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FEATURE ENERGY MANAGEMENT


FINDING RELIABLE SUPPLIES FOR ENERGY-INTENSIVE PROCESSES


Cement manufacturing is particularly energy- intensive. In order to reduce the use of expensive primary fuels such as coal and oil, cement plant operators are increasingly using alternative fuels and raw materials (AFR). In order to help customers efficiently convey, store and dose the treated fuels, BEUMER Group has established the new business segment called AFR systems


B


esides mineral waste that can be used as alternative raw material, the


market primarily employs the use of fuel alternatives, because approximately 30 per cent of production costs are spent on energy. In addition to fluid alternative fuels, such as used oil or solvents, the majority of solid fuels consist of complete or shredded scrap tyres, scrap wood, or mixtures of plastic, paper, composite materials or textiles. After they have been treated and quality- controlled, they show calorific values similar to brown coal. The calorific value of scrap tyres is even


comparable to that of stone coal. When producing cement, it is also necessary to ensure that the quality of the ash residues matches the quality of the end product. As all material components are completely incorporated into the clinker and mineralised, their use makes for an economic production process. In addition, primary raw and fuel supplies are conserved and landfill volume is reduced. Pre-treated secondary fuels are mostly


supplied from external vendors, ready for incineration. BEUMER Group now offers tailor-made AFR systems to lime and cement plants for the safe transport and storage of solid materials. Based on wide-ranging experiences and the customer’s requirements, the systems comprise the entire chain, from receiving and unloading the delivery vehicle, up to storing, sampling, conveying and dosing solid alternative fuels. BEUMER Group, provider of intralogistics, supplies its customers worldwide now with three systems, from one single source.


TAILORED TO EVERY APPLICATION BEUMER Group’s programme includes the starter system that is used at the main


24 MAY 2016 | AUTOMATION


Above: The alternative fuels are conveyed from the storage to the main burner, low in noise and dust-proof


Inset: If suppliers encounter problems in regards to the quality of their processing, BEUMER AFR systems can be upgraded and are suitable for high substitution rates


burner. In the cement and limestone industry, primary fuels are usually ground to grain sizes of less than 100 micrometres and fed via the burner. At the end of the rotary kiln, the burner heats up to 2,000°C, the temperature that is needed for limestone, sand, clay and ore to react and become clinker as an intermediate product. In order to use solid secondary fuels in the clinkering zone burner, they should deliver a calorific value that is at least similar to brown coal (ca. 22 ± 2MJ/kg), have grain sizes of less than 30 millimetres and burn out while being fed. The oven-ready material is usually


Fill level measuring probes and other measuring technology monitor the automated processes


delivered in moving-floor trailers. BEUMER Group provides a docking station that also serves as storage on site. Once the trailer is emptied, it is completely replaced or refilled in the large tent using a wheel loader. The material is metered volumetrically and conveyed to the clinkering zone burner. This solution is deliberately designed as a test system. This way, the operator can test their suppliers, the quality of the fuels and their furnace behaviour.


SOLUTION FOR THE CALCINER With the second system, the calciner can be fed with more coarse alternative fuels, such as tyre derived fuel or the fuels described above, but in a more coarse state. They are generally less processed, contain three-dimensional particles and therefore require more time to burn out than, for example, the more intensively processed, exclusively two-dimensional secondary fuels for the main burner. The coarse calciner fuel is delivered in


moving-floor trailers or tippers. The secondary fuels are quickly unloaded and stored temporarily in a dust-proof way. Another storage serves as a flow buffer,


which can hold the overall capacity of 900 cubic metres of the preceding bunker. From here, the pipe conveyor transports the material to the calciner in the preheater tower. Here, the secondary fuel is weighed and dosed. During the feed towards the hearth in the calciner, there is often the risk that the material or the conveying system can catch fire due to thermal radiation or pulsations. For this reason, the valveless special feed was developed, so the material can be safely fed to the calciner.


AUTOMATIC OPERATION In order to ensure safe and automatic fuel supply after successful testing, BEUMER Group provides systems for permanent operation with high thermal substitution rates. The systems consist of the receiving area and a storage system, where the crane system can store material of different quality into different storage zones and boxes. Experiences so far have shown that you always have to calculate with disruptives or quality deficits in the fuel. This is why the entire storage and conveying technology in the hall can be provided with equipment that is able to separate metal, wet and three- dimensional disruptives from the fuel for the main burner and keep disrupting oversized grains from the calciner fuel. Equipped with the necessary sensor technology, the operation runs automatically. The crane can be used independently for homogenisation, in order to minimise quality variations or feed the lines towards the main burner and the calciner.


BEUMER Group T: 020 8283 1700 www.beumergroup.com


/AUTOMATION


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