Enhancing Alternate Fuel in Cement Manufacturing Process :

A Sustainable Technological approach

13th Green Cementech 11th - 12th May 2017

Balesh Kumar Singh
Content

Introduction
AFR : Today‘s Demand and Challenges
KHD Pyro Equipment for Burning AFR – PYROCLON® Calciner
KHD Pyro Equipment for Burning AFR – PYROJET® Kiln Burner

AFR : Alternative Raw materials

AFR : KHD‘s References [India]

Conclusion
 Introduction
Alternative Fuels and Raw Materials-Introduction
Indian Cement Industry is on 350 MTPA mark with more than 190 Large Plants and 350 small
units.

Cement Despatch remains as consistent always except few slow-downs which gives thrust to
cost competitiveness and subsequently innovative reforms.

Indian Cement Industry is operating at Lowest Specific Heat consumption of Average 725 Kcal/
kgcl against world Average 850 Kcal/ Kgcl.

Similarly Sp. Power consumption is Lowest in the world as 82 Kwh/T Cement against 100-110
Kwh/t Cement in World average.

Despite Efficient operation the average AFR Usage In Indian Cement Industry is below 2-3 % TSR
which is far lower than Developed countries.
KHD continuously worked upon enhancement of Alternate fuels and Raw materials in the
cement Plants Hence few important equipment invented/ developed to fulfil this requirement.

(Data from IBM & CII 2013-14 & 2014-15)

Introduction
AFR : Today‘s Demand and Challenges
KHD Pyro Equipment for Burning AFR – PYROCLON® Calciner
KHD Pyro Equipment for Burning AFR – PYROJET® Kiln Burner

AFR : Alternative Raw materials

AFR : KHD‘s References [India]

Conclusion
AFR : Today‘s Demand and Challenges

AFR Usages Comparison: Alternative Fuels (AF) utilization rate in the German Cement Industry.

5
Introduction - Alternative Fuel Availability in India

Waste Generation Statistics: India

States Generated Treated (TPD)

(TPD)
Andhra Pradesh* 4760 6402
Chhattisgarh* 1896 168
Delhi 8370 3240
Gujarat 9988 2644 34,752
Haryana 3103 188
Jammu & Kashmir* 1792 320 141064
Jharkhand* 3570 65
Karnataka 8697 3000
West Bengal 9500 851
Madhya Pradesh 6678 - Only 25 % of Generated
Maharashtra 22,570 5,927 Waste is Treated,
Punjab* 4105 350
Rajasthan* 5037 490
Tamil Nadu 14500 1607
Telengana 6740 3016
Uttar Pradesh 19180 5197
Other 10578 1287
Total 1,41,064 34,752
(Data of CPCB Annual Report 2013-14 & 2014-15)
 AFR
AFR::Today’s
Today‘sdemand
Demandandand
Challenges
Challenges
Global Demands:
Alternative Fuels and Raw Materials-Introduction
 Saving of natural resources

 Reduction of CO2 emissions (Emission trading)

 Thermal Recycling

 Material Recycling

Individual Demands:

 Earning of disposal fees

 Reduction of fuel costs “negative fuel costs”

 Stronger market position

Challenges:

 Identifying of new (fuel) sources for consistency in fuel supply.

 Preparing of waste to alternative fuel.

 Installation of AFR handling equipment.

(Data of CPCB Annual Report 2013-14 & 2014-15)
 Plant up-grade.
 AFR : Today‘s Demand and Challenges
Challenges on energy balance, increase of specific heat consumption.
 Increased waste gas volumes (higher fuel moisture, fuel chemical composition, higher excess air
demand, more fuel to maintain hot sintering zone).
 Higher amount of primary air (transport air) and leakage air, decrease of recuperation air from clinker
cooler.
 Increased heat losses by radiation (shifting temperature profile of kiln to kiln inlet chamber).
 In case of Bypass System losses due to bypass gas extraction.

Challenges on plant operation stability

 High demands on fuel dosing equipment, continuous fuel feed.
 Formation of build-ups in case of Cl- and S-rich alternative fuels in the area kiln inlet, riser duct,
bottommost cyclone.  More manual cleaning efforts or Bypass System necessary

Challenges on clinker quality

 “Raining” of un-burnt fuel out of the kiln flame to the clinker bed => reduced burning conditions.
 Cooling down of the sintering zone.
 Possible enrichment of harmful elements in clinker, e.g. MgO, P2O5 (depending on Alternative Fuel ash
composition).
 Adaption of raw mix, e.g. high Fe-content in Alternative Fuel.

