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ReduDust A System for Bypass dust recovery By: Ing. Jonathan forinton ing. Pedro montes de Oca

ReduDust A System for Bypass dust recovery By: Ing. Jonathan forinton ing. Pedro montes de Oca. Redudust. Agenda: Introduction Basic Concept Products Application Pilot Plant Industrial Installation Summary. Introduction. Many plants have implemented a bypass for removing

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ReduDust A System for Bypass dust recovery By: Ing. Jonathan forinton ing. Pedro montes de Oca

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  1. ReduDustA System for Bypass dust recoveryBy: Ing. Jonathan forinton ing. Pedro montes de Oca

  2. Redudust Agenda: • Introduction • Basic Concept • Products • Application • Pilot Plant • Industrial Installation • Summary

  3. Introduction • Many plants have implemented a bypass for removing chlorine from the pyrosystem • Main Advantage: • Stable operation despite Cl input • Main challenges today: • Clean disposal of bypass dust • Recuperation of raw material • Winning of byproducts

  4. Introduction • Properties of Bypass dust: • Very poisonous for the ambient in contact with water • Alkalis (K2O, Na2O), • Chlorine (Cl) • Sulfur (SO3) • Mercury, heavy Metals • Use today: • Limited addition to cement • Rest landfilled • Use with REDUDUST: • Economically friendly solution: conversion to marketable products: salts + clean raw meal

  5. Basic concept • Before leaching – particles covered with Micro Crystals of Chlorine based salts • Water dissolves the Micro Crystals - uncovered particles are now able to react with water • Blue areas indicate free lime • Free lime reacts to Lime Hydrate (orange)

  6. Principleprocessdiagram Chemicals Bypass-Dust- Silo Brine Treatment & Conditioning Separation of Brine and Filter Cake Mixing Filter Cake Waste Heat Source Crystallization Heat Supply Salt Products

  7. Mass Balance Overview Data givenfortypical Egypt bypassdust 5,0 t/h 6,0 t/h 1,0 t/h 10 MW 6,0 t/h 4,0 t/h 2,0 t/h Bypass Dust Product Material ReduDust Process Plant Sewage water Potable Water Cement Waste Heat Chemicals Salts

  8. Intermediate Products • Limestone slurry • collected sediments from CO2 precipitation • Heavy metal sludge • collected sediments from heavy metal treatment process Both are usually not leaving the process !! Limestone slurry (dry) Heavy metals sludge (dry)

  9. Final Products • Lime hydrate filter cake • Desalted bypass dust released from filter press • Salt • Crystallized mixture of all salt contained in brine • Separation and purification of main elements possible e.g. Potassium chloride (KCl) Filter cake Salt

  10. ProductApplications • Filter cake (low chlorine) –approximately 35% of residual moisture • Reintroduce back to process into cement mill due to low Cl content (<1%) • SO2 Trap Preheater Tower and/or Filter Equipment • Recycling as Raw Material: Calcining at 580°C, Energy 1.99MJ/kg CaO instead of 3.17 MJ/kg CaO • Additive for Cement Blends • No need for new material licenses, because it is considered as bypass dust

  11. ProductApplications • Salts • Valuable product on market (e.g. fertilizer production at around 300 €/t market price) • Valuable Raw Material for various processes in the chemical Industry • Meets all European laws for chemical products

  12. Pilot Installation Pilot Plant ATEC Technical Center (AUT)

  13. PILOT INSTALLATION

  14. Pilot Installation Crystallizing Chemical Treatment Drying Filtration