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Utilization of fluff: from reception to burner
Höver Plant, Germany
39th Cement Manufacturing Conference 2006
Klaus Eichas
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Index
Waste market survey
Kiln system
Fluff project survey costs
equipment specifications Quality impact
Overall results
Messages
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Industrial waste regional availability for recovery Comments
Waste market survey
Market volume (‘000t)
3 081
384
111
397
304
380
475
188
310
1 267
1 031
435
908
147675
367
Markets within ~300 km around
the plants offer enough volume
for fluff production
Due to the extremely high
volumes of 3 Mio. t NRW may
have a positive price effect on
Hoever market area
Waste spread within the total on
average:
50 % industrial waste
20 % production residue
30 % construction waste
Laegerdorf market area
Hoever market area
Holcim
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
What is fluff ?
Fluff = shredded
and classified
industrial and
municipal waste
particle size
< 30 mm
net calorific value
21 – 24 MJ/kg
Chlorine < 1 %
residual moisture
content < 15 %
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Industr ial waste for co-processing in the cement industry – payment by the suppliers
price range:
€/t
Estimated Price and Volume
5 -10
2004 2005 2006 2007 2008 2009
price dumpingby landfills
10 -15 20 -30price development linked to
incineration prices25 -35
the volume available for recovery
increases by 40% between 2000
and 2006
4 main outputs for fluff
cement
power plants using steam coa
power plants using lignite
incineration
0
2'000'000
4'000'000
6'000'000
8'000'000
10'000'000
12'000'000
1995 2000 Expectation
2006
Expectation
2012
Construction and demolition waste
Production residuesIndustrial waste
5 966 600
7 523 500
10 460 50010 695 600
change in German landfill directive
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Index
Waste market survey
Kiln system
Fluff project
survey costs
equipment specifications Quality impact
Overall results
Messages
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
KHD-Kiln with planetary cooler and 4 stage preheater
main burner:
- lignite (coal)
- animal meal
- fluff (shredded plastics)
kiln inlet:
- waste tires
- filter cake (AR)
- satellite cooler (10 cooler tubes 2,2 m x 22 m)
- rotary kiln 5,4 m x 80 m
- 4-stage preheater
- BDP 2850 t/d
- spec. heat consumption 3460 kJ/kgKlinker
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Index
Waste market survey
Kiln system
Fluff project
survey costs
equipment specifications Quality impact
Overall results
Messages
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Project survey
The objective was to burn solid alternative fuels like fluff
at the main burner up to 8 t/h
the average throughput at the moment is 9,5 t/h commissioning: October 2003
CAPEX: 3,3 Mio €
pay back: 1,8 years
TSR (2006) 68 %
TEE (2006) 85 %
annual savings today: 5,7 Mio €/a
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Flow sheet: fluff handling system
Storage capacity3.600 m³ / 700 t fluff
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Storage hall
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Automatic crane
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Index
Waste market survey
Kiln system
Fluff project survey costs
equipment specifications Quality impact
Overall results
Messages
Th l f th CEM I 52 5 h th t th 1 d
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
The example of the CEM I 52.5 shows that the 1 day
compressive strength deteriorated over the last years
22
23
24
2526
27
28
29
30
31
32
1997 1998 1999 2000 2001 2002 2003 2004 2005
1 d a y s
t r e n g t h N / m
m ²
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
s u p h a
t i z a t i o n g r a d e
1 day strength sulphatization grade
Lo n g - t e r m t r e n d
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Avoid double flame
Decreasing grade of sulphatization by long main flame
Double flame was created by using lignite (brown coal) and fluff
This has to be avoided by right burner settings and adequate
waste fuels like solvents or fossil fuels like steam coal
Burner t ip
Burner
3.5 m
unstable
coating
7.5 m
stable
coating
30 m
stable
coating
Burner t ip
Burner
3.5 m
unstable
coating
7.5 m
stable
coating
30 m
stable
coating
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Index
Waste market survey
Kiln system
Fluff project survey costs
equipment specifications Quality impact
Overall results
Messages
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
0.0
10.0
20.0
30.0
40.0
50.0
60.0
s u
b s t i t u t i o n
r a t e
%
black carbon 0.0 0.0 1.5 0.8 0.0 0.0
animal meal 0.0 8.4 18.1 9.5 4.0 1.4
fluff 0.0 0.0 4.8 11.6 31.5 44.5
waste tires 6.8 5.7 1.8 4.8 5.9 6.3
2000 2001 2002 2003 2004 2005
Step change in use of AFR 2000 - 2005
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
The fluff installation at the plant works very successful
and reliable with an average throughput of 9,5 t/h
The kiln has a BDP of 2850 t/h and works now at a rate
of 2450 t/h
The maximum applicable throughput of fluff without
creating clinker reactivity problems is to be found yet.