Challenges on emissions
 Influence on avoiding NOx formation and / or NOx reduction.
 CO formation in case of inadequate calciner technology or unsuitable secondary fuels.
 Saving of primary fuel related CO2 emissions.
Introduction
AFR : Today‘s Demand and Challenges
KHD Pyro Equipment for Burning AFR – PYROCLON® Calciner
KHD Pyro Equipment for Burning AFR – PYROJET® Kiln Burner

AFR : Alternative Raw materials

AFR : KHD‘s References [India]

Conclusion
 AFR : Today‘s Demand and Challenges
Challenges and Sustainable Innovative approach:
It’s not easy to add AFR without deeper analysis and knowledge as process related impacts can cause
big problems!

KHD with 160 years of industrial history has the experience and process knowledge to identify and
to solve these challenges to reach high and stable AFR firing rates.
 Introduction – Feed points for Alternative Fuels and Raw Materials

Cement Mill: Kiln Burner: Kiln Inlet: Calciner:

• Synthetic Gypsum • Sorted municipal • Whole Tires • Sorted municipal
• Gran. Blast Furn. Slag and industrial • Pasty sludge and industrial
• Fly Ash waste (RDF) • …… waste, low Quality
• ……. • Dried sewage • Sewage Sludge
sludge • Tire Chips
• Liquid hazardous • …….
wastes, Solvents
• …….

Raw Mill:
• Slag
• Fly Ash
• …….

11
KHD Pyro Equipment for Burning AFR – PYROCLON® Calciner

KHD PYROCLON® Calciner Technology – Overview

PYROTOP® Mixing Chamber for complete fuel burn-out

Design of Calciner length to reach suitable residence time

(6-10 sec) for complete burn-out

High velocity to ensure lifting of coarse fuels, avoidance

of thick coatings

Orifice to maintain gas balance and avoidance of coarse

fuel fall through

Tertiary Air Duct with Dust Settling Chamber or extended

Kiln Hood to reduce clinker dust recirculation
Calciner - Pyroclon® Technology

Pyroclon-R Pyroclon-R LowNOx Pyroclon-R LowNOx AF Pyroclon-R with

In-line calciner (ILC) ILC with staged combustion ILC with staged combustion Combustion Chamber
ILC with CC

Latest generation
KHD Pyro Equipment for Burning AFR – PYROCLON® Calciner

KHD PYROCLON® Calciner Technology – Combustion Chamber

• Utilization of coarse fuels with extremely poor ignition and burning

properties like coarse anthracite, petcoke and coarse secondary
fuels or waste derived fuels.

• Ignition and start of combustion in pure air at high temperature (T >

1200°C).

• Calciner retention time > 7 sec.

• High efficiency and flexibility.

• Lower demand on fuel quality and preparation efforts.

 Saving of alternative fuel costs.

KHD Pyro Equipment for Burning AFR - PYROROTOR®

KHD AFR BURNING TECHNOLOGY – PYROROTOR®

KHD Pyro Equipment for Burning AFR - PYROCLON® Calciner
KHD PYROCLON® Combustion Chamber – Norway, 3 500 tpd
KHD Combustion Chamber: 60 % of total fuel (thermal)

• Coal / Petcoke / Animal Meal mix: 10 th-%

• Solid Hazardous Waste: 27 th-%
• Fluff RDF: 63 th-%

Typically 16 to 18 t/h of solid hazardous waste and Fluff RDF

are fed into the KHD Combustion Chamber.

In 2014, after 10 years in operation

Calculation Example:
16 t waste/h  384 t/d  assumed plant run time of 310 d/y
119 040 t/y  1 190 400 t waste in 10 years.

Waste Density: 0,3 t/m³

Waste Volume: 3 968 000 m³ (in 10 years)

In Other Numbers
Storage Height: 5m
Storage Area: 891 m x 891 m !!!!

Result = Stable feeding of approx. 90 th-% of alternative fuels to the calciner.

KHD Pyro Equipment for Burning AFR - PYROCLON® Calciner
KHD PYROCLON® Combustion Chamber – Latvia, 4 000 tpd

KHD Combustion Chamber: 60 % of total fuel (thermal)

 Coal (as stand-by for fast response): 3 th-%

 Solid Residue Fuel: 70 th-%
 Waste Wood Chips: 2 th-%
 Tyre Chips and Fluff: 15 th.-%
 Neutralized Sulphuric Acid Tar: 10 th.-%

Typically 20 t/h of Alternative Fuels are fed to the KHD

Combustion Chamber.

