© Schenck Process 2012
Schenck Process Americas S.A.S / FCT Combustion Pty
FICEM APCAC COSTA RICA 2012
CONTENTS
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© Schenck Process 2012
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Schenck Process Americas S.A.S
Presentation
FCT Combustion Pty Ltd
Presentation
Efficient and Optimum Cement Production with Alternative Fuels
By
© Schenck Process 2012
Sanjiv Dhanjal (FCT Combustion, USA)
and
Fernando Garcia (Schenck Process Americas S.A.S, Colombia)
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Your partner in cement Industry
Clay
Sand
Products:




Crusher relief
screen
Belt weigher
Limestone
crusher
Return grits
Flowmeter




Bin weighing
Mass flow feeders
MULTICOR
Homogenization
Limestone
Separator
Alternative:
SCHENCK Fuel Master
Feeding of Alternative Fuels
Flow gates
Bucket elevator
Belt weigher to be
installed in apron
conveyor
Kiln
Clinker
Gypsum
Additive
Return
grits
Separator
Store
Cementmill
Cooler
Blaine value
Measurement
MULTICOR-K - Feeding
of pulverized coal
(10 bar pressure proof)
Cement
© Schenck Process GmbH 2006
Seite 4
MECHATRON
FE2SO4
Bucket
elevator
Truck and train
scales
Alternative fuels.
Sand
Clay
Raw mill
Screens
Loading automation
Sand
Clay
Reclaimer wheel
Loss in weigh feeder
MECHATRON
MULTISTREAM


Limestone
Apron feeder
Weighfeeder
SCHENCK Fuel Master
Feeding of Alternative Fuels
Cement
Cement
Feeding systems FUEL-Master
solutions for alternative fuels
The goal:
Reduce the operation costs in cement kilns by substituting of:
More expensive primary fuels (Coal, Oil, Gas) for alternative low cost
fuel.
© Schenck Process GmbH 2006
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... Giving the less impact on:
– Clinker quality
– Production capacity
– stability of kiln
– and atmosferic emisions.
Feeding systems FUEL-Master
solutions for alternative fuels
© Schenck Process GmbH 2006
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Design requirements for fuel systems:

They must feed a wide range of materials.

Hi accuracy and high feeding constancy.

High reliability and high availability.

Capacity of manage very big sizes of material.

Easy integration on existing installations.

Easy maintenance

Cheap return cost
Feeding systems FUEL-Master
solutions for alternative fuels
3 golden rules
for design of alternative fuels plants:
1. Specifying robust equipment despite low density!
 Ensure high availability of systems.
2. Avoid bottleneck - Alternative fuels tries to create bridges.
 Avoid dead times for plugging.
3. Design a wide range of densities and flow properties.
© Schenck Process GmbH 2006
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 Makes sure high flexibility using several materials.
Feeding systems FUEL-Master
solutions for alternative fuels
Reception
Storing and transport
50000
30000
69
00
+ 12,100
6000
1800
2400
- 4,300
6050
8500
6000
+ 0,450
±0 = 314,000
1500
© Schenck Process GmbH 2006
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20000
Weighing and feeding
© Schenck Process 2012
FCT TURBU-JET
FOR REGULAR AND ALTERNATIVE FUEL
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FUEL COMBUSTION
Gaseous
Nozzle design is based on flow and pressure. Typically multiple holes
Liquid
Atomization required for efficient combustion
Pressure atomization requires up to about 40 barg (600 psig)
Air and steam also used for atomization, typically at about 6-8 barg
(90-120 psig)
Solid
© Schenck Process 2012
Grind coal or coke to about 90% through 75 micron sieve
Final size depends on volatile fraction
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Purpose is to facilitate fuel and air mixing
ALTERNATIVE FUELS COME IN ALL SHAPES AND
SIZES
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Wood Waste
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Diapers
Paper and Plastics
Tire Shreds
Rice Husks
Cherry Stones
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TESTING AND MODELING TO DETERMINE BEST
WAY TO FIRE ALTERNATIVES
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FCT ALTERNATIVE FUEL NOZZLE
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KILN MINERALOGICAL REACTIONS
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C3S
C2S
C3A,
C4AF
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FCT MODELING FOR BURNER DESIGN
© Schenck Process 2012
Physical Modelling
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Water Bead
Acid/Alkali
Mathematical
EXAMPLE – PROBLEM
1650 TPD kiln firing coal/coke/gas can only
fire 30% coke before high CO and build up
© Schenck Process 2012
Model shows
The burner provides incorrect
momentum to entrain the
combustion air.
The burner position and angle in the
kiln cause flame impingement.
The kiln is operated with too little
excess air.
Flame length is excessive at all
reasonable excess air levels.
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EXAMPLE - SOLUTION
Model used to design new burner
© Schenck Process 2012
New burner
Shorter flame length at all excess air
levels, can operate at 2% oxygen
Performs best when aligned with the
kiln axis
Has correct burner momentum for
short flame.
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EXAMPLE - BENEFITS
The benefits to the plant are
Petcoke usage has now increased to 100% - previously 30%
Clinker quality has improved dramatically, with 28 day strengths increasing by 10%
Almost no build up has been experienced in the kiln and riser duct, where previously
build up was restricting kiln performance even with 30% petcoke
© Schenck Process 2012
A fuel saving of about 45 kcal/kg cli was seen by the plant, partly attributable to a
change in the coal dosing system and partly to the new burner
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© Schenck Process 2012
FCT GYRO-THERM BURNER
FOR GAS AND COAL
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COSMA OUTPUT IN REAL TIME
On-Line X-Ray Diffraction Analyzer
Measures mineral phases directly, like alite, belite,
gypsum de-hydration and free lime
Data sent to process control system for automatic quality
control and process optimization
Continuous mineral analysis in Real Time
© Schenck Process 2012
Control quality continuously
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Increase limestone or pozzolan addition
Reduce free lime variability, lower fuel, reduce
NOx, less grinding energy
Ensure clinker quality, especially when burning
alternatives
SUMMARY
© Schenck Process 2012
1. MATERIAL HANDLING
2. COMBUSTION EFFICIENCY
3. PRODUCT QUALITY CONTROL
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© Schenck Process 2012
THANK YOU VERY MUCH.
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