Copy of AFR Profile 2003 Guidelines

8/11/2019 Copy of AFR Profile 2003 Guidelines

1/13

AFR Profile 2002 - Guidelines (Version 01.06.2002)

last update: April 8, 2002

GUIDELINES FOR PREPARATION OF THE "Holcim" AFR PROFILE FOR CEMENT PLANTS

RICHTLINIEN ZUR ERSTELLUNG DES "Holcim" AFR PROFILS FR ZEMENTWERKE

DIRECTRICES PARA LA CONFECCION DEL PERFIL AFR DE PLANTAS DE CEMENTOS "Holcim"

DIRECTIVES POUR LA REDACTION DU PROFIL AFR DES USINES "Holcim"

2014

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ATR2001

2

SF

IL

OL

SL

342 ff

2.2

This report should be completed asaccurately as possible for each calendar year

and sent to HGRS/CTS not later than the

30th January of the following year. It is

imperative to use the Questionnaire, supplied

by HGRS/CTS as an EXCEL-file. Please

return the Questionnaire via Lotus Notes or

Internet to the email address

[email protected]

By using the supplied EXCEL-file, pleasetake note of these general remarks:

General

The bluemarked parts of the spreadsheetcontain data retrieved from the ATR

The yellowmarked parts of the spreadsheetcontain data not part of the ATR

1. ATR Questionnaire (complete file)

Section 2: specific information per kiln line

- Precalciners

2.1

Classification of precalciners:

Type of precalciner as installed. If there is no

precalciner installed, then write NA in the cell.

Espaol

General Remarks Allgemeine Bemerkungen Remarques gnrales

English Deutsch Franais

Observaciones generales

secondary firing calciners (no

tertiary air duct)

Fuel allocation in calciner for each kiln line as % of

heat consumption for clinker production:

The sum of all fuels attributed "PC" in the ATR

lines 241 - 265

(Pre-) Combustion Chambers are small cyclone-

like vessels, protected with a meal curtain at the

wall, where the calciner fuel is ignited in pure

tertiary air (e.g. Polysius CC-Chamber, RSP-

calciner).

2. Equipment for Clinker Burning

in-line (kiln gas through calciner)

off-line (only tertiary air incalciner, but kiln and calciner gas

merge after calciner)

separate-line (two strings, one for

kiln gas, one for calciner gas)

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ATR2001 EspaolEnglish Deutsch Franais

2.3

136

2.4

226

2.5

Supplier

Pillard

Pillard

FLS

FLS

KHD

Unitherm

Greco Greco

Gross CKD production = amount of dust collected

in the exhaust filter, bypass, fall-through kiln seal &

LEPOL grate, etc. expressed as percentage of the

clinker production (during the production of the

predominant type of clinker). This applies for all

types of kilns. Dust recirculated to the kiln system

is included in this calculation.

Net CKD production = amount of dust collected

and removed from the kiln system as a percentage

of the clinker production (during the production of

the predominant type of clinker). This applies for

all types of kilns. Dust recirculated to the kiln

system is notincluded in this calculation.

Installed calciner volume (inside refracrtory),

defined as follows:From above the restriction (throat) near kiln inlet

and from the inlet of the tertiary air (e.g. off line

calciner) until the inlet to the cyclone, including pre-

combustion chambers.

Product name of the main burner installed.

- Bypass & CKD

PyroJet

Mono-Airduct-System (M.A.S.)

Productname(to be given)

Rotaflam (coal -radial air -axial air)

3-Channel (radial air -coal -axial air)

Duoflex

Centrax

CKD dumped = amount of dust removed from the

kiln system, not used in products, not sold etc. but

discarded in land filling or by other means

expressed as a percentage of the clinker

production (during the production of the

predominant type of clinker). This applies for all

types of kilns.

Kiln bypass gas percentage = amount of bypass

gas, as a percentage of total kiln gas quantity at

kiln inlet during production of the predominant type

of clinker. This applies only for DG, DS and PC

kilns. If there is no bypass then write N/A in thecell.

2.6

- Main Burners

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2.7

2.8

Type(to begiven)

EF

BF-R

BF-PJ-low

BF-PJ-high

MC

GF

HY

SNCR

SCR

Lime-Inj

Lime-Add

Bicar-Inj

Scrub-wet

Scrub-semi

Scrub-dry

ACF

ACI

FA

CFBA

RTO

2.9

Type of kiln gas dedusting (filter), indicated withone of the following abbreviations:

Bag Filter (Pulse Jet, high

pressure)

Multicyclone

Gravel Bed Filter

Electro-Filter

Bag Filter (Reverse Gas)

Bag Filter (Pulse Jet, low

pressure)

Description

Installednominal capacity of primary air fanin

Nm3/h. For burners with separate blowers andventilators for axial and radial air, the sum of both

units is asked for. Transport air blowers of any

kinds are excluded.

