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2009
A TEC WORLDWIDE
World Leader in Cement Pyroprocess Technology
A TEC Company Presentation
2009 2
A TEC WORLDWIDE
Mexico, Puebla
China, Beijing
Poland, Chelm
India, Delhi
Malaysia, Kuala Lumpur
Headquarter, Austria
2009 3
A TEC ORGANIZATION CHART
2009 4
A TEC BOARD MEMBERS
Dipl. Ing. Friedrich Willitsch
Chief Technical Officer (CTO)
Heading Contract Management, Research
and Development, Process Technology
Dr. Günther Schwaiger
Chief Executive Officer (CEO) Heading Sales, Marketing and Finance
2009 5
A TEC MISSION
2009 6
A TEC – KEY ACCOUNTS
Client structure:
and many more…
2009 7
POWER OF A TEC
A TEC offers patented products,
innovative process technologies
and consulting service know-how.
Hands-on experience in planning,
implementation and plant operation -
A TEC is a reliable business partner.
2009 8
A TEC OPTIMIZATION
ENERGY
EFFICIENCY
ENVIRONMENT
2009 9
CEMENT PYROPROCESS
2009 10
A TEC CHINA
2009 11
A TEC CHINA
2009 12
A TEC CHINA
2009 13
A TEC PROJECT EXAMPLES
STRABAG Greenfield Plant, Hungary
Lafarge Wössingen, Germany
Belarusian Cement Plants, Belarus
W&P Wietersdorf, Austria
Cementizillo, Fanna, Italy
Cemex Assuit, Egypt
Al Safwa, Saudi Arabia
2009 14
STRABAG GREENFIELD PLANT
LimestoneCrusher
Quarry
Capacities
1000 t/h
ClayCrusher
Quarry250 t/h
Transport
railroad7000 t/d
Preblending
storage
2 x 15.000 t
Sand-storage
625 t
Iron-storage
625 t
Sand
Iron
Raw Mill 200 t/h
Raw Mill Silo
8.000 t
Coal/PetcokeCoal-storage
8.000 t
Coal Mill
15 t/h
Kiln Line
(Preheater,
Kiln,
Cooler)
2500 t/d
(104 t/h)
Clinker
Cement
mills
2 x 100t/h
Cement
Storage Limestone pure
10.000 t
Limestone
pure
Crusher 190 t/hGypsum
Additives
Cement Storage
4 x 10.000 t
Packing plant
125 t/h
Truck loading
2 x 200t/h
Rail loading
200t/h
Clinker storage
60.000 t
2009 15
STRABAG GREENFIELD PLANT
overall project management
plant arrangement, process design
complete tender support to client
sub-contracts negotiation
progress & quality assurance
interface and technical clarification
supervision services & training
2009 16
LAFARGE WÖSSINGEN
Project Scope – Main Plant Sections
Raw Mill and kiln Filter modification of ESP
Bypass Filter modification of ESP
Bypass Dust storage and dosing new
Conditioning tower new
Raw meal transport from silo to dosing new
Lime hydrate storage and dosing new
SNCR dosing systems new
Kiln – 2 reuse of usable kiln and kiln parts new
Burner and fuel dosing systems new
Clinker cooler new
Cooler Filter new
Clinker transport new
2009 17
LAFARGE WÖSSINGEN
2009 18
W & P – WIETERSDORF, AUSTRIA
Project Period: 16 months
Shut-Down: 69 days
New Preheater & Calciner
• New preheater complete
• New low-NOx calciner incl. Comb. Chamber
• New tertiary air duct,
• New hot gas duct
• New preheater fan
• Kiln shortening
• New kiln inlet sealing
• New kiln inlet chamber
Results
• Production increase from 1000 to 1777 t/d
• NOx <500 mg/nm³ (without SNCR)
2009 19
W & P – WIETERSDORF, AUSTRIA
2009 20
CEMEX – ASSIUT KILN 2+3, EGYPT
Project Period: 8 months
Shut-Down: 39 days
Modification on Preheater & Calciner
• Disassembly of preheater equipment
except
• Cyclone cone stage 2 & 4
• Meal pipes stage 2 & 4
• Installation of new preheater equipment
• Extension existing 2 string calciner
• New hot gas duct
Results:
• Production increase from 4000 to 4500
t/d with a shut down of only 39 days!!!
