AFS SKEWER BURNER TECHNOLOGY OPTIMIZING WHOLE TIRE FUEL FOR - - PowerPoint PPT Presentation

AFS SKEWER BURNER TECHNOLOGY

• OPTIMIZING WHOLE TIRE FUEL

FOR PRECALCINER KILNS

AFS SKEWER BURNER TECHNOLOGY

• Prepared by: John Tiernan
• Presented by: Raul Montes de Oca

INTRODUCTION

Challenges of using whole tire fuel in precalciner kilns

• Sulfur Cycle
• Localized Reduction

History of Suspension Burning The Latest in Suspension Burning Technology Maximum Performance Potential

Precalciner Kil iln - Tire Fuel P Performance

Precalciner kilns are typically limited in the amount of whole-tire fuel they can burn.

• Traditionally tires are fed in to the low
• xygen environment of the kiln backend
• Localized Reducing Conditions
• Excessive sulfur buildup
• 5% to 10% substitution rates

DOUBLE GATE AIRLOCK VALVE

Double Gate Airlock Valve

KILN TIRE CHUTE BACK END FEED SHELF

2% Excess Oxygen High Temps of 1050° C Extended Sulfur Cycle Riser Duct

COAL BURNERS

DOUBLE GATE AIRLOCK VALVE

Cause for Limited Feed Shelf Firing In Precalciner Kilns

Localized Reducing

SUSPENSION BURNERS

COAL BURNERS

Whole Tire Suspension Burning

Rack-Style Suspension Burner System

La Calera, Chile

• 1 tph per burner
• No sulfur buildup issues from tires

The La Calera, Chile

Rack-Style Suspension Burner System

The La Calera, Chile

Rack-Style Suspension Burner System 3 Phase Project starting in 2001

• Testing Burner
• Automated Burner with Hook Elevator
• Second Burner in 2007

Rack Style Suspension Burners provide 0.7 to 1 ton per hour of whole tyre fuel

The La Calera, Chile

Rack-Style Suspension Burner System

• Allows for 2 car tires or 1 truck tire
• Wire buildup on forks was an ongoing

The problem that inspired the idea of skewer

The Skewer

Originally designed to suspend a shish kabob… and now your tires

THE SKEWER BURNER

since 2013

Rod Length = Feed Rate

Feed rate rule of thumb 1 tph / 1 meter of skewer rod 2.0 m = 2.0 tph

Rod Length = Feed Rate

4 m = 4 tph Feed rate rule of thumb 1 tph / 1 meter of skewer rod

The First Skewer Suspension Burner

For TXI Midlothian

Skewer Suspension Burner prototype

New Spanning Skewer with Wire Removal

for San Gabriel

WEIGHT AND DIAMETER MEASUREMENTS DOUBLE GATE AIRLOCK VALVE LOADING CHAMBER HOT RAM SKEWER ROD WIRE RECOVERY

New Spanning Skewer with Wire Removal

• Enclosed loading chamber
• No hydraulics
• Electric servo motors
• Air cylinders for airlock valve

Skewer Rod Life

• Shown is skewer rod after 12

months use in calciner.

• Rated for 1,200°C.
• First rod was used for a total
• f 36 months

Cantilevered Skewer vs. Spanning Skewer

Cantilevered Skewer Spanning Skewer

CALCINER OD

Truck Tire Performance

• 4 truck tires per meter of skewer
• 5 car tires per meter of skewer
• Truck tires are 4.5 x heavier
• 180 kgs vs 50 kgs / meter
• 3.6 time more fuel / meter
• Less problematic in conveyors
• Overall excellent fuel for skewer

FUEL COST SAVINGS EXAMPLE

COMPLETE SKEWER SYSTEM INCLUDING: SEMI-AUTOMATIC HANDLING SYSTEM WITH INSTALLATION

• 3 tons/hour x 330 days of system operation =

23,760 metric tons of tire fuel annually

• Approximate tyre heat value 1.2 times coal =

Replacement of 28,512 tons of coal annually

• Coal cost savings of $100/ton =

$2.85 million/year fuel cost savings

• Approximate turnkey system cost $2.0 million USD

Approximately 9 month return on investment

AFS Fully Automatic Tire Feeding Systems

La Calera Chile System Hook Elevator System

HOOK ELEVATOR CENTERING CONVEYOR MANUAL LOADING BELT MAINTENANCE PLATFORM

5.7 m O.D. CALCINER 5m SKEWER ROD FOR COMBUSTION CONVEYOR SYSTEM FROM GROUND LEVEL SKEWER LOADING SYSTEM

San Gabriel Skewer Burner System

4.0 t/h Rated capacity

SUMMARY

Precalciner kilns are whole-tire fuel limited when tires are fed to the kiln backend, which causes localized reducing conditions leading to excessive sulfur buildup in the riser duct and upper vessels. The Skewer Suspension Burner enables cement kilns to retain high amounts of whole-tire fuel in the optimal burning position of the

• xygen rich calciner.

As a result, precalciner kilns can burn higher amounts of whole-tire fuel without creating additional CO or SO2 from tire combustion.

Muchas gracias por su atencion

www.afstechnology.com

Preguntas?

Localized Reduction

• Reduction involves a decrease in oxygen and in this case it is a decrease in the

raw material oxygen

• The gas stream is being reduced by the volatiles in the fuel
• When the volatiles deplete the gas stream of its oxygen, this

leaves no oxygen for the slower burning fixed fuel carbon

• The fixed fuel carbon needs its oxygen for combustion from somewhere and finds

it in the raw material sulfur

This is localized reduction