Installednominal pressure of primary air faninmbar. For burners with separate blowers and

ventilators for axial and radial air, the nominal

pressure of the axial air blower is asked for.

Electro & Bag Filter (Hybrid)

- Exhaust Gas Cleaning

Regenerative Thermal Oxidizer

Circulating Fluidized Bed

Absorber

SO2-Scrubber (dry)

Activated Carbon Filter

Activated Carbon Injection

Fluegas Absorber

SO2-Scrubber (wet)

SO2-Scrubber (semi-dry)

Slaked Lime Injection for SO2

reduction

Slaked Lime Addition for SO2

reduction

Selective Catalytic Reaction for

NOx reduction

Natrium Bicarbonate Injection for

SO2 reduction

Selective Non Catalytic Reaction

for NOx reduction

2.10

Indicate the installed type of kiln gas cleaning

system, if no such system is available type NA.

Classification of systems:

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RCO

3.1 - 3.2

SP/PC kilns

LEPOl kilns

long dry / wet

kilns

3.3 - 3.7

Average LEPOL fall-through dust

(LOI, SO3, K2O, Na2O, Cl)

Average hot meal analysis (LOI,

SO3, K2O, Na2O, Cl)

Average filter dust analysis (LOI,

SO3, K2O, Na2O, Cl)

- Process Data

Information relevant for Chlorine and Sulfur flows.

Average can be average of spot samples or

composite samples during production of normal

clinker and stable operation.

Indicate the average kiln gas composition (O2, CO)

at the kiln inlet, measured with the kiln inlet gas

probe during normal operation. The tip of the probe

must reach into the rotating part of the k iln and

must notbe close to the kiln seal.

3. Key Operating Data (ATR and process data)

Regenerative Catalytic Oxidizer

Precalcined Material Addition

others...

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5, 35, 112, 315

7,114

Raw Material

Fuel

ls

g

v

p

m

4.3

at feed point

as fired

Moisture content of the raw

materials, when dumped into thefirst crusher or unloading hopper

(in case these values should not

be measured periodically, one

can indicate approximate mean

values and estimated

minimum/maximum values)

Moisture content of preparedfuels (e.g. ground coal, sludge's

after co-grinding) as present in

the firing system for kiln and

precalciner.

substituting traditional fuels (AF)

Moisture as received at the plant gate, given as

weight percentage of the wet material

What is the substitution purpose of the material

4. AFR Properties relevant for Process

4.1

4.4

substituting raw materials (AR)

Classification of possibilities:

Industry of origin of industrial material. For biofuels

(e.g. rice husks, pea nut shells, etc) industry of

origin is "agriculture"

Locally used name of the product

viscous: high viscosity but no

solids content, normally reduced

by heating the material4.2

liquid state

muddy: liquified mix of fine solids

with liquid, pumpable (e.g. slurry,

wet sludge)

gaseous state

Physical state of the material:

solid state

pasty material, mix of fine solids

with some liquid (e.g. concrete,

sludge), pumpaple only with

pumps similar to concrete pumps

Moisture given as weight percentage of the

material as present at the respective location.

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4.5 - 4.17

4.18

4.19

4.20

4.21

1 kp*s/m2

1 kp*h/m2

1 g/cm*s

1 lb/(ft*hr)

1 kg/(ft*hr)

1 lb/(ft*s)

4.23

5

5.1

5.2

= 0.41338 cP

= 1488.2 cP

= 100 cP

= 0.91134 cP

Solids contents of the AFR, expressed in % weight

fraction of dry solids per total weight of liquid asfired.

Section 5: specific information per AFRinstallation. This section refers to each individualinstallation for handling and feeding of AFR. Later

in section 7, for each type of AFR the assigned

handling installation is identified. Section 5 asks

from the installation point of view, and NOTfromthe AFR stream point of view.

pH value as fired

Dynamic viscosity at feed temperature in cP

[centi Poise = 0.01 g/(cm*s) = 0.001 kg/(m*s)]

- liquid, visquous, pasty & muddy Alternative Fuels

Transformation of dynamic viscosity units into cP

Bulk density of solid AFR as delivered. It issufficient to give the figures as on the truck: "tons

loaded divided by volume of the truck load"

Local name and HAC code of the installations for

AFR handling, storage and feeding.