2009 21
CEMEX – ASSIUT KILN 2+3, EGYPT
2009
Please visit:
www.atec-ltd.com
THANK YOU FOR YOUR ATTENTION
2009
A TEC WORLDWIDE
World Leader in Cement Pyroprocess Technology
A TEC Company Presentation
2009 2
A TEC WORLDWIDE
Mexico, Puebla
China, Beijing
Poland, Chelm
India, Delhi
Malaysia, Kuala Lumpur
Headquarter, Austria
2009 3
A TEC ORGANIZATION CHART
2009 4
A TEC BOARD MEMBERS
Dipl. Ing. Friedrich Willitsch
Chief Technical Officer (CTO)
Heading Contract Management, Research
and Development, Process Technology
Dr. Günther Schwaiger
Chief Executive Officer (CEO) Heading Sales, Marketing and Finance
2009 5
A TEC MISSION
2009 6
A TEC – KEY ACCOUNTS
Client structure:
and many more…
2009 7
POWER OF A TEC
A TEC offers patented products,
innovative process technologies
and consulting service know-how.
Hands-on experience in planning,
implementation and plant operation -
A TEC is a reliable business partner.
2009 8
A TEC OPTIMIZATION
ENERGY
EFFICIENCY
ENVIRONMENT
2009 9
CEMENT PYROPROCESS
2009 10
A TEC CHINA
2009 11
A TEC CHINA
2009 12
A TEC CHINA
2009 13
A TEC PROJECT EXAMPLES
STRABAG Greenfield Plant, Hungary
Lafarge Wössingen, Germany
Belarusian Cement Plants, Belarus
W&P Wietersdorf, Austria
Cementizillo, Fanna, Italy
Cemex Assuit, Egypt
Al Safwa, Saudi Arabia
2009 14
STRABAG GREENFIELD PLANT
LimestoneCrusher
Quarry
Capacities
1000 t/h
ClayCrusher
Quarry250 t/h
Transport
railroad7000 t/d
Preblending
storage
2 x 15.000 t
Sand-storage
625 t
Iron-storage
625 t
Sand
Iron
Raw Mill 200 t/h
Raw Mill Silo
8.000 t
Coal/PetcokeCoal-storage
8.000 t
Coal Mill
15 t/h
Kiln Line
(Preheater,
Kiln,
Cooler)
2500 t/d
(104 t/h)
Clinker
Cement
mills
2 x 100t/h
Cement
Storage Limestone pure
10.000 t
Limestone
pure
Crusher 190 t/hGypsum
Additives
Cement Storage
4 x 10.000 t
Packing plant
125 t/h
Truck loading
2 x 200t/h
Rail loading
200t/h
Clinker storage
60.000 t
2009 15
STRABAG GREENFIELD PLANT
overall project management
plant arrangement, process design
complete tender support to client
sub-contracts negotiation
progress & quality assurance
interface and technical clarification
supervision services & training
2009 16
LAFARGE WÖSSINGEN
Project Scope – Main Plant Sections
Raw Mill and kiln Filter modification of ESP
Bypass Filter modification of ESP
Bypass Dust storage and dosing new
Conditioning tower new
Raw meal transport from silo to dosing new
Lime hydrate storage and dosing new
SNCR dosing systems new
Kiln – 2 reuse of usable kiln and kiln parts new
Burner and fuel dosing systems new
Clinker cooler new
Cooler Filter new
Clinker transport new
2009 17
LAFARGE WÖSSINGEN
2009 18
W & P – WIETERSDORF, AUSTRIA
Project Period: 16 months
Shut-Down: 69 days
New Preheater & Calciner
• New preheater complete
• New low-NOx calciner incl. Comb. Chamber
• New tertiary air duct,
• New hot gas duct
• New preheater fan
• Kiln shortening
• New kiln inlet sealing
• New kiln inlet chamber
Results
• Production increase from 1000 to 1777 t/d
• NOx <500 mg/nm³ (without SNCR)
2009 19
W & P – WIETERSDORF, AUSTRIA
2009 20
CEMEX – ASSIUT KILN 2+3, EGYPT
Project Period: 8 months
Shut-Down: 39 days
Modification on Preheater & Calciner
• Disassembly of preheater equipment
except
• Cyclone cone stage 2 & 4
• Meal pipes stage 2 & 4
• Installation of new preheater equipment
• Extension existing 2 string calciner
• New hot gas duct
Results:
• Production increase from 4000 to 4500
t/d with a shut down of only 39 days!!!
