visite lx alf-cemind
TRANSCRIPT
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LIXHE PLANTLIXHE PLANTALF-CEMIND study tour 29 Augustus 2007g
B. GastoutPlant ManagerPlant Manager
Benelux 1
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Lixhe Plant - Overview
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Clinker Historical
1950 First the plant in Loën (kiln A&B)1960 kiln C VH - stopped in 19921967 kiln D – 1800T/d WL – stopped in 20011976 kiln E – 3500T/d DL2001 Modernization Kiln E Design 4200T/dA t l li k itActual clinker capacity : – Average 4400T/d (achieved in 2005: 4394T/d)– BDP 4630T/dBDP 4630T/d
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Lixhe plant location
Romont Quarry
Underground
Con e or BeltQuarry Conveyor Belt
2.2Km
LIXHE Plant
Loen Quarry
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Lixhe Clinker Data
Clinker productionWet line Kiln D: 500 000 Tons/y (stop 2001)– Wet line Kiln D: 500,000 Tons/y (stop 2001)
– Dry line Kiln E: Build 1974 - 1,100,000 Tons/yModif 2000 – 1,400,400 Tons/y
Clinker storage2 Sil 45 95 kT– 2 Silos: 45 + 95 kT
– Halls: 40kT + 20kTQuality:Quality:– C3S: 66.6% C2S: 11.7% C3A: 6.9%– Sat: 96.75% M.Si: 2.58 M.Al: 1.38– Free CaO: 0.3% Eq Na: 0.67% SO3: 0.6%
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Mineral substitution in clinker
Substitution of Al, Fe, Si oxyde by secondary , , y y ymaterials :– Waste from steel industry (Fe, Si)– Fly Ash (Si, Al)– Shales (Al)
Blast furnace Slag (Si Ca Al)– Blast furnace Slag (Si, Ca, Al)– Sludge from water treatment (Al)– …
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Mineral substitution 2 750 000 tons2.750.000 tons
Secondary Gypsum2% Special clinkers2%
Water treatment sludge
Chalk and marl68%
2%
Bl t f l
Misc.2%Secondary
Materials
Fly ash7%
Blast furnace slag16%
Iron by-products1%
Natural gypsum
7%
Silt2%
Natural gypsum0%
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Secondary Fuels
Process Caracteristics :High Temperatureg pOxydizing conditions– Necessary for clinker production
High residence time
No waste, no ash !Ashes contribute to clinker formation– Ashes contribute to clinker formation
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Implementation of a calciner and full revamping of the preheater
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Calciner arrangement
LOOP DUCTLOOP DUCTCONNECTING CONNECTING ARRANGEMENTARRANGEMENT
MINOX DUCTMINOX DUCT
SWIRLSWIRL BURNERBURNER
MIXING MIXING CHAMBERCHAMBER
SWIRL CALCINERSWIRL CALCINER
TERTIARY AIR DUCTTERTIARY AIR DUCT
Benelux 10
KILN GASESKILN GASES
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Lansink Scale
Preventing wastePreventing waste production
li h dRecycling the product
Recycling the materialy g
Incineration with heat recoveryrecovery
Incineration without In only one operation,heat recovery
Dump site
y p ,
Without any secondary waste !
Benelux 11
Dump site
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The Kiln
Precalciner :Impregnated saw dustTextile pellets Main burner :
I d dp
Shredded oil filtersPolluted soilsMisc.
Impregnated saw dustAnimal mealLiquid wastesPolluted water
Kiln Inlet :Whole tires
Polluted water
Dewatered sludge
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Secondary FuelSubstitution ratio (energy %)
Substitution rate evolution
OP200660%
Substitution rate evolution
40%
50%
20%
30%
10%
20%
0%1993 1995 1997 1999 2001 2003 2005 F2006
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Mix fuel 2006 Total fuel substitution rate : 53.3%
Hazardous fuel substitution rate : 28.3%
Waste liquids0.7%
Mix Coal45.6%
Shredded oil filters2.4%
Gaz
Tires7.8%
Impregnated saw dust25.2%
1.1%
Dewatered sludge0 7%
Animal meals13.6%
Textile pellets2.7%
0.7%Dry Step
0.3%
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Secondary Fuels
Main burner 55% of the heat– Fine solid fuels (<2mm) or liquidFine solid fuels (<2mm) or liquid– High heat value
⇒Impregnated saw dust⇒Animal meal⇒Solvents - Oil⇒…⇒…
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Main Burner
Multi-channel burner designed for secondary fuels (PILLARD)
Benelux 16
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Main burner : animal meals
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Main burner : liquids
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Main burner : resofuel
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Secondary Fuels
Précalcinateur 35% of the heatC f l OK ( 3 )– Coarser fuels OK (<3cm)
– Low heat value OK⇒Impregnated saw dust⇒Impregnated saw dust⇒Filtration earth⇒Plastic, RDF
P ll t d il (“ êté l”)⇒Polluted soil (“arrêté sol”)⇒Dry sewage sludge⇒Paper sludge⇒Meals, seeds,…⇒…
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Precalciner (TECHNIP)
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Precalciner : resofuel and plastics
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Secondary Fuels
Kiln Inlet 10% of the heat– Bulky FuelsBulky Fuels
⇒Whole tires – Dewatered Sludge : pumping of pasty sludge;
d i d i i ti i hdrying and incineration in one phase⇒Urban Sewage Sludge
– Limited flow (kiln unstability)Limited flow (kiln unstability)
Benelux 23
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Kiln inlet : tyres
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Kiln inlet : dewatered sludge
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injection of injection of Dewatered sludgesDewatered sludgesDewatered sludgesDewatered sludges
in clinker kilnin clinker kiln
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Definition
Dewatered Sludge= Residuary sludge coming from water g y g gtreatment from urban and industrialForm:– humid (80% H2O)– semi dry (60% H2O)
dry (20% H2O)– dry (20% H2O)Don’t mix with dredging sludge !!!