The total storage capacity of the equipment,

including reception storage, intermediate storage

of pretreatment (if available) and storage of the

feeding installation (e.g. feed bin) in metric tons.

Indicate the mean chemical composition of the rawmaterials, as well as that of fuel ash and the ash of

other materials used in the burning process.

Concentrations are based on dry material, ash on

loss free basis.

Give the maximum particle size of the solid AF in

mm. For AF prepared in a mill, give % residue on

200mm sieve as follows: R200 = ...%

Temperature of the liquid close to the burner

- Raw Material and Ash Composition

- solid Alternative Fuels

- AFR installation

4.22

= 9806.65 cP

5. AFR Installations, Handling and Feeding

= 0.3532 cP

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5.3

Class

activated floor

mechanicalconveyor

loader / crane

pump

Class

volumetric flow

mass flow

mass flow

mass flow

mass flow

mass flow

mass flowmass flow

Classmechanical

transport

pneumatic

transport

liquid, sludge

transport

Poldos

e.g. front loader, automated

crane

Example of dosing equipment

weighing screw

Type(to be given & supplier)5.6

Example of transport equipment

e.g. redler, belt conveyor, ..

e.g. centrifugal pump, concrete

pump

rotary valve

more....

belt scale

rotating disk feeder

Equipment used for flow control of the AFR.

Provide the specific type and add the suppliers

name.

5.5

Type(to be given & supplier)

apron feeder

loss in weight measurement

5.4 e.g. screw, apron feeder

Examples of storage extraction equipment:

Main equipment used to transport the material to

the mill or the kiln. Provide the specific type and

add the suppliers name.

Main equipment used for storage extraction.

Provide the specific type and add the suppliers

name.

e.g. walking floor

Type(to be given & supplier)

The designedmaximum feed rate of the equip-

ment in t/h. Note the difference between the designfeed rate and the feed rate during normal

operation.

e.g. centrifugal pump, screw

pump

pneumatic transport

coriolis flow meter

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CR

PB

RM

SEP

KF

HM

MF

SFPC

MidK

C

more....

feed hopper

feed shute

bucket elevator

feed bin

cyclone

hot meal duct

raiser duct

kiln inlet

calciner bottom

Clinker Cooler

near restiction

introduction into the lowest hot

meal duct (feeding into kiln inlet)

of the preheater

introduction into cyclones, e.g.

raw mill dedusting or preheater

cyclones

introduction into the bucketelevator, e.g. bucket elevator of

mill separator or of kiln feed

main feed hopper for crusher,

mills, etc

5.8

Classification of locations:

direct introduction into the feed

shute (e.g. raw mill), bypassing

the main feed hopper.

introduction into the feed bin of

existing dosing equipment, e.g. of

raw meal additives or kiln feed

Mid kiln

Precalciner

Main firing

Hot meal

Kiln feed

Raw mill

5.7

Classification of main feed points:

Pre-blending bed

Raw mill separator

Exact location of the feed point mentionned in 5.7

from the equipment point of view.

In case that below pre-defined locations do not

match the respective situation, enter your ownlocation into the questionnaire and provide

explanation by adding a comment to the cell

Secondary firing

Raw material crusher

introduction into the raiser duct

Feed point of the material from the process point

of view.

introduction into the kiln inlet

chamber

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calciner top

hot spot

teriary air duct

pre-combustion

chamber

flame center

on top of burner

kiln hood

more....

dumping

actuated gate

rotary valve

pneumatic

mechanic

controlled hot spot near thecalciner bottom (requires two

feed points of the meal, control-

led by an activated splitter gate)

injection into the TA duct

near cyclone

5.9

Used method to move, transport, force or let pass

the material into the process.

Classification of possible injection methods:

applicable only, where there is no

further mechanism between the

material discharge and the target

location (e.g. truck dis-charge

into feed hopper). Dumping into

the kiln would require an open

door without any air lock.

applicable only if the rotary valve

discharges directly to the target

location (e.g. rotary valve

dischages onto the feed shute of

the raw mill). If another transport

follows the valve (e.g. a

pneumatic transport or a belt),

then see below "pneumatic" or"mechanic"

actuated gates (singe, double,

tripple) are normally used forlump or coarse material at mills

or kiln preheater

pneumatic transport with open

end to the target location

mechanic transport with open

end to the target location

(normally feed circuits for liquids

or sludgy and viscous products)

see explanation to 2.2

injection through a pipe which is

fixed on top of the main burner

injection into the secondary air at

the kiln hood/cooler hood.

injection through the burner

central axis into the flame center

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more....

