Maximising the thermal substitution rate of alternative fuels in kiln and calciners: Tahir Abbas, Cinar (UK)

Filmed at Cemtech Asia 2015, 21-24 June, Grand Hyatt, Bangkok, Thailand


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Today, I'll just talk about what are the opportunities which we have for burning alternative fuels and what are the barriers and constraints. So we'll go bit more into the flames and how we burn these fules and what are the difficulties. So to start with the introduction, Cinar was incorporated in 1988, so we have been providing services to the combustile industries and cement aligned industries over 25 years.

Some of Cinar's clients among these multinational companies as well as smaller companies For Holcim alone, we have done almost 30 projects for the various kilns and calciners. Including Cilacap and Narogong plants in Indonesia and Thailand, we're working for SCG on their plant Thong Song to improve the thermal substitution and their calciner of biomass and Tyre Derived Fuel.

So, and also I just put this light to show we don't not just provide the advice and the solution to the question which was asked on Sunday, we have a Cinar associates, so we work with fives Pillard Group, Cementis from Switzerland and ALTCrros from States and also PM Technologies from Austria, and with the help of these partners, we're able to provide low-CapEx solutions on permitting issues, and then the business planning, and on burner design and on feeding and dozing system of alternative fuels. And also the upgrades I presented last year, some results on the upgrade projects which we did with PM Tech, so that's now coming back to alternative fuels and biomass. AFR has already mentioned about the waste content, water content of the waste, and the ash content, so these needs to be looked at before we look at the taking any advantages of burning biomass and alternative fuels. And then is the false air and the oxygen level, this could be controlled through the technologies, better technologies, handling systems, and reducing the air leakage, and to combustion and process optimization. So today, it will be more on the the false air reduction and the oxygen. If these are not controlled, then we have heat consumption and also the production losses, the clinker production.

So, that's data coming from Holcim, I will not go through the details. That's a plant, Holcim plant, Portland and U.S., and they were firing 20% of thermal substitution rates of the cheap dice and beyond that they had built up issues, so we worked with them and designed eventually, that's the tyre inlet pipe over there and that is the venturi over the distance of around three meters and that's the computational grid, I'll describe the model briefly later on. So basically, in the riser they had velocity of 28 m/s and that wasn't enough to revert the chips which were falling down two inches by two inches, and that was reduced to give a velocity of around 40m/s over the distance of around 3m. So that's the plant feedback. A refractory throat restriction was added and tyre chip thermal substitution rate was increased from 2 to 8 tons per hour and that is 65% of the calciner thermal input.

And when we look at the price difference, 30 tons, $30 per ton, so the plant was able to save around 1.3 million per year basis and these are the cost. So the study cost was very little and 7% was the implementation cost, and the payback was within a month, but plant implemented these recommendations within a year or so, so now they're able to go even higher around 10 times per hour.

So, simulation tool which we use at Mineral Interactive Computational Flow Dynamics, which is in house to help models which we develop at Emperial College, that's from where the CFD modelling started, and it has multi-fuel firing capabilities, so we can fire coal, natural gas, oil, and all these alternative fuels together, and combustion model is directly coupled with

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