2009 21
CEMEX – ASSIUT KILN 2+3, EGYPT
2009
Please visit:
www.atec-ltd.com
THANK YOU FOR YOUR ATTENTION
1 Priviledged Information not to be copied. All rights reserved.
MUNICIPAL SOLID WASTE (MSW) REFUSE DERIVED FUEL (RDF)
EVENT: FICEM-APCAC Conference 2009
PLACE: Bogota
DATE: 2009Sept07
By Jonathan [email protected]
BASURA MUNICIPAL COMBUSTIBLE
2
Who is A TEC?
Since 1996 A TEC has
improved the Pyro-process
with 17 patented innovations.
Austrian engineering company:
>10 years experience in alternative
fuels implementation
Priviledged Information not to be copied. All rights reserved.3
TYPICAL ALTERNATIVE FUELS
1. Waste oil
2. Solvent
3. Contaminated and waste wood
4. Tire and rubber waste
5. Plastic waste
6. Thermal fraction of domestic waste
7. Thermal fraction of industrial waste
8. Animal meal
9. Sewage sludge
Priviledged Information not to be copied. All rights reserved.4
RAW MATERIAL
Municipal Solid Waste … it’s free!
Priviledged Information not to be copied. All rights reserved.5
TYPICAL FUELS CONTAMINANTS
Priviledged Information not to be copied. All rights reserved.6
MSW COMPONENTS & TRAJECTORIES
Step 1
pre-crushing
max.
150mm
Step 2
drying,
hygienisation,
separation of fine
fraction ~20 min.
150 C
Step 3
cutting
60-80mm
Step 4
further
processing
depending on
requirements
Step 5
separation
of
impurities
Step 6
further
separation
depending on
requirements
Problematic
materials ~1%
Thermal
fraction calorific
value: 17-21
MJ/kg
Wa
ste
ma
teria
l
Exa
mp
le
Water ~31%
Organics ~9%Textiles ~7%Wood ~8%Plastics ~7%
Composite materials ~6%Paper ~6%Metal ~7%
Glass and inert materials ~7%
MTP
Priviledged Information not to be copied. All rights reserved.7
BEHAVIOUR OF TRACE ELEMENTS
COMPONENTS in RDF: Behaviour in the Pyro-Process
Elements involved Components/ Carriers Transfer Details
Chrome, Zinc, Nickel,
Arsenic, Vanadium, etc.,
Sulfur from the fuel
Clinker mineral elements,
Low volatile metals
Sulfur component of fuel
Hardly volatile: mainly transfer into the clinker
TOC, Lead, Mercury
Sulfur from raw meal
Non burnt organics,
Products of combustion
Volatile: Mainly transfer into the preheater exhaust
gas
Thallium, Cadmium, Mercury Volatile trace metals
Linked to dust particles
Volatile: Likely build up of internal cycles.
Transfer into preheater exhaust dust, cycle builds
until overflow is picked up at filter and recirculated via
raw meal. Mixing filter dust to cement bleeds cycle.
Chlorine,
Sodium, Potassium
Halogens, alkalis,
residuals conveyed with
clinker
Build up of internal cycles likely:
By-pass system can bleed elements to external
disposal.