Main burner: 40 % of total fuel (thermal)

Coal: 78 th-%
Solid Residue Fuel, fine: 22 th-% (= 2,5 t/h)

Result = Stable feeding of approx. 68 th-% of Alternative Fuels to the kiln / calciner.
Cemex Rüdersdorf, Germany – 6.000 tcli./d
Core equipment
Worlwide unique Plant Concept
Clinker Pyroline combined with CFBR  5 Stage Cyclone Preheater WT PRZ
7648/3
Circulating Fluidized Bed Reactor
 PYROCLON R® Low NOx Calciner w.
A gasifyer operating on the principle of PYROTOP
circulating fluidized bed to extent the
 2-Pier Rotary Kiln, PYRORAPID® Ø 5,2
options for using a wide range of x 61 m
different secondary materials.
 15% Bypass
The produced lean gas is burned in the  3-Grate Cooler with hammer crusher
calciner firing system while the
reaction residues are discharged at the Result
reactor floor and finally used in the
raw mill.  Since 1995 in operation
 Capacity proven for up to 6.500 t/d
 AFR ratio up to 85%
 WHR in connection with powerplant
Heidelberger Cement Teutonia, Germany – 2.500 tcli./d

Core equipment
 1-String Pre-Heater, 4-stage. Type 7346/4
 PYROCLON® R LowNOx with PYROTOP®
 Tertiary Air Duct with Dust Setting Chamber
 Bypasssystem, design for 14 %
 2-Station Rotary Kiln PYRORAPID® 4,2 x 50 m
 Kiln Burner PYROJET® HPJ/230
 Clinker Cooler IKN 3000/52/56/5/3 P, Grate Area
55 m²
Alternative Fuel Alternative Fuel Fossil Fuel
Rate
Kiln 15 % Animal Meal 85 % Coal

LowNOx Calciner 70 % RDF 30 % Coal

Total 48 % Alt. Fuel 52 % Foss.

Fuel

Result
RDF  Since 1996 in operation
 Capacity proven for up to 2.500 t/d
 AFR ratio up to 50 %
KHD Pyro Equipment for Burning AFR - PYROCLON® Calciner
KHD Combustion Chamber – Reference List
Customer Country Year [t/d] Preheater / Dimensions Kiln Fuel
5,0 x 69
Cimentos Liz S.A. Brazil 2011 5000 PR 9067 / 5, PYROCLON R Coal
PYRORAPID
4,6 x 54
Maras II Turkey 2011 4500 PR 8864 / 5,PYROCLON R Coal
PYRORAPID
4,4 x 52
Sengelejewski Russia 2007 3000 PR 7950 / 4,PYROCLON R Gas
PYRORAPID
Cimpor Yibitas 4,2 x 50 Petcoke, Local Waste
Turkey 2007 2500 PR 7648 / 5,PYROCLON R
Hasanoglan Plant PYRORAPID Derived Fuels
OAO Mordowzement,
Komsomolski Russia 2006 6000 PRZ 7950 / 5,PYROCLON R 5,2 x 65 Gas
MORDOW 3
Coal / Petrol Coke
Holcim Campulung
Romania 2006 4000 PR 8861 / 5,PYROCLON R 4,8 x 66 Natural Gas, Oil Sludge,
Cement
Fluff RDF
Coal / Petrol Coke, Local
Cemex Broceni 4,6 x 54
Latvia 2006 3500 PR 7650 / 4,PYROCLON R Waste Fuels, Wood,
Latvia plant, Broceni Line V PYRORAPID
Shredded tyres
Oil
PRZ 6442 / 4,PYROCLON R
Cimenterie National S.A.L. Lebanon 2005 3800 4,4 x 64 Petrol Coke
a
Alternative Fuels
Guangzhou Heidelberg 5,2 x 70 Hard Coal, Anthrazite,
PR China 2003 6000 PRZ 7950/5,PYROCLON R
Yuexiu Cement Pyrorapid Sewage Sludge
Coal
Norcem A.S., Brevik PRZ 5635/4,PYROCLON R
Norway 2003 3500 4,4 x 68 Alternative Fuels, Waste
Dalen plant Line VI Bypass
Fuel
KHD Pyro Equipment for Burning AFR - PYROCLON® Calciner

KHD PYROCLON® Combustion Chamber – Global Cemfuel Award

6th Global Cemfuels Conference 2012, in

Aachen, Germany.