5.10

5.11

5.12

e.g. 25 m/s

"free fall"

"N/A"

more....

none

mechanical

air

steam

more....

5.14

The used method for atomizing liquids and sludgy

or viscous products is asked

liquids are merely pumped intothe system with an open end of

the circuit

atomization with air in dual or

multi-fluid nozzles (generally

used for solvents)

Classification of atomization methods:

Not Applicable when using

atomizers for liquids

5.13

Injection velocity based on the equipment design

Classification of options:

calculated velocity, expressed in

meters per second, for pneumatic

transports

"free fall" describes all those

applications where the injection

velocity is governed by gravity

Designed fuel load in transport air expressed in kg

fuel per Nm3transport air. The number is

calculated automatically in the spreadsheet by

dividing line 5.3 by line 5.11

Type "yes" or "no"

Designedair flow, espressed in Nm3/h, forpneumatic injection systems identified in 5.9

- AF Injection & Atomization

mechanical atomization applies

for all single-fluid nozzles working

at high pressures (e.g. water

sprays in conditionning towers or

heavy oil atomizers)

atomization with steam in dual or

multi-fluid nozzles (a variant of air

nozzles, also used for high

viscosity oil atomization)

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ATR2001 Espa olEnglish Deutsch Franais

5.15

6.1 - 6.26

6.27 - 6.30

7.1 - 7.10

7.11

7.13

7.14

6. AFR Properties relevant for Environment

The maximum sustainable feed rate in tons per

hour of the material (regardless of the reason) is

asked for during stable process conditions. For

alternative raw materials, type "N/A".

Describe all set point changes compared to

operation without this particular AFR that are

necessary to maintain correct operation (e.g. LSF

+2%, O2kiln inlet +1.5%, kiln feed - 2t/h)

Normal operating pressure of atomizers for liquidsand sludgy or viscous products. For dual fluid

nozzles give the pressure of the auxiliary media

(air or steam).

- Experiences with AFR materials

For each AFR, the name or HAC-code of the

installation (from line 5.1) handling and feeding the

material is asked for.

7. Combustion, Impacts and Limits of AFR / Experience- Process limits as defined by the plant

For each kiln line, the locally defined process limits

for the use of AFR's are asked for. The defaultsubjects (e.g. chlorine limit) are only hints. The

plant is asked to provide its own process relatedcriterias and limits (see default subjects, e.g. feed

rate limits due to unsufficient storage capacity or

logistics is NOTprocess related and especiallyasked for in 7.15).

Classification of the materials according to

- physico-chemical properties

- hazards classification

- toxicological properties

- selected other characteristics

The mean concentration of the respective

elements/substances in alternative fuels and raw

materials, refered to the condition as received

(= on wet basis as received).

- Organic Compounds, Halogenes & Heavy Metals

- Hazards Identification

7.12

For alternative fuels: give all kiln numbers, in which

the fuel is actually burned (e.g. #1 & #3)

For alternative raw materials: give all names of the

different raw mixes in which the respective AR is

used (e.g. "normal", "sulfur resistant").

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AFR market

logistics

on site storage

handling

feeding

installation

process (e. g.

CO formation)

emissions

permit

more....

7.16 - 7.19

7.15

The main limiting factor governing the use of each

AFR.In case that below pre-defined factors do not

match the respective situation, enter your own

words into the questionnaire and provide

explanation by adding a comment to the cell

Classification of possible limiting factors:

AFR feeding installation running

at maximum rate (e.g. manual

feed of tires)

uncertain intervalls of delivery

forcing to reduce the rate in ordernot to run out of material

limited availability of the product

on the market

Describe in your words specific experiences made

with each product in the fields of

- handling and dosing

- equipment operation (kiln, mill , crusher, ..)

- quality of products (clinker, cement)

- emissions

limited on-site storage capacity

forcing to reduce the rate

between delivery (e.g. on

weekends)

process reasons / limits (as

defined in 7.1 - 7.10)

permit dictating the feed rate

emission values limiting the feed

rate of AFR (e.g. organic content

in AR, increased SO2 emissions

in wet plants for combustion

reasons)

limited feed rate due to handling

or transport difficulties (e.g. sticky

material, blockage of pneumatic

transports)

Page 13 of 13

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