Priviledged Information not to be copied. All rights reserved.8
THE PROCESS
collection storage transport dosingprocessing
Operation Guidlines
& Adjustment
Process Design
& Evaluation
Combustion
Technology
Standard Alternative Fuel Preparation Technology
Production and process technology for utilization of alternative fuels
Priviledged Information not to be copied. All rights reserved.9
THE PROCESS
Domestic or
Industrial
Solid Waste
optional
A TEC -
MTP
Hot air
(Clinker cooler)
Contaminated
gas
Storage
Untreated material
STORAGE
Storage
Material <
300mm
Material < 50mm
Storage
Sorting
Automatically or
hand-operated
Shredding
< 15 mm
Shredding
< 300 mm
Shredding
< 50 mm
A TEC rotary
combustion
chamber
Calciner section
& combustion
chamber
Main burner
Storage
Material < 15mm
Plant engineering from DELIVERY to
COMBUSTION is ONE concept…
300 mm = 12”
50 mm = 2”
15 mm = 5/8”
Priviledged Information not to be copied. All rights reserved.10
THE PRODUCTION LEVEL
Typical Preheater Exhaust Gas Volumes
at 2% false air; 3300 kJ/kgcli
Approx. Gas Volume [Nm3/kgcli]
Coal 1,50 base
Heavy oil 1,60 + 6,6 %
RDF 10% moisture 1,65 + 10,0 %
Natural gas 1,70 + 13,3 %
Priviledged Information not to be copied. All rights reserved.11
THE EFFICIENCY LEVELS
Reductionclinker production
Increase heat consumption
Moisture [t/t H2O] 2.00 [MJ/kg H2O] 2.10
False air [t/kNm³ air] 0.23 [MJ/Nm³ air] 1.00
Oxygen [% t/%O2] 5.50 [% MJ/%O2] 1.60
1t metric = 1.102 st 1 MJ/kg = 430 BTU/lb1 kNm3 = 35’000 ft3 STP 1 MJ = 950 BTU
OPTIMISATION IS ESSENTIAL !!!
1,0 [GJ] primary fuel 1,2 [GJ] alternative fuel
Priviledged Information not to be copied. All rights reserved.12
REFERENCE PLANT FOTOS (1)
Drum separation plant
Hand sorting creates jobs
Priviledged Information not to be copied. All rights reserved.13
REFERENCE PLANT FOTOS (2)
Plastic Waste arrives in tied bales
Bales on pan conveyor to Stage 1 shredder
Priviledged Information not to be copied. All rights reserved.14
REFERENCE PLANT FOTOS (3)
Heat treatment eliminates bio-hazard
Priviledged Information not to be copied. All rights reserved.15
REFERENCE PLANT FOTOS (4)
Feed chute to RSP combustion chamber
RSP Combustion Chamber
Priviledged Information not to be copied. All rights reserved.16
PLANT DESIGN FOR 80% A.F.
TAD 4
TAD 3
TAD 2TAD 1
Bypass
Quench
Tires < 1,000 mm
MAIN BURNERPlastics, Animal Meal
Fine Coal
< 20 mm
COMBUSTION CHAMBERPlastics, Sewage Sludge, Fine Coal
< 50 mm
CALCINER
MIXING
CHAMBER
RSP-Technology in cooperation with Taiheiyo Engineering
Priviledged Information not to be copied. All rights reserved.17
EXAMPLE ECONOMICS
Income 462‘200 USD
Costs - 466‘800 USD
Clinker production: 51‘500 t
Σ Fuel Cost = 0.09 USD/t clinker
Series1; 258'270
Series1; 88'456
Series1; 64'740 Series1;
49'002 Series1; 3'663
Series1; 2'708
INCOME; 462'246
Fuel COSTS (RED)
coal Supplier A
coal Supplier B
coal Supplier C
petcoke
saw mill waste
wood chips
fuel income
-381'358
-20'529
-19'287
-10'059 -31'013
COSTS; 466'839
Fuel INCOME (BLUE)
