7 Sanjiv Dhanjal

© Schenck Process 2012
Schenck Process Americas S.A.S / FCT Combustion Pty

FICEM APCAC COSTA RICA 2012
CONTENTS
Schenck Process Americas S.A.S

1
Presentation
FCT Combustion Pty Ltd

2
Presentation
2
Efficient and Optimum Cement Production with Alternative Fuels
By
Sanjiv Dhanjal (FCT Combustion, USA)

and
Fernando Garcia (Schenck Process Americas S.A.S, Colombia)
3
Your partner in cement Industry
Clay
Products: Sand
Crusher relief
 Belt weigher screen
Limestone Clay Sand


Apron feeder
Weighfeeder Limestone
crusher
Reclaimer wheel
 Loss in weigh feeder
MECHATRON Return grits
 Flowmeter
Homogeni-
Separator
Lime-
stone
Clay Sand
MULTISTREAM Alternative:
zation
Raw mill
 Bin weighing SCHENCK Fuel Master

Feeding of Alternative Fuels
Mass flow feeders Flow gates
Bucket elevator
MULTICOR Bucket
MECHATRON
FE2SO4

elevator
Screens Return Separator
grits

Belt weigher to be Additive
Truck and train installed in apron
Clinker Gypsum
scales conveyor Store

Blaine value
 Kiln Cooler Cement- Measurement

Loading automation mill
 Alternative fuels. MULTICOR-K - Feeding

of pulverized coal
(10 bar pressure proof)
Cement Cement Cement
© Schenck Process GmbH 2006
SCHENCK Fuel Master

Feeding of Alternative Fuels
Seite 4
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.
... Giving the less impact on:
– Clinker quality
– Production capacity
– stability of kiln
– and atmosferic emisions.
Seite 5
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

Seite 6
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.
 Makes sure high flexibility using several materials.
Seite 7
Reception Storing and transport Weighing and feeding
50000
20000 30000
+ 12,100
00
69
6000 6000 1800

8500
2400
6050
+ 0,450
1500
±0 = 314,000
- 4,300
Seite 8
FCT TURBU-JET
FOR REGULAR AND ALTERNATIVE FUEL
9
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
Grind coal or coke to about 90% through 75 micron sieve
Final size depends on volatile fraction
Purpose is to facilitate fuel and air mixing
10
ALTERNATIVE FUELS COME IN ALL SHAPES AND
SIZES
Wood Waste Paper and Plastics Rice Husks

Diapers Tire Shreds Cherry Stones

11
TESTING AND MODELING TO DETERMINE BEST
WAY TO FIRE ALTERNATIVES
12
FCT ALTERNATIVE FUEL NOZZLE
13
KILN MINERALOGICAL REACTIONS
C3S
C2S
C3A,
C4AF
14
FCT MODELING FOR BURNER DESIGN
Physical Modelling
Water Bead Acid/Alkali Mathematical

15
EXAMPLE – PROBLEM
1650 TPD kiln firing coal/coke/gas can only

fire 30% coke before high CO and build up
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.
16
EXAMPLE - SOLUTION
Model used to design new burner
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.
17
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
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
18
FCT GYRO-THERM BURNER
FOR GAS AND COAL
19
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
Control quality continuously
Increase limestone or pozzolan addition

Reduce free lime variability, lower fuel, reduce

NOx, less grinding energy
20
Ensure clinker quality, especially when burning
alternatives
SUMMARY
1. MATERIAL HANDLING
2. COMBUSTION EFFICIENCY
3. PRODUCT QUALITY CONTROL
21
THANK YOU VERY MUCH.
22

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© Schenck Process 2012

Schenck Process Americas S.A.S / FCT Combustion Pty

Schenck Process Americas S.A.S

FCT Combustion Pty Ltd

Sanjiv Dhanjal (FCT Combustion, USA)

 Belt weigher screen

Limestone Clay Sand

 Bin weighing SCHENCK Fuel Master

scales conveyor Store

 Kiln Cooler Cement- Measurement

 Alternative fuels. MULTICOR-K - Feeding

SCHENCK Fuel Master

Reduce the operation costs in cement kilns by substituting of:

... Giving the less impact on:

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.

 Cheap return cost

1. Specifying robust equipment despite low density!

2. Avoid bottleneck - Alternative fuels tries to create bridges.

6000 6000 1800

Purpose is to facilitate fuel and air mixing

Wood Waste Paper and Plastics Rice Husks

Diapers Tire Shreds Cherry Stones

Water Bead Acid/Alkali Mathematical

1650 TPD kiln firing coal/coke/gas can only

Model used to design new burner

The benefits to the plant are

Petcoke usage has now increased to 100% - previously 30%

On-Line X-Ray Diffraction Analyzer

Control quality continuously

Increase limestone or pozzolan addition

Reduce free lime variability, lower fuel, reduce

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