A TEC Company Presentation

A TEC WORLDWIDE
World Leader in Cement Pyroprocess Technology

2009
 A TEC WORLDWIDE

Headquarter, Austria

Poland, Chelm

China, Beijing

Mexico, Puebla India, Delhi

Malaysia, Kuala Lumpur

2009 2
 A TEC ORGANIZATION CHART

2009 3
 A TEC BOARD MEMBERS

Dr. Günther Schwaiger

Chief Executive Officer (CEO)
Heading Sales, Marketing and Finance

Dipl. Ing. Friedrich Willitsch

Chief Technical Officer (CTO)
Heading Contract Management, Research
and Development, Process Technology

2009 4
 A TEC MISSION

2009 5
 A TEC – KEY ACCOUNTS

Client structure:

and many more…

2009 6
 POWER OF A TEC

A TEC offers patented products,

innovative process technologies
and consulting service know-how.

Hands-on experience in planning,

implementation and plant operation -
A TEC is a reliable business partner.

2009 7
 A TEC OPTIMIZATION

ENERGY

EFFICIENCY

ENVIRONMENT

2009 8
 CEMENT PYROPROCESS

2009 9
 A TEC CHINA

2009 10
 A TEC CHINA

2009 11
 A TEC CHINA

2009 12
 A TEC PROJECT EXAMPLES

STRABAG Greenfield Plant, Hungary

Lafarge Wössingen, Germany
Belarusian Cement Plants, Belarus
W&P Wietersdorf, Austria
Cementizillo, Fanna, Italy
Cemex Assuit, Egypt
Al Safwa, Saudi Arabia

2009 13
 STRABAG GREENFIELD PLANT
Capacities

Crusher
Limestone 1000 t/h
Quarry

Crusher
Clay 250 t/h
Quarry

Transport
7000 t/d
railroad

Preblending
storage
Limestone 2 x 15.000 t
pure
Sand-storage
Sand
625 t
Iron Iron-storage
625 t

Raw Mill 200 t/h

Raw Mill Silo

8.000 t
Coal-storage
Coal/Petcoke
8.000 t
Kiln Line 2500 t/d
Coal Mill (Preheater, (104 t/h)
15 t/h Kiln, Clinker
Cooler)

Storage Limestone pure Clinker storage

10.000 t 60.000 t

Cement 2 x 100t/h
Gypsum Crusher 190 t/h
mills Cement

Additives

Cement Storage
4 x 10.000 t

Packing plant Truck loading Rail loading

125 t/h 2 x 200t/h 200t/h

2009 14
 STRABAG GREENFIELD PLANT

overall project management

plant arrangement, process design
complete tender support to client
sub-contracts negotiation
progress & quality assurance
interface and technical clarification
supervision services & training

2009 15
 LAFARGE WÖSSINGEN

Project Scope – Main Plant Sections

Raw Mill and kiln Filter modification of ESP
Bypass Filter modification of ESP
Bypass Dust storage and dosing new
Conditioning tower new
Raw meal transport from silo to dosing new
Lime hydrate storage and dosing new
SNCR dosing systems new
Kiln – 2 reuse of usable kiln and kiln parts new
Burner and fuel dosing systems new
Clinker cooler new
Cooler Filter new
Clinker transport new

2009 16
 LAFARGE WÖSSINGEN

2009 17
 W & P – WIETERSDORF, AUSTRIA

Project Period: 16 months

Shut-Down: 69 days

New Preheater & Calciner

• New preheater complete
• New low-NOx calciner incl. Comb. Chamber
• New tertiary air duct,
• New hot gas duct
• New preheater fan
• Kiln shortening
• New kiln inlet sealing
• New kiln inlet chamber

Results
• Production increase from 1000 to 1777 t/d
• NOx <500 mg/nm³ (without SNCR)

2009 18
 W & P – WIETERSDORF, AUSTRIA

2009 19
 CEMEX – ASSIUT KILN 2+3, EGYPT

Project Period: 8 months

Shut-Down: 39 days

Modification on Preheater & Calciner

• Disassembly of preheater equipment
except
• Cyclone cone stage 2 & 4
• Meal pipes stage 2 & 4
• Installation of new preheater equipment
• Extension existing 2 string calciner
• New hot gas duct

Results:
• Production increase from 4000 to 4500
t/d with a shut down of only 39 days!!!

