Utilization of fluff: from reception to burner

Hver Plant, Germany

39th Cement Manufacturing Conference 2006

Klaus Eichas

Index
Waste market survey
Kiln system
Fluff project
 survey
 costs
 equipment specifications
Quality impact
Overall results
Messages

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Waste market survey

Industrial waste regional availability for recovery

Comments

384
367

Markets within ~300 km around

188
147

675
397

the plants offer enough volume

for fluff production
Due to the extremely high

3 081
310

380

Market volume (000t)

Laegerdorf market area

Hoever market area
Holcim

908

475
304

volumes of 3 Mio. t NRW may

have a positive price effect on
Hoever market area
Waste spread within the total on

average:

435

50 % industrial waste
1 267

111
1 031

20 % production residue
30 % construction waste

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

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 %
4

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Estimated Price and Volume

Industrial waste for co-processing in the cement industry payment by the suppliers
2004

2005

2006

2007

2008

2009

price range:
5 -10

/t

20 -30

10 -15

price dumping
by landfills

25 -35

change in German landfill directive

12'000'000
10 460 500

10 695 600

6'000'000

the volume available for recovery

increases by 40% between 2000

and 2006

10'000'000
8'000'000

price development linked to

incineration prices

7 523 500
5 966 600

4 main outputs for fluff

4'000'000

cement

2'000'000

power plants using steam coal

0
1995

2000

Expectation
2006

Expectation
2012

power plants using lignite

incineration

Construction and demolition waste

Production residues
Industrial waste

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

5
21.09.2006/KEi

Index
Waste market survey
Kiln system
Fluff project
 survey
 costs
 equipment specifications
Quality impact
Overall results
Messages

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

KHD-Kiln with planetary cooler and 4 stage preheater

- 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
main burner:
- lignite (coal)
- animal meal
- fluff (shredded plastics)

kiln inlet:
- waste tires
- filter cake (AR)

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Index
Waste market survey
Kiln system
Fluff project
 survey
 costs
 equipment specifications
Quality impact
Overall results
Messages

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

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
9

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Flow sheet: fluff handling system

Storage capacity
3.600 m / 700 t fluff

10

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Storage hall

11

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Automatic crane

12

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Index
Waste market survey
Kiln system
Fluff project
 survey
 costs
 equipment specifications
Quality impact
Overall results
Messages

13

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

The example of the CEM I 52.5 shows that the 1 day

compressive strength deteriorated over the last years
1.4
1.2

30
29

1.0

28

0.8

27
26

Long
-term

25

0.6

trend

0.4

24

suphatization grade

1 day strength N/mm

32
31

0.2

23
22

0.0
1997

1998

1999

2000

1 day strength

2001

2002

2003

2004

2005

sulphatization grade
14

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Avoid double flame

7.5 m
3.5 m
stable un stable
coating coating

30 m
stable
coating

Burner tip

Burner

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
15

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Index
Waste market survey
Kiln system
Fluff project
 survey
 costs
 equipment specifications
Quality impact
Overall results
Messages

16

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Step change in use of AFR 2000 - 2005

substitution rate %

60.0
50.0
40.0
30.0
20.0
10.0
0.0

2000

2001

2002

2003

2004

2005

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
17

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Overall results
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
18

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Index
Waste market survey
Kiln and burner
Fluff project
 survey
 costs
 equipment specifications
Quality impact
Overall results
Messages

19

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

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%.

20

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Annex

21

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

High momentum burner

fluff

coal
ignition
lance
oil,
waste oil,
add. waste
liquids or
solids
swirl air
animal meal
axial air
22

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Equipment specification
The plant covers a closed storage hall with truck tipping

place, 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/m

closed storage hall:

length 40 m
width 18 m
height 18 m
3.600 m / 700 t fluff







storage capacity:
2 truck tipping places
explosion protected dedusting filter: 50.000 m/h
activated carbon smell filter
fire protection system
23

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Crane specification
automatic crane with hydraulic grab







load-carrying capacity: 11,0 t

grab capacity:
8,0 m
grab weight:
4,7 t
automatic evacuation of the trucks tipping-place
automatic feeding into the dosing box
automatic material relocation/blending

24

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Feeder specification
dosing box (installation of a 2nd box in Oct. 2004)





capacity:
35,0 m
bottom: 4 speed adjustable screws, diameter 630 mm
1 collector screw, speed adjustable, diameter 800 mm
radar level switch

25

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

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

26

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Conveyor specification
conveyor to burner platform



length
belt width

67,0 m
800 mm

rotary feeder


diameter

630 mm

pneumatic transport


pipeline length

50 m

27

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi

Impact on quality: At Hver plant the increasing TSR goes

along with decreasing early strength behavior

substitution rate %

60.0

30
29

40.0

28

0.0

N/m m

20.0

2000

2001

2002

2003

2004

2005

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

27
26
25

1 day strength development CEM I 52,5R

24
1997

1998

1999

2000

2001

2002

2003

2004

2005

Note: at the moment Hver is carrying out a comprehensive quality

improvement program; The maximum applicable throughput of fluff without
creating clinker reactivity problems is to be found yet by the ongoing
optimization measures.

28

Holcim (Deutschland) AG

39th Cement Manufacturing Conference 2006

21.09.2006/KEi