calciners tomaximise the use of its 5RF without impacton output and 503 cycles and build up.EmissionsSRF with its potential high T5Rs can befactored into longer-term planning forC02 credits and or trading.

CO and even VOC increases can be anissue for plants that do not have qualityor preparation and feeding control, plusoplimised SRF injection.

Generally all AFR show a reductionin NOx, however, the SRF preparationstogether with hot reburn potential canleave many plants not needing 5NCR tomeet their NOx permits. BMH can advise

on how to optimise the drop in NOxpotential for SRF.Clinker qualityCoarse ash is an issue that can limit theuse of AFR, due to the need to get It intosolid solution. This is why BMH seeksto minimise the inerts in the 5RF by

ALTERNATIVE FUELS

separation during processing.A typical limit fOf a process is 0.5 per

cent coarse quartz, which would be 1.5per cent ash from AFR on clinker for a 10per cent a h 5RF this allows >90 per centTSR while for a 25 per cent ash AFR withan appropriately lower CV, it is on y at 30percentT5R. _

SEPTEMBER 2011 tea 103

For the calciner it is more complicateddue the most plants being different andthe injection locations. They also need tohave their modes adjusted when fed withSRF to achieve higher T5Rs.

Where would you put the SRF tomaximise TSR and avoid increased COor unburnts in the hot meal that increase503 cycles, build up and lost output? BMHoffers advises for all types of calciners tomaximise the use of its 5RF without impacton output and 503 cycles and build up.EmissionsSRF with its potential high T5Rs can befactored into longer-term planning forC02 credits and or trading.

CO and even VOC increases can be anissue for plants that do not have qualityor preparation and feeding control, plusoplimised SRF injection.

Generally all AFR show a reductionin NOx, however, the SRF preparationstogether with hot reburn potential canleave many plants not needing 5NCR tomeet their NOx permits. BMH can advise

on how to optimise the drop in NOxpotential for SRF.Clinker qualityCoarse ash is an issue that can limit theuse of AFR, due to the need to get It intosolid solution. This is why BMH seeksto minimise the inerts in the 5RF by

ALTERNATIVE FUELS

separation during processing.A typical limit fOf a process is 0.5 per

cent coarse quartz, which would be 1.5per cent ash from AFR on clinker for a 10per cent a h 5RF this allows >90 per centTSR while for a 25 per cent ash AFR withan appropriately lower CV, it is on y at 30percentT5R. _

SEPTEMBER 2011 tea 103