2009 20
 CEMEX – ASSIUT KILN 2+3, EGYPT

2009 21
THANK YOU FOR YOUR ATTENTION

Please visit:
www.atec-ltd.com

2009
A TEC Company Presentation

A TEC WORLDWIDE
World Leader in Cement Pyroprocess Technology

2009
 A TEC WORLDWIDE

Headquarter, Austria

Poland, Chelm

China, Beijing

Mexico, Puebla India, Delhi

Malaysia, Kuala Lumpur

2009 2
 A TEC ORGANIZATION CHART

2009 3
 A TEC BOARD MEMBERS

Dr. Günther Schwaiger

Chief Executive Officer (CEO)
Heading Sales, Marketing and Finance

Dipl. Ing. Friedrich Willitsch

Chief Technical Officer (CTO)
Heading Contract Management, Research
and Development, Process Technology

2009 4
 A TEC MISSION

2009 5
 A TEC – KEY ACCOUNTS

Client structure:

and many more…

2009 6
 POWER OF A TEC

A TEC offers patented products,

innovative process technologies
and consulting service know-how.

Hands-on experience in planning,

implementation and plant operation -
A TEC is a reliable business partner.

2009 7
 A TEC OPTIMIZATION

ENERGY

EFFICIENCY

ENVIRONMENT

2009 8
 CEMENT PYROPROCESS

2009 9
 A TEC CHINA

2009 10
 A TEC CHINA

2009 11
 A TEC CHINA

2009 12
 A TEC PROJECT EXAMPLES

STRABAG Greenfield Plant, Hungary

Lafarge Wössingen, Germany
Belarusian Cement Plants, Belarus
W&P Wietersdorf, Austria
Cementizillo, Fanna, Italy
Cemex Assuit, Egypt
Al Safwa, Saudi Arabia

2009 13
 STRABAG GREENFIELD PLANT
Capacities

Crusher
Limestone 1000 t/h
Quarry

Crusher
Clay 250 t/h
Quarry

Transport
7000 t/d
railroad

Preblending
storage
Limestone 2 x 15.000 t
pure
Sand-storage
Sand
625 t
Iron Iron-storage
625 t

Raw Mill 200 t/h

Raw Mill Silo

8.000 t
Coal-storage
Coal/Petcoke
8.000 t
Kiln Line 2500 t/d
Coal Mill (Preheater, (104 t/h)
15 t/h Kiln, Clinker
Cooler)

Storage Limestone pure Clinker storage

10.000 t 60.000 t

Cement 2 x 100t/h
Gypsum Crusher 190 t/h
mills Cement

Additives

Cement Storage
4 x 10.000 t

Packing plant Truck loading Rail loading

125 t/h 2 x 200t/h 200t/h

2009 14
 STRABAG GREENFIELD PLANT

overall project management

plant arrangement, process design
complete tender support to client
sub-contracts negotiation
progress & quality assurance
interface and technical clarification
supervision services & training

2009 15
 LAFARGE WÖSSINGEN

Project Scope – Main Plant Sections

Raw Mill and kiln Filter modification of ESP
Bypass Filter modification of ESP
Bypass Dust storage and dosing new
Conditioning tower new
Raw meal transport from silo to dosing new
Lime hydrate storage and dosing new
SNCR dosing systems new
Kiln – 2 reuse of usable kiln and kiln parts new
Burner and fuel dosing systems new
Clinker cooler new
Cooler Filter new
Clinker transport new

2009 16
 LAFARGE WÖSSINGEN

2009 17
 W & P – WIETERSDORF, AUSTRIA

Project Period: 16 months

Shut-Down: 69 days

New Preheater & Calciner

• New preheater complete
• New low-NOx calciner incl. Comb. Chamber
• New tertiary air duct,
• New hot gas duct
• New preheater fan
• Kiln shortening
• New kiln inlet sealing
• New kiln inlet chamber

Results
• Production increase from 1000 to 1777 t/d
• NOx <500 mg/nm³ (without SNCR)

2009 18
 W & P – WIETERSDORF, AUSTRIA

2009 19
 CEMEX – ASSIUT KILN 2+3, EGYPT

Project Period: 8 months

Shut-Down: 39 days

Modification on Preheater & Calciner

• Disassembly of preheater equipment
except
• Cyclone cone stage 2 & 4
• Meal pipes stage 2 & 4
• Installation of new preheater equipment
• Extension existing 2 string calciner
• New hot gas duct

Results:
• Production increase from 4000 to 4500
t/d with a shut down of only 39 days!!!