mixed plastic
waste plastic pipes
sewage sludge - dry
sewage sludge - non dried
reject paper
fuel costs
18 Priviledged Information not to be copied. All rights reserved.
Please visit www.atec-ltd.com
THANK YOU FOR YOUR
ATTENTION
A TEC AMERICA
11 Poniente No. 2702 Dept. 5
Col. La Paz, 72160 Puebla, MEXICO
Tel.: +52 222 889 7907
E-Mail: [email protected]
Presentation - HURRIVANE/ 1
.09.2009
FICEM-APCAC Cement
Industry Technical
Conference
2009 Bogotá, Colombia
Dipl. Ing. Pedro Montes de Oca
Presentation - HURRIVANE/ 2
.09.2009
1. Introducción – Efectos al tener mayor volumen de gas
2. Tecnología del HURRIVANE
a) Funcionamiento
b) Efectos en torre de precalentador
c) Ejemplo de ahorro
3. Aumento de eficiencia
4. Cementos Progreso Planta San Miguel
a) Instalación Horno 1
b) Instalación Horno 2
Tratando con mas gas de escape
Presentation - HURRIVANE/ 3
.09.2009
1. Introducción –
Efectos del gas
Presentation - HURRIVANE/ 4
.09.2009
Efectos del gas
Más volumen de gas
Más kW en el ID-Fan
Más Costos
Tecnología ATEC para contrarestar estos efectos =
1. INTRODUCTION – ALTERNATIVE FUEL
Presentation - HURRIVANE/ 5
.09.2009
2. HURRIVANE –
Tecnología
Presentation - HURRIVANE/ 6
.09.2009
HURRIVANE Típico
1. Se agrega al tubo de inmersión del ciclón
2. Vanes en dirección del flujo
3. Reducción de la pérdida de presión
a) Reducción de kW ID Fan
b) Reducción Energía Específica
1. INTRODUCTION – ALTERNATIVE FUEL
Presentation - HURRIVANE/ 7
.09.2009
1. INTRODUCTION – ALTERNATIVE FUEL
Sin
HURRIVANE
Con
HURRIVANE
delta
Presión estática [mbar] -72 -68 -4
Gas Temp [°C] 320 320 0
Caudal Gas [Nm3/h] 207’667 207’667 0
Caudal Gas [Am3/h] 538’535 536’260 -2275
N
A
A
N
N
A
T
T
p
p
V
V
Efectos en torre de precalentador:
Reducción de dP menos volumen de gas
La reducción de presión gracias al
HURRIVANE se refleja en el volumen
de gas que tira el ventilador principal
Ejemplo 1: Producción Constante
Presentation - HURRIVANE/ 8
.09.2009
Efectos en torre de precalentador:
Reducción de dP menos aire falso
1. INTRODUCTION – ALTERNATIVE FUEL
sin
HURRIVANE
Con
HURRIVANE
delta
Presión estática[mbar] -72 -68 -4
Cantidad Gas [Am3/h] 538535 536260 -2275
Aire falso [Am3/h] 26927 26816 -114
AAir,
N Air,
N ρΔp2ρ
AkVAir False
La reducción de presión gracias al
HURRIVANE se refleja en la cantidad de aire falso
Ejemplo 1: Producción Constante
Presentation - HURRIVANE/ 9
.09.2009
Efectos en torre de precalentador
Menos ∆P & menor gas → menos kW ID Fan
1. INTRODUCTION – ALTERNATIVE FUEL
Sin
HURRIVANE
Con HURRIVANE delta
Cantidad gas [Am3/kg cli.] 538535 536260 -2275
kW ID Fan 1346 1274 -73
kWh/t cli. 11.54 10.92 -0.62
Energía en ID-Fan -5%
η
ΔPVkW A
La reducción de presión, menor gas y menor aire falso gracias
al HURRIVANE se refleja en un ahorro de energía del 5% en
el ID-Fan
Ejemplo 1: Producción Constante
Presentation - HURRIVANE/ 10
.09.2009
Efectos en torre de precalentador
kW Id Fan = const → Aumento de producción
1. INTRODUCTION – ALTERNATIVE FUEL
Sin
HURRIVANE
Con
HURRIVANE
delta
Gas [Am3/kg cli] 538535 536260 -2275
kW ID Fan 1346 1274 -73
