Pretreatment of Waste Fuels for the

Cement Industry

ECRA – Seminar
Retznei - Austria
2011, September 16th

Hubert Baier

Vecoplan FuelTrack GmbH

A company of ThyssenKrupp Polysius AG and Vecoplan AG
Pretreatment of waste fuels for the Cement Industry
Dr. Hubert Baier
16.09.2011
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 ThyssenKrupp Polysius and Vecoplan established the joint venture
“Vecoplan FuelTrack GmbH”
a Company dedicated to the environmental technology
in Cement and Lime Industry

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Table of Content

1. Initial position
2. Mechanical processing for the use at the calciner
3. Use of alternative fuels in a main burner
4. Optimised clinkering zone firing system at the rotary kiln

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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 Cost cake and Development of the Thermal Substitution Rate*

Thermal Substitution Rate (TSR) of

Engineered Fuels + Biomass
70%

60%
Cost cake of cement production
50%
Germany
40% EU 27
TSR

Emerging Countries
30% Industrial Countries
global
20%

10%

0%
2006 2009 2030 2050
Period
*Source: VDZ 2010

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Seeking + Sourcing

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Waste-Assessment
food

textile

• Identify feasible waste high calorific paper

glass fraction
compounds + shares
leather, rubber

• Identify chemical and metal polymeric pack

wood
process benefits or construction
obstacles waste
stones

• Define capabilities and

requirements for co-
processing

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Technical Assessment

• Exploring capabilities and the best

options for co-processing
• Detect technical defaults and process
faults
• Define basic conditions for dimensioning
pro-processing and handling and dosage

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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From Waste to Engineered Energy

< 250 mm PREPOL

Sourcing + Identification cv ~ 14.000 kJ/kg
SC

Pre-Processing
< 80 mm Calciner
cv ~ 16.000 kJ/kg

< 25 mm
cv ~22.000kJ/kg
Main-
burner
< 3 mm
cv ~24.000kJ/kg

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Impacts of Missing Quality Assurance
alkaline corrosion

ring creation

chlorine corrosion

reductive burn

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Fundamental Principles of Fuel Conversion

Useful
heat

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Table of Content

1. Initial position
2. Mechanical processing for the use at the calciner
3. Use of alternative fuels in a main burner
4. Optimised clinkering zone firing system at the rotary kiln

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Preparation: High Calorific Fraction (HCF < 300 mm)
HCF < 300 mm
Pre-sorting

< 300 mm
Sieving

Residues, Wastes & Biomass

Classifier

Drop out QM
HCF < 300 mm

Screening

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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HCF-handling to feed the PREPOL Step-Combustor
HCF < 300 mm

Step-Combustor
& Calciner

HCF < 300 mm

MS - Calciner

Tertiary air

Rotary kiln
Step combustor

HCF < 300 mm

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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PREPOL StepCombustor
tertiary air HCF < 300 mm
suspending coke
with meal
and ash fraction

No mechanical installations
– only fixed shockblowers
Calciner separate light from heavy
2-3 unburnt fractions and feeds
~12 min
min the material into the calciner
Ignition/ Drying/
by controlled steps.
conversion pyrolisis
Pretreatment of waste fuels for the Cement Industry
Dr. Hubert Baier
16.09.2011
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RDF-handling to feed the Calciner

Calciner

RDF < 80 mm

RDF < 80 mm

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Dust-proof Fuel Transport for RDF and SRF

closed system = no dust and air emission

air cushion effect = low energy consumption

no track wheels = low maintenance efforts

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Type of Calciner as a function of retention time

Air-Separate (AS) Multi-Stage (MSC) AS + Combustion- MSC + CC

Chamber (CC)

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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 Tire chips

RDF 80 mm

Biomass

coal/ petcoke

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Table of Content

1. Initial position
2. Mechanical processing for the use at the calciner
3. Use of alternative fuels in a main burner
4. Optimised clinkering zone firing system at the rotary kiln

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Preparation: Solid Recovered Fuel (SRF < 30 mm)

RDF < 80 mm

Classifier

SRF < 30 mm
QM

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
20 RDF < 80 mm
Table of Content

1. Initial position
2. Mechanical processing for the use at the calciner
3. Use of alternative fuels in a main burner
4. Optimised clinkering zone firing system at the rotary kiln

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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SRF-Feeding to Main Burner

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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The Main Burner POLFLAME©

SRF < 30 mm

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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RDF-Mill to feed the Sinter Zone Burner

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Pre-Processing for a Customized Co-Processing…

Solid Waste

1. Level:
High Calorific Fraction PREPOL SC™
(250 – 80 mm)

2. Level:
RDF PREPOL™
(< 80 mm)

3. Level:
SRF POLFLAME™
(30 - < 20mm)

RDF-Mill
POLFLAME™
100% < 3 mm

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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Contact to fit your process right …
www.vecoplan-fueltrack.com
Vecoplan FuelTrack GmbH
Vor der Bitz 10
D - 56470 Bad Marienberg

Fon: +49 2661 6267-871

info@vecoplan-fueltrack.com

Pretreatment of waste fuels for the Cement Industry

Dr. Hubert Baier
16.09.2011
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