Benelux 27
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Technical Data
%H2O % 65-75Vol %/dry 60-65Ash %/dry 35-30PCS GJ/d 15 16PCS GJ/dry 15-16Ash composition (on dry basis)SiO2 % 5-10 Pb ppm 1000SiO2 % 5-10 Pb ppm 1000Al2O3 % 1-6 Sb ppm 200-2000Fe2O3 % 1-6 Ti ppm 5-10.000ppCaO % 2-10 Zn ppm <10.000P2O5 % 1-5 Hg ppm <1
PCI: ~2 GJ/TbrutNB: ppm = 1 gr for 1000 kg
Benelux 28
NB: ppm = 1 gr for 1000 kg
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Minor elementsLimite
sur MB Permis agricultureH2O Humidité % 80 sur sec sur sec
Boue STEP
Cl Chlore % < 2 0,2 1,0S Souffre % < 3 0,4 2,0
F+Br+I autres allogènes ppm < 2000 0g pp
Sb Étain ppm < 200 0As Arsenic ppm < 200 0Cd Cadmium ppm < 70 0 < 10Cr Chrome ppm < 1000 0 < 500Co Cobalt ppm < 200 10 50Cu Cuivre ppm < 1000 6 30 < 600Sn Étain ppm < 1000 28 140Mn Manganèse ppm < 2000 200 1.000Hg Mercure ppm < 3 0,2 1 < 10g ,Ni Nickel ppm < 1000 4,0 20 < 100Pb Plomb ppm < 1000 14,0 70 < 500Tl Thallium ppm < 10 0,0
Benelux 29
V Valadium ppm < 1000 12,2 61Zn Zinc ppm < 5000 230 1.150 < 2000
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Installation Lixhe
ompe àPompe à ���� � S �����
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Pilot InstallationP S h iPompe Schwing KPS12
Trémie 10m3
Stockage 100m3
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New installation
Unloading cover hoper 30m³Storage silo 500m³Storage silo 500m³Handling by screwSludge pomp: 1 – 7 T/hSludge pomp: 1 – 7 T/h Investment:
– For CBR: 150.000 € (Civil Work)S 800 000 € ( 1 €/ C– For SoTraEx: 800.000 € (contract phi 15€/T charged to CBR cover the
utilization incl. maintenance – exploitation, breakdown service by CBR)– Savings: 1M€/year (35kT/y at 45-15€/T)
Planning:Planning: – Erection: October à December 04– Electrical erection and programming : January 05
C i i i F b 05– Commissioning: February 05
Benelux 32
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Flow sheet
Benelux 33
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Flow sheet
Benelux 34
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Installation industrielle
Silo stockage 500m³
Trémie de réception 30m²réception 30m²
avec vis d’évacuation
Pompe à boue Schwing
Benelux 35
Fosse de déchargement
Vis d’extraction sous silo Vis de gavage
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Layout
Pompe Fosse
déchargement pSchwing
Trémie exterieur vers pompe
déc a ge e t1 + 1 réserve
Cit
Silo stockage
vers pompeCiterne eau
stockage boue
Boxe stockage ext – alim par
Benelux 36
chargeur
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Constraints and Limitations
Technical
EnvironmentalEconomical
EnvironmentalValorization
SafetyLegal S e yLegal
Benelux 37
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Environnement 2006
56 81
High 8 Nbr 9Avg 7
32 3011 9530 (50 4) 2T l d
Permit limitEmissionWID limit 1Pollutant, mg/Nm3
dioxin&furan ng/Nm3
56 81
High 8 Nbr 9Avg 7
32 3011 9530 (50 4) 2T l d
Permit limitEmissionWID limit 1Pollutant, mg/Nm3
dioxin&furan ng/Nm3
0.17
1.65
56.81
0
0
32
20.031 2HF
150.0810 2HCl
3011.9530 (50 4) 2Total dust
0.17
1.65
56.81
0
0
32
20.031 2HF
150.0810 2HCl
3011.9530 (50 4) 2Total dust
1120.1060.0440,05 3Hg (our analyser): MES
1125 8
0.050,05 3Cd+Tl
800560800 (1200 5) 2NOX
1120.1060.0440,05 3Hg (our analyser): MES
1125 8
0.050,05 3Cd+Tl
800560800 (1200 5) 2NOX
,
10,5 3Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V
0.050,05 3Hg
,
10,5 3Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V
0.050,05 3Hg
3078 627 7TOC recalculate
45.2 0 2504.250 2 6SO2
0.10,1 3Dioxins & furans
3078 627 7TOC recalculate
45.2 0 2504.250 2 6SO2
0.10,1 3Dioxins & furans
3078.627.7TOC recalculate
1221 2 1000346By authority 2CO
3078.627.7TOC recalculate
1221 2 1000346By authority 2CO
Benelux 38
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Kiln and preheater tower
Benelux 39