2009 20
 CEMEX – ASSIUT KILN 2+3, EGYPT

2009 21
THANK YOU FOR YOUR ATTENTION

Please visit:
www.atec-ltd.com

2009
MUNICIPAL SOLID WASTE (MSW)
 REFUSE DERIVED FUEL (RDF)
BASURA MUNICIPAL  COMBUSTIBLE
By Jonathan Forinton
j.forinton@atec-america.com

EVENT: FICEM-APCAC Conference 2009

PLACE: Bogota
DATE: 2009Sept07

1 Priviledged Information not to be copied. All rights reserved.

 Who is A TEC?
Austrian engineering company:
>10 years experience in alternative
fuels implementation

Since 1996 A TEC has

improved the Pyro-process
with 17 patented innovations.

2
 TYPICAL ALTERNATIVE FUELS

1. Waste oil
2. Solvent
3. Contaminated and waste wood
4. Tire and rubber waste
5. Plastic waste
6. Thermal fraction of domestic waste
7. Thermal fraction of industrial waste
8. Animal meal
9. Sewage sludge

Priviledged Information not to be copied. All rights reserved.

3
 RAW MATERIAL

Municipal Solid Waste … it’s free!

Priviledged Information not to be copied. All rights reserved.

4
 TYPICAL FUELS CONTAMINANTS

Priviledged Information not to be copied. All rights reserved.

5
 MSW COMPONENTS & TRAJECTORIES

Step 4 Step 5 Thermal

further separation
fraction calorific
processing of
impurities
value: 17-21
depending on
requirements MJ/kg
Water ~31%
Waste material

Organics ~9%
Example

Textiles ~7%
Wood ~8%
Plastics ~7%
Composite materials ~6%
Paper ~6%
Metal ~7%
Glass and inert materials ~7%
Problematic
materials ~1%
Step 1 Step 2 Step 3
pre-crushing drying, cutting MTP Step 6
max. hygienisation, 60-80mm further
150mm separation of fine separation
fraction ~20 min. depending on
150 C requirements

Priviledged Information not to be copied. All rights reserved.

6
 BEHAVIOUR OF TRACE ELEMENTS

COMPONENTS in RDF: Behaviour in the Pyro-Process

Elements involved Components/ Carriers Transfer Details
Chrome, Zinc, Nickel, Clinker mineral elements, Hardly volatile: mainly transfer into the clinker
Arsenic, Vanadium, etc., Low volatile metals
Sulfur from the fuel Sulfur component of fuel
TOC, Lead, Mercury Non burnt organics, Volatile: Mainly transfer into the preheater exhaust
Sulfur from raw meal Products of combustion gas

Thallium, Cadmium, Mercury Volatile trace metals Volatile: Likely build up of internal cycles.
Linked to dust particles Transfer into preheater exhaust dust, cycle builds
until overflow is picked up at filter and recirculated via
raw meal. Mixing filter dust to cement bleeds cycle.
Chlorine, Halogens, alkalis, Build up of internal cycles likely:
Sodium, Potassium residuals conveyed with By-pass system can bleed elements to external
clinker disposal.

Priviledged Information not to be copied. All rights reserved.

7
 THE PROCESS

Standard Alternative Fuel Preparation Technology

collection processing storage transport dosing

Operation Guidlines Process Design Combustion

& Adjustment & Evaluation Technology

Production and process technology for utilization of alternative fuels

Priviledged Information not to be copied. All rights reserved.