kWh/t cli. 11.54 10.92 -0.62
kWh/t cli. 0.62 0.62 +5%
Ejemplo 2: Aumento de producción
Por lo tanto:
73 kW permiten aumento de producción del 5%
o reducción de kWh/t cli del 5%
Presentation - HURRIVANE/ 11
.09.2009
3. Aumento de eficiencia
Presentation - HURRIVANE/ 12
.09.2009
4. POTENTIAL COST REDUCTION
Cálculo de posibles ahorros
Process Data Plant Data
Gas amount at ID Fan 1.78 [Nm3/kg cli] Clinker Production 2800[t/d]Current T at ID-Fan 320 [°C] Level above Sea 800[m]
dp Stage 2 1500 [Pa] Fuel cons. 3538[kJ/kg cli]
dp with HV 30 [%] Prod. Days/year 321[days]
Static Pressure ID Fan -72 [mbar] Energy costs 0.10[USD/kWh]Cp Gas PH Outlet 1.523 [kJ/Nm³ K]O2 Top Stage 5 [%]ID Fan efficiency 0.8 [-]Temperature top stage 348 [°C]Gas amount at pH Outlet 1.69 [Nm3/kg cli]Pressure top stage -69 [mbar]Temperature water injection 25 [°C]
Presentation - HURRIVANE/ 13
.09.2009
4. POTENTIAL COST REDUCTION
Cálculo de posibles ahorros (2)
SavingsProduction Increase when kW at ID-Fan = const
Pressure drop reduction 450[Pa]
Gas amount at ID Fan 2,745[Am3/h]
kW ID Fan 88[kW]Productionincrease 2.14[t/h]
kWh ID Fan 0.75[kWh/t cli]
Savings kWh 2,106kWh/day
Savings kWh 675,979kWh/year
Savings USD 67,598USD/ year
En este caso la ganancia de 88 kW en el ID-Fan permite:
Un ahorro de 0.75 kWh/ t cli
o un aumento de producción del 2%
Presentation - HURRIVANE/ 14
.09.2009
4. Referencias en
Planta San Miguel de
Cementos Progreso
Presentation - HURRIVANE/ 15
.09.2009
a). Rendimiento constante
Cementos Progreso:
Efectos en horno 1
Delta 0.11 -77.8 -55.96 -93 -65.7 0.0671 1.35
6% ahorro energético específico
Se consumen 66 kW menos en el ventilador
Reducción de caída de presión de 55.96 mm H20
Alimentación
constante kW en
Ventilador
Presentation - HURRIVANE/ 16
.09.2009
2. Aumento de rendimiento.
Esta opción no se ha evaluado debido a nivel de demanda
del mercado, pero si se asume un incremento del 3% como
en horno 2, la mejora esperada sería:
Cementos Progreso: Efectos en horno 1
Alimentación futuro + 2.45 t/h
Consumo específico - 0.62 kWh/t cli
Clinker futuro + 1.49 t/h
Aumento de producción + 3%
Presentation - HURRIVANE/ 17
.09.2009
a) Rendimiento Constante:
1.35 kWh/t clinker menos implica un
ahorro anual de US$ 80,272. (TRT 80%).
b) Aumento 3% Rendimiento:
Este escenario dependerá de la demanda
del mercado y de la ganancia en cada
tonelada vendida
Cementos Progreso:
Ventajas económicas en horno 1
Presentation - HURRIVANE/ 18
.09.2009
Cementos Progreso: Efectos en horno 2
a) Rendimiento constante.
12.4% ahorro energético específico
Delta 0.1 -2.7 -59.6 -193.6 -163 0.04 -2
kWh en
Ventilador
Alimentación
constante
Se consumen 162 kW menos en el ventilador
Reducción de caída de presión de 59.6 mm H20
Presentation - HURRIVANE/ 19
.09.2009
b) Aumento de Rendimiento
Cementos Progreso:
Efectos en horno 2Producción de
clinker
Caída de
presión
Delta 4.2 16.3 47.5 -11.4 16 2.55 -0.3
aumento de producción del 3.2%
Presentation - HURRIVANE/ 20
.09.2009
Cementos Progreso:
Ventajas Económicas horno 2
b) Aumento de
Rendimiento
a) Rendimiento
constante.