KHD Combustion Chamber

KHD wins the award for the most innovative

technology for alternative fuel use.
Introduction
AFR : Today‘s Demand and Challenges
KHD Pyro Equipment for Burning AFR – PYROCLON® Calciner
KHD Pyro Equipment for Burning AFR – PYROJET® Kiln Burner

AFR : Alternative Raw materials

AFR : KHD‘s References [India]

Conclusion
 KHD Pyro Equipment for Burning AFR - PYROJET® Kiln Burner

Refractory

Jet-Air Nozzles

Coal Dust Nozzle

Swirl Element
Primary Air Amount:
Depending on fuel scenario
 Lower for primary fuels ( Low NOx Burner)
 Higher for alternative fuels Inner Tubes for Alt. Fuels
 KHD Pyro Equipment for Burning AFR - PYROJET® Kiln Burner

AFR Swirl Nozzle – Special Feature for higher AFR rates

 Retractable swirl element.

 No additional primary air necessary for AFR
nozzle.
 Adjustable during operation.
 Fracturing, mixing of the AF flow shortly
before entering the kiln (spraying angle).
 Improving the mixture within the flame core
and with oxygen.
 Oxygen enrichment is also possible.

Increase of alternative fuel firing rate

AF Channel with retractable

Swirl Nozzle
KHD Pyro Equipment for Burning AFR - PYROJET® Kiln Burner

AFR Swirl element in front position  Poor AFR distribution

AFR Swirl element in back position  Good AFR distribution into the flame
KHD Pyro Equipment for Burning AFR - PYROJET® Kiln Burner

Reference List for Burner Modification with newly developed AFR Nozzle

Clinker
AFR Rate Kiln AFR Fuel
Plant Company Production Project
Burner [%] Type
[t/d]
Existing
Burglengenfel Heidelberger Plastic and Burner,
2000 50-60
d, D Cement paper foils retrofit with
AFR Nozzle
Existing
RDF,
Burner,
Outão, PT SECIL 3500 40-50 Sawdust,
retrofit with
Wood Chips
AFR Nozzle
Existing
Spenner Burner,
Erwitte, D 2000 Commissioning started
Zement retrofit with
AFR Nozzle
Lampang, Siam
5500 Future intention to burn AFR New Burner
Thailand Cement
Introduction
AFR : Today‘s Demand and Challenges
KHD Pyro Equipment for Burning AFR – PYROCLON® Calciner
KHD Pyro Equipment for Burning AFR – PYROJET® Kiln Burner

AFR : Alternative Raw materials

AFR : KHD‘s References [India]

Conclusion
 AFR : Alternative Raw materials
Use of Alternative Raw Materials
Novotroizk, Russia, 2 x 3 000 tcli./d

Special Feature:
Up to 30% of raw material: Blast Furnace Slag
Fe-corrective component: Siemens Martin Slag
Slag Dump as raw material source

Source:
Slag dump from nearby steel works

Result:
Spec. Heat Consumption only ~ 600 kcal/kgcli.

A successful project as an example of using

Alternative Raw Materials.
Introduction
AFR : Today‘s Demand and Challenges
KHD Pyro Equipment for Burning AFR – PYROCLON® Calciner
KHD Pyro Equipment for Burning AFR – PYROJET® Kiln Burner

AFR : Alternative Raw materials

AFR : KHD‘s References [India]

Conclusion
AFR : KHD‘s References [India]

Plant Type of Fuel

Tyre Chips, Municipal Waste, Paint Sludge,

UTCL Reddipalayam
Agro Waste

UTCL Vikram Cement Tyre Chips, Municipal Waste, Agro Waste

UTCL Tadipatri Pharmaceutical Waste

Agricultural Waste, Municipal & Industrial

Lafarge Sonadih
Waste

UTCL Aditya Cement Paint Sludge

Introduction
AFR : Today‘s Demand and Challenges
KHD Pyro Equipment for Burning AFR – PYROCLON® Calciner
KHD Pyro Equipment for Burning AFR – PYROJET® Kiln Burner

AFR : Alternative Raw materials

AFR : KHD‘s References [India]

Conclusion
 Conclusion
AFR - Alternative Fuels and Raw Materials

Utilization of alternative fuels is a state-of-the-art technology for cement plants.

Alternative fuels reduce fossil fuel consumption hence conservation of natural resources.
Broad variance in alternative fuels leads to many influences on the clinker process which
have to be known and taken into account.
Different technical solutions exists for the utilization of secondary fuels in cement plants.
Due to steadily rising prices for primary fuels, the utilization of alternative fuels will
become more and more a possibility for decreasing or maintaining the operational
costs.

 KHD’s 160 years of industrial history and experience helps our customers to
implement alternative fuel projects into their process.
THANK YOU!