8
 THE PROCESS
Domestic or
Industrial
300 mm = 12”
Solid Waste 50 mm = 2”
optional 15 mm = 5/8”
Hot air
(Clinker cooler)

Shredding A TEC - Sorting

Storage < 300 mm MTP Automatically or
hand-operated
Untreated material
STORAGE
Contaminated
Calciner section gas A TEC rotary
& combustion combustion
chamber chamber

Shredding Shredding
< 15 mm
Storage < 50 mm
Storage
Material < 50mm Material <
300mm

Main burner Plant engineering from DELIVERY to

Storage COMBUSTION is ONE concept…
Material < 15mm

Priviledged Information not to be copied. All rights reserved.

9
 THE PRODUCTION LEVEL

Typical Preheater Exhaust Gas Volumes

at 2% false air; 3300 kJ/kgcli

Approx. Gas Volume [Nm3/kgcli]

Coal 1,50 base

Heavy oil 1,60 + 6,6 %
RDF 10% moisture 1,65 + 10,0 %
Natural gas 1,70 + 13,3 %

Priviledged Information not to be copied. All rights reserved.

10
 THE EFFICIENCY LEVELS

OPTIMISATION IS ESSENTIAL !!!

1,0 [GJ] primary fuel  1,2 [GJ] alternative fuel

Reduction Increase
clinker production heat consumption

Moisture [t/t H2O] 2.00 [MJ/kg H2O] 2.10

False air [t/kNm³ air] 0.23 [MJ/Nm³ air] 1.00

Oxygen [% t/%O2] 5.50 [% MJ/%O2] 1.60
1t metric = 1.102 st 1 MJ/kg = 430 BTU/lb
1 kNm3 = 35’000 ft3 STP 1 MJ = 950 BTU

Priviledged Information not to be copied. All rights reserved.

11
 REFERENCE PLANT FOTOS (1)

Hand sorting creates

jobs

Drum separation plant

Priviledged Information not to be copied. All rights reserved.

12
 REFERENCE PLANT FOTOS (2)

Bales on pan conveyor

to Stage 1 shredder
Plastic Waste arrives in
tied bales

Priviledged Information not to be copied. All rights reserved.

13
 REFERENCE PLANT FOTOS (3)

Heat treatment
eliminates bio-hazard

Priviledged Information not to be copied. All rights reserved.

14
 REFERENCE PLANT FOTOS (4)

RSP Combustion
Chamber

Feed chute to RSP

combustion chamber

Priviledged Information not to be copied. All rights reserved.

15
 PLANT DESIGN FOR 80% A.F.
RSP-Technology in cooperation with Taiheiyo Engineering

TAD 4

CALCINER
COMBUSTION CHAMBER
Plastics, Sewage Sludge, Fine Coal
< 50 mm
TAD 3
TAD 2
TAD 1
MIXING
CHAMBER
Quench MAIN BURNER
Plastics, Animal Meal
Tires < 1,000 mm Bypass Fine Coal
< 20 mm

Priviledged Information not to be copied. All rights reserved.

16
 EXAMPLE ECONOMICS

Fuel COSTS (RED) Fuel INCOME (BLUE)

INCOME;
462'246 COSTS;
coal Supplier A
466'839 mixed plastic
Series1;
258'270 coal Supplier B
waste plastic pipes
coal Supplier C -381'358
sewage sludge - dry
petcoke
sewage sludge - non
saw mill waste
dried
Series1; wood chips reject paper
88'456
Series1; fuel income fuel costs
-20'529
Series1; 2'708 Series1; 64'740 -19'287
-31'013
Series1; 3'663 49'002 -10'059

Income 462‘200 USD Clinker production: 51‘500 t

Costs - 466‘800 USD

Σ Fuel Cost = 0.09 USD/t clinker

Priviledged Information not to be copied. All rights reserved.
17
 THANK YOU FOR YOUR
ATTENTION

Please visit www.atec-ltd.com

A TEC AMERICA
11 Poniente No. 2702 Dept. 5
Col. La Paz, 72160 Puebla, MEXICO
Tel.: +52 222 889 7907
E-Mail: inbox@atec-america.com

18 Priviledged Information not to be copied. All rights reserved.

 FICEM-APCAC Cement
Industry Technical
Conference

2009 Bogotá, Colombia

Dipl. Ing. Pedro Montes de Oca

Presentation - HURRIVANE/ 1
.09.2009
Tratando con mas gas de escape

1. Introducción – Efectos al tener mayor volumen de gas

2. Tecnología del HURRIVANE

a) Funcionamiento
b) Efectos en torre de precalentador
c) Ejemplo de ahorro

3. Aumento de eficiencia

4. Cementos Progreso Planta San Miguel

a) Instalación Horno 1
b) Instalación Horno 2

Presentation - HURRIVANE/ 2
.09.2009
1. Introducción –
Efectos del gas

Presentation - HURRIVANE/ 3
.09.2009
Efectos del gas

Más volumen de gas

 Más kW en el ID-Fan

 Más Costos

Tecnología ATEC para contrarestar estos efectos =

Presentation - HURRIVANE/ 4 1. INTRODUCTION – ALTERNATIVE FUEL

.09.2009
2. HURRIVANE –
Tecnología

Presentation - HURRIVANE/ 5
.09.2009
HURRIVANE Típico

1. Se agrega al tubo de inmersión del ciclón

2. Vanes en dirección del flujo

3. Reducción de la pérdida de presión

a) Reducción de kW ID Fan
b) Reducción Energía Específica

Presentation - HURRIVANE/ 6 1. INTRODUCTION – ALTERNATIVE FUEL

.09.2009
Efectos en torre de precalentador:
Reducción de dP  menos volumen de gas
Ejemplo 1: Producción Constante

Sin Con delta

HURRIVANE HURRIVANE
Presión estática [mbar] -72 -68 -4
Gas Temp [°C] 320 320 0
Caudal Gas [Nm3/h] 207’667 207’667 0
Caudal Gas [Am3/h] 538’535 536’260 -2275

VA pN TA
VN pA TN La reducción de presión gracias al
HURRIVANE se refleja en el volumen
de gas que tira el ventilador principal
Presentation - HURRIVANE/ 7 1. INTRODUCTION – ALTERNATIVE FUEL
.09.2009
Efectos en torre de precalentador:
Reducción de dP  menos aire falso

Ejemplo 1: Producción Constante

sin Con delta

HURRIVANE HURRIVANE
Presión estática[mbar] -72 -68 -4
Cantidad Gas [Am3/h] 538535 536260 -2275
Aire falso [Am3/h] 26927 26816 -114

A
False Air VN k 2 Δp ρ Air,A
ρ Air, N
La reducción de presión gracias al
HURRIVANE se refleja en la cantidad de aire falso
Presentation - HURRIVANE/ 8 1. INTRODUCTION – ALTERNATIVE FUEL
.09.2009
 Efectos en torre de precalentador
Menos ∆P & menor gas → menos kW ID Fan
Ejemplo 1: Producción Constante
Sin Con HURRIVANE delta
HURRIVANE
Cantidad gas [Am3/kg cli.] 538535 536260 -2275
kW ID Fan 1346 1274 -73
kWh/t cli. 11.54 10.92 -0.62
Energía en ID-Fan -5%

VA ΔP
kW
η
La reducción de presión, menor gas y menor aire falso gracias
al HURRIVANE se refleja en un ahorro de energía del 5% en
el ID-Fan
Presentation - HURRIVANE/ 9 1. INTRODUCTION – ALTERNATIVE FUEL
.09.2009
Efectos en torre de precalentador
kW Id Fan = const → Aumento de producción

Ejemplo 2: Aumento de producción

Sin Con delta

HURRIVANE HURRIVANE
Gas [Am3/kg cli] 538535 536260 -2275

kW ID Fan 1346 1274 -73

kWh/t cli. 11.54 10.92 -0.62
kWh/t cli. 0.62 0.62 +5%

Por lo tanto:
73 kW permiten aumento de producción del 5%
o reducción de kWh/t cli del 5%

Presentation - HURRIVANE/ 10 1. INTRODUCTION – ALTERNATIVE FUEL

.09.2009
 3. Aumento de eficiencia

Presentation - HURRIVANE/ 11
.09.2009
 Cálculo de posibles ahorros

Process Data Plant Data

Gas amount at ID Fan 1.78 [Nm3/kg cli] Clinker Production 2800[t/d]

Current T at ID-Fan 320 [°C] Level above Sea 800[m]
dp Stage 2 1500 [Pa] Fuel cons. 3538[kJ/kg cli]
dp with HV 30 [%] Prod. Days/year 321[days]
Static Pressure ID Fan -72 [mbar] Energy costs 0.10[USD/kWh]
Cp Gas PH Outlet 1.523 [kJ/Nm³ K]
O2 Top Stage 5 [%]
ID Fan efficiency 0.8 [-]
Temperature top stage 348 [°C]
Gas amount at pH Outlet 1.69 [Nm3/kg cli]
Pressure top stage -69 [mbar]
Temperature water injection 25 [°C]

Presentation - HURRIVANE/ 12 4. POTENTIAL COST REDUCTION

.09.2009
Cálculo de posibles ahorros (2)

Production Increase when kW at ID-

Savings Fan = const
Pressure drop reduction 450[Pa]
Gas amount at ID Fan 2,745[Am3/h]
Production
kW ID Fan 88[kW] increase 2.14[t/h]
kWh ID Fan 0.75[kWh/t cli]

Savings kWh 2,106kWh/day

Savings kWh 675,979kWh/year
Savings USD 67,598USD/ year

En este caso la ganancia de 88 kW en el ID-Fan permite:

Un ahorro de 0.75 kWh/ t cli
o un aumento de producción del 2%
Presentation - HURRIVANE/ 13 4. POTENTIAL COST REDUCTION
.09.2009
 4. Referencias en
Planta San Miguel de
Cementos Progreso

Presentation - HURRIVANE/ 14
.09.2009
Cementos Progreso:
Efectos en horno 1 Alimentación
constante kW en
a). Rendimiento constante Ventilador

Delta 0.11 -77.8 -55.96 -93 -65.7 0.0671 1.35

Reducción de caída de presión de 55.96 mm H20

Se consumen 66 kW menos en el ventilador

6% ahorro energético específico
Presentation - HURRIVANE/ 15
.09.2009
Cementos Progreso: Efectos en horno 1

2. Aumento de rendimiento.
Esta opción no se ha evaluado debido a nivel de demanda
del mercado, pero si se asume un incremento del 3% como
en horno 2, la mejora esperada sería:

Alimentación futuro + 2.45 t/h

Consumo específico - 0.62 kWh/t cli
Clinker futuro + 1.49 t/h
Aumento de producción + 3%

Presentation - HURRIVANE/ 16
.09.2009
Cementos Progreso:
Ventajas económicas en horno 1
a) Rendimiento Constante:
1.35 kWh/t clinker menos implica un
ahorro anual de US$ 80,272. (TRT 80%).

b) Aumento 3% Rendimiento:
Este escenario dependerá de la demanda
del mercado y de la ganancia en cada
tonelada vendida

Presentation - HURRIVANE/ 17
.09.2009
Cementos Progreso: Efectos en horno 2
Alimentación
a) Rendimiento constante. constante kWh en
Ventilador

Delta 0.1 -2.7 -59.6 -193.6 -163 0.04 -2

Reducción de caída de presión de 59.6 mm H20

Se consumen 162 kW menos en el ventilador

12.4% ahorro energético específico
Presentation - HURRIVANE/ 18
.09.2009
Cementos Progreso:
Caída de
Efectos en horno 2 presión
Producción de
b) Aumento de Rendimiento clinker

Delta 4.2 16.3 47.5 -11.4 16 2.55 -0.3

aumento de producción del 3.2%

Presentation - HURRIVANE/ 19
.09.2009
Cementos Progreso:
Ventajas Económicas horno 2
a) Rendimiento b) Aumento de
constante. Rendimiento

Presentation - HURRIVANE/ 20
.09.2009
 Thank you
ENERGY for your attention!