Presentation - HURRIVANE/ 21
.09.2009 www.atec-ltd.com
Thank you
for your attention!ENERGY
EFFICIENCY
ENVIRONMENT
A TEC > Dealing with more Chlorine / 11 ATEC/JF: Confidential Information
Dealing with More Chlorine
Tratando con más Cloruro
A TEC > Dealing with more Chlorine / 2
REASONS FOR USING A BYPASS IN THE CEMENT INDUSTRY
Raw meal which have high contents of chlorine,
alkalis and sulphur
Using a high amount of alternative fuels
containing chlorine & sulphur
Build ups and heavy coating in the area of the
kiln riser duct and meal pipe to the kiln
Strict environmental regulations
A TEC > Dealing with more Chlorine / 3
GAS TAKE OFF DUCT
Main Advantages:
Big take off area
Low take off velocity
Particles < 10 µm
• No cyclones needed
• Gas can be used for raw meal
drying to reduce thermal losses
A TEC > Dealing with more Chlorine / 4
QUENCHING CHAMBER
Made completely of metal
(no lining required)
Cooling in 1 step to 200 C
Minimum space requirement
Simple & trustworthy operation
A TEC > Dealing with more Chlorine / 5
STANDARD BYPASS SYSTEM
Comp. Air
A TEC > Dealing with more Chlorine / 6
Coating/Build Up Conditions
original
operation
operation
without bypass
operation with
bypass
A TEC > Dealing with more Chlorine / 7
Bypass Rate Efficiency
5...10 % bypass rate is sufficient for chloride bypass systems
A TEC > Dealing with more Chlorine / 8
A TEC Bypassat
Castle Cement
Bypass Dust Cyclone and Ducting
bypass
cyclone
1st stage
quench
2nd stage
quench
mixed gas
duct to filter
coarse dust
return
A TEC > Dealing with more Chlorine / 9
refractory liningrefractory lining
refractory liningrefractory lining
Design
< 1,5 % Cl in hot meal
Design
< 1,5 % Cl in hot meal
Operating RangeOperating Range
gas from preheatergas from preheater
reserves onto required
design data
reserves onto required
design data
Design Data for GuarantiesDesign Data for Guaranties
CASTLE BYPASS SYSTEM
A TEC > Dealing with more Chlorine / 10
Quench Chamber
Main Shut Off
Damper
Quench Air
Shut Off
Damper
Quench
Chamber
Quench Fan
A TEC > Dealing with more Chlorine / 11
Quench Chamber Emergency Air
Generator starts
on power failure to
run fan to keep
equipment
downstream of
emergency shut
off valve cool
Emergency Fan
A TEC > Dealing with more Chlorine / 12
Bag Filter / Silo Arrangement
Mounted directly on top of 120 m3 (approx 70 ton) Silo.
Sweeping Auger screws dust out to centre discharge
Screw & Rotary Feeder to Loading Head
Wagon loading 30tph
Water Spray on dust at loading head
Discharge capacity 30 t/h
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Bag house
Bypass dust silo
Truck loading
station
Some details:
Mounted directly on top of
120 m3 (approx 70 ton) Silo.
Sweeping Auger screws dust
out to centre discharge
Screw & Rotary Feeder to
Loading Head
Truck loading 30tph
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Silo Discharge
Auger Drive
Auger Rotation
Shutoff Slide
Rotary Feeder
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Loading Spout
Water Sprays on Loading
Head to control dust
Dust from Bag Filter goes to
Quarry
Alternative uses for dust
such as washing out chloride
& reusing dust currently
under examination
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Performance Test Result
• Cl in bypass dust 14%
• Cl in dust return to hot meal chutes 3.5%
• Cl in raw materials 0.0083%, clinker basis
• Gas flow at kiln inlet approx. 80,000 Nm3/hr
• Bypass % of gas flow at kiln inlet 8 %
• Dust in gas at input to quench chamber 0.25 kg/Nm3
• Dust to quench chamber 38 te/day
• Dust out of quench chamber (including KCl) 45 te/day
• Dust to waste 22.5 te/day
• Dust return to hot meal chute 22.5 te/day
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Operational Results Today
Operation Period since start up: 30 months
Total unscheduled maintenance: insignificant
Total bypass dust saved from depositing: approx. 20‘000 tons
Total waste utilised for alternative fuel: approx. 165‘000 tons
Chloride in bypass dust: average 12% to 16%
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11 Poniente No. 2702 Dept. 5
Col. La Paz, 72160 Puebla, MEXICO
Tel.: +52 222 889 7907
E-Mail: [email protected]