Optimization measures are in progress.
The GAV is 5.7 Mio. in 2006
Overall results
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Index
Waste market survey
Kiln and burner
Fluff project survey costs
equipment specifications Quality impact
Overall results
Messages
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Messages
Waste markets around the plant must offer enough
volume.
The fluff quality must fulfill all quality requirements.
The installation for using fluff has to be very reliable.
Appropriate safety installations are necessary !!!
High momentum main burner is a prerequisite.
Fluff in conjunction with lignite leads to poor burning
conditions with negative impact on the clinker rectivity.
The kiln performance is decreasing by 10 – 15% with a
TSR > 50%.
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39th Cement Manufacturing Conference 2006 21.09.2006/KEiHolcim (Deutschland) AG
Annex
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High momentum burner
animal meal
oil,
waste oil ,add. waste
liquids or
solids
ignition
lance
fluff
coal
swirl air
axial air
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Equipment specification
The plant covers a closed storage hall with truck tippingplace, automatic grab-crane, dosing box, weighing belt,
dedusting filter and conveying system to the kiln burner.
designed throughput: 1,0 - 8,0 t/h
bulk density fluff: 0,1 - 0,2 t/m³
closed storage hall: length 40 mwidth 18 m
height 18 m
storage capacity: 3.600 m³ / 700 t fluff
2 truck tipping places
explosion protected dedusting filter: 50.000 m³/h
activated carbon smell filter
fire protection system
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Crane specification
automatic crane with hydraulic grab load-carrying capacity: 11,0 t
grab capacity: 8,0 m³
grab weight: 4,7 t automatic evacuation of the trucks tipping-place
automatic feeding into the dosing box
automatic material relocation/blending
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Feeder specification
dosing box (installation of a 2nd box in Oct. 2004) capacity: 35,0 m³
bottom: 4 speed adjustable screws, diameter 630 mm
1 collector screw, speed adjustable, diameter 800 mm radar level switch
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Equipment specification
2 Debris screens wide x length 1.200 x 2.500 mm
screen
- feeding area: rods, distance 60 mm- other: Mesh 70 mm
2 Weighing belts
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Conveyor specification
conveyor to burner platform length 67,0 m
belt width 800 mm
rotary feeder diameter 630 mm
pneumatic transport
pipeline length 50 m
Impact on quality: At Höver plant the increasing TSR goes
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p q y p g g
along with decreasing early strength behavior
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1997 1998 1999 2000 2001 2002 2003 2004 2005
N / m
m ²
1 day strength development CEM I 52,5R
Note: at the moment Höver is carrying out a comprehensive quality
improvement program; The maximum applicable throughput of fluff withoutcreating clinker reactivity problems is to be found yet by the ongoing
optimization measures.
0.0
20.0
40.0
60.0
s u b s t i t u t i o n r a t e
%
black carbon 0.0 0.0 1.5 0.8 0.0 0.0
animal meal 0.0 8.4 18.1 9.5 4.0 1.4
fluff 0.0 0.0 4.8 11.6 31.5 44.5
waste tires 6.8 5.7 1.8 4.8 5.9 6.3
2000 2001 2002 2003 2004 2005