EFFICIENCY

ENVIRONMENT

www.atec-ltd.com
Presentation - HURRIVANE/ 21
.09.2009
 Dealing with More Chlorine

Tratando con más Cloruro

A TEC > Dealing with more Chlorine / 1

1 ATEC/JF: Confidential Information
REASONS
FOR USING A BYPASS IN THE CEMENT INDUSTRY

Raw meal which have high contents of chlorine,

alkalis and sulphur

Using a high amount of alternative fuels

containing chlorine & sulphur

Build ups and heavy coating in the area of the

kiln riser duct and meal pipe to the kiln

Strict environmental regulations

A TEC > Dealing with more Chlorine / 2

 GAS TAKE OFF DUCT
Main Advantages:
Big take off area
Low take off velocity
Particles < 10 µm

• No cyclones needed
• Gas can be used for raw meal
drying to reduce thermal losses

A TEC > Dealing with more Chlorine / 3

QUENCHING CHAMBER
Made completely of metal
(no lining required)
Cooling in 1 step to 200 C
Minimum space requirement
Simple & trustworthy operation

A TEC > Dealing with more Chlorine / 4

STANDARD BYPASS SYSTEM

Comp. Air

A TEC > Dealing with more Chlorine / 5

Coating/Build Up Conditions

operation
without bypass

original
operation

operation with
bypass

A TEC > Dealing with more Chlorine / 6

Bypass Rate Efficiency

5...10 % bypass rate is sufficient for chloride bypass systems

A TEC > Dealing with more Chlorine / 7
 A TEC Bypass
bypass
cyclone
2nd stage
quench at
mixed gas
duct to filter
Castle Cement
coarse dust
return

Bypass
Dust Cyclone and
1st stage Ducting
quench

A TEC > Dealing with more Chlorine / 8

CASTLE BYPASS SYSTEM

reserves onto required

design data

gas from preheater

Design Data for Guaranties Operating Range

refractory lining

refractory lining

Design
< 1,5 % Cl in hot meal

A TEC > Dealing with more Chlorine / 9

 Quench Chamber

Main Shut Off

Damper

Quench Air
Shut Off
Damper

Quench
Chamber

Quench Fan

A TEC > Dealing with more Chlorine / 10

 Quench Chamber Emergency Air

Generator starts
on power failure to
run fan to keep
equipment
downstream of
emergency shut
off valve cool

Emergency Fan

A TEC > Dealing with more Chlorine / 11

 Bag Filter / Silo Arrangement

Mounted directly on top of 120 m3 (approx 70 ton) Silo.

Sweeping Auger screws dust out to centre discharge

Screw & Rotary Feeder to Loading Head

Wagon loading 30tph

Water Spray on dust at loading head

Discharge capacity 30 t/h

A TEC > Dealing with more Chlorine / 12

 Bag house

Some details:
Mounted directly on top of
120 m3 (approx 70 ton) Silo.
Sweeping Auger screws dust
Bypass dust silo out to centre discharge
Screw & Rotary Feeder to
Loading Head
Truck loading 30tph

Truck loading
station
A TEC > Dealing with more Chlorine / 13
 Silo Discharge

Auger Drive

Auger Rotation

Shutoff Slide

Rotary Feeder

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Loading Spout

Water Sprays on Loading

Head to control dust
Dust from Bag Filter goes to
Quarry
Alternative uses for dust
such as washing out chloride
& reusing dust currently
under examination

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 Performance Test Result

• Cl in bypass dust 14%

• Cl in dust return to hot meal chutes 3.5%
• Cl in raw materials 0.0083%, clinker basis
• Gas flow at kiln inlet approx. 80,000 Nm3/hr
• Bypass % of gas flow at kiln inlet 8%

• Dust in gas at input to quench chamber 0.25 kg/Nm3

• Dust to quench chamber 38 te/day
• Dust out of quench chamber (including KCl) 45 te/day
• Dust to waste 22.5 te/day
• Dust return to hot meal chute 22.5 te/day

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Operational Results Today

Operation Period since start up: 30 months

Total unscheduled maintenance: insignificant

Total bypass dust saved from depositing: approx. 20‘000 tons

Total waste utilised for alternative fuel: approx. 165‘000 tons

Chloride in bypass dust: average 12% to 16%

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 THANK YOU FOR YOUR
ATTENTION
Please visit www.atec-ltd.com

11 Poniente No. 2702 Dept. 5

Col. La Paz, 72160 Puebla, MEXICO
Tel.: +52 222 889 7907
E-Mail: inbox@atec-america.com

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