RCA Kiln Nar2 Due To Analyzer

Maximizing NAR TSR
Pre and Co-processing concept

(Proposal)
HIL / CE
© Holcim Group Support Ltd 2011
HIL TSR Journey 2006 – 2012 and Aspiration
Target 2016 :
TSR NAR-1 : 24.13%
Actual Projection TSR NAR-2 : 19.81%
TSR CIL-2 : 7.35%
Actual 2011 TSR HIL : 16.12%
TSR NAR-1 : 10.7%
TSR NAR-2 : 9.4%
TSR CIL-2 : 1.4%
TSR HIL : 7.0 %
Geocycle Asia Network Meeting, Singapore, 29 Feb 2008 © 2012 Legal entity 2
Way forward : 2012 to 2016 HIL Journey planned
© 2012 Legal entity 3

Summary Capex Finplan Road Map 2012 – 2016
Related with Increasing Waste Utilization in Kiln
© 2012 Legal entity

AFR Preparation – Waste and AFR
Solid
Solid
ISW
Coarse ILC fuel
NAR-1
Consumer
Products
Incoming waste/AFR
Fine solid SLC
Ready to burn AFR

fuel NAR-2
Sorted Plastic
Waste from
MSW
ILC fuel NAR-2
(ISD)
Sludge
KI fuel NAR-2
(Non CV AF)
low viscosity Oil sludge
sludge Liquid waste
- Oil sludge Pumpable

Pasty & - Paint sludge sludge
Solid sludge - Other sludge
- Drilling cuttings
KI fuel NAR-2
- Contaminated Soil
AR with - WWT Sludge
Organic - Foundry Sand
- Fly ash 5
© Holcim Group Support Ltd 2011 26.09.2011/SCE
AFR Preparation Sites – Basic Concept
Solid
ISW
Solid
Shredding line
Consumer phase 3 Coarse ILC fuel
Products NAR-1
Sorted Plastic
Waste from Fine solid SLC
MSW fuel NAR-2
Sludge ILC fuel NAR-2

(ISD)
low viscosity Oil sludge KI fuel NAR-2

sludge Liquid waste (Non CV AF)
- Oil sludge Sludge platform

Pasty & - Paint sludge
Solid sludge - Other sludge Pumpable
sludge
- Drilling cuttings
- Contaminated Soil
AR with - WWT Sludge
Organic - Foundry Sand KI fuel NAR-2
- Fly ash 6
AFR Feeding installations – Basic Concept
NAR-1
Solid
Coarse ILC fuel

NAR-1
Shredding line Coarse ILC fuel
phase 3 feeding
Fine Solid SLC
Fuel NAR-2
ILC fuel NAR-2 Fine SLC Fuel

(ISD) Feeding
KI fuel NAR-2
NAR-2
(non CV AF)
ILC / Kiln Inlet

Feeding
Sludge platform Pumpable
sludge
Putzmeister
Pump
KI fuel NAR-2
7
Platform Capacity
• Solid preparation plant: 135’000 t/a
• Sludge preparation plant: 25’000 t/a (Sludge 18’000 t/a
and AR with Organic 7’000 t/a)
• Total Capacity : 160’000 t/a
8
© Holcim Group Support Ltd 2011 AFR Turntable India 2011 04.08.2011/MAI
Location
(proposal)
Solid & Sludge AFR Platform
9
Proposed new location Solid and Sludge Platform
New proposed
location for
AFR platform
10
Proposed new location Solid and Sludge Platform
New
proposed
location for
AFR
platform
Geocycle Platform IDR 129 Bio

1 Solid waste Pre-processing Facility (waste shredding, sorting, blending equipment and facilities)
2 Sludge waste Pre-processing facilities (waste preparation, sorting, blending equipment and facilities)
Utility facilities (Secure access, fire safety, waste water treatment, water catchment basin, customer center for vendor
3
audits , witness process, etc.)
4 Fully complaint with design safety criteria
11
Solid AFR Platform
12
New shredding line
• Phase 3: Production of ILC fuel (<150mm) for NAR1&2
and SLC fuel (<30mm) for NAR2
 67‘500t/y ISW/RDF (<150mm)
 67‘500t/y ISW/RDF (<30mm)
400k
Primary Second.
Table Screen Air SLC fuel (2D
Shredding Fe Shredding 2D
Feeder (50 mm) Classifier <30mm)
< 150mm <30mm
ILC fuel (2.5D

ILC fuel <150mm)
(<50mm)
Manual sorting of
heavy fraction
13
© Holcim Group Support Ltd 2011 Inert 26.09.2011/SCE
Flow sheet Solid AFR Platform
14
Lay out Solid AFR Platform
SOLID AFR platform : Future:

- Walking floor Belt conveyor system
- Primary shreeder to preheater NAR 1 &
- Star Screen 2
- Magnetic separator
- Air classifier
- Secondary shreeder
- Conveyor systems
15
Lay out Solid AFR Platform
Product size <30mm
Star screen
Primary shreeder
Air Classifier
Secondary shreeder
Product size 30 – 150 mm
Walking floor Feeder
16
Solid AFR Platform – Basic Design
Basic design :
 Roofed Storage cap. for receiving material 525 t
 Dimension 60x25x4, eff storage 60%  3500 m2
 Est. BD : 0.15 t/m3
 Main equipment
 Walking floor feeder
 Primary shredder (Max capacity 30 tph)
 Star Screen
 Magnetic separator
 Air classifier
 Secondary shredder (Max Cap 15 tph)
 Conveyor systems
 Facilities :
 Water pond for fire suppression : 1000 m3
 Water pond for rain polluted water (roofed): 300 m3
 AFR Office
 Access concrete road (wide 10 m)
17
Sludge AFR Platform
18
Flow sheet Sludge AFR Platform
Sludge Platform
74x38 = 2812m2
19
Basic design Sludge AFR Platform
Storage capacity :
• Total est receiving 17.875 t/y
• Receiving area 2430 m2 (450 t)
• Total drum 900 (180t); jumbo bag 270
(270t)
• Stock capacity 7 day operation
Production capacity :
• Max production 2.5 tph (60 tpd)
Handling material :
Static crane Jonsered
Mixer
Sludge Pump (existing)
Shreeder (M&J 1000)
20
Lay out Sludge AFR Platform
Mixer
Existing
Sluge pump
Shreeder
21
2013
Sludge platform
• Operating principle of the sludge platform: Production of
pumpable sludge
Hydraulic arm for
Four unloading pits for material handling
low viscosity sludge
and pasty material in
drums, jumbo bags Collection pit or
and bulk container for solids
Mixing pit (no screen)
Movable shredder for Shredding of screen rejects

opening of bags, until size is ok for concrete
mixer -> impregnation ->
drums, containers etc. contam. soil or RDF feeding
(M&J 1000-6)
Post shredding pit (no Piston pump with

screen) tiltable screen
(50mm)
22
Ready to pump pit
(100mm screen)
2013
Sludge platform
• Operating principle of the sludge platform: Production of
contaminated soil
Feedhopper and
belt weight feeder
in PH tower
Contaminated
soil
Material transport
into PH tower by
contruction elevator
Pasty material
Double shaft batch

Storage and packing of
concrete mixer for
impregnated material in
impregnation of
the neighbouring building
pasty material
23
End of Slides
24
© Holcim Group Support Ltd 2011 AFR Turntable India 2011 04.08.2011/MAI
Roadmap – NAR-2
2013
• Improvement of
existing solid feeding
installation at NAR-2
for contaminated soil
feeding
• Mixing of cont. soil
and pasty/solid oil
sludge by loader
Sludge
TSR (sludge): <2%
2013
Total sludge to NAR-2:

41t/d
25
2013
AFR feeding NAR-2
• As light (RDF) and heavy (solid sludge & contaminated
soil) material shall be dosed with the same system, it is
suggested to install a belt weigh feeder which contorls
the speed of the extractor.
• The density of the two materials differ by factor 10. This
cannot be handled with the same belt weigh feeder.
• Design of extraction hopper and belt weigh feeder shall
be for RDF.
• In case of feeding of heavy material, only one extraction
screw shall be running and the signal of the belt weigh
feeder shall be ignored (only volumetric dosing as feed
rate is small).
26
2013
AFR feeding NAR-2
• Flowsheet
27
2013
AFR feeding NAR-2 – Screw Extraction Hopper
• Double screw extration hopper design
„Funnel“ to
facilitate jumbo Length of hopper:
bag emptying 4000mm
Height of hopper:
2000mm
Pitch of screw at Pitch of screw at Pitch of screw at
beginning of hopper: end of hopper: after hopper:
200mm (cont. 300mm 350mm (avoid
increasing) blockages)
Width of hopper:
1000mm
Shaft diameter: Outer screw diameter:

2 x 300mm 2 x 500mm
28
2013
AFR feeding NAR-2 - Screw Extraction Hopper
• Capacity estimation for one extraction screw (RDF)
29
2013
• Capacity estimation for one extraction screw (CS)
30
2013
• Feeding capacities and buffer time estimation
 Light Material (0.1t/m3, both screws running): 0.3 – 1.8t/h
 Buffer time in case of 1.8t/h RDF: 20min*
 Heavy Material (1.2t/m3, one screw running): 1.8 – 11t/h
• If heavy material is fed, the 1.8t/h is still well below the

max. recommended coarse ash input of 2% based on
clinker.
• For transportation of light and heavy material to the PH
tower of NAR-2, the hoist currently used at NAR-1 shall
be moved to NAR-2 as soon as the construction
elevator is installed at NAR-1.
*Hopper volume 8m3, usable 75% -> 0.6t, density 0.1t/m3
31

RCA Kiln Nar2 Due To Analyzer

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Maximizing NAR TSR

Pre and Co-processing concept

© 2012 Legal entity 3

© 2012 Legal entity

Ready to burn AFR

- Oil sludge Pumpable

Sludge ILC fuel NAR-2

low viscosity Oil sludge KI fuel NAR-2

- Oil sludge Sludge platform

Coarse ILC fuel

ILC fuel NAR-2 Fine SLC Fuel

ILC / Kiln Inlet

Solid & Sludge AFR Platform

Geocycle Platform IDR 129 Bio

ILC fuel (2.5D

SOLID AFR platform : Future:

Product size <30mm

Product size 30 – 150 mm

Walking floor Feeder

Mixing pit (no screen)

Movable shredder for Shredding of screen rejects

Post shredding pit (no Piston pump with

Double shaft batch

Total sludge to NAR-2:

Shaft diameter: Outer screw diameter:

• If heavy material is fed, the 1.8t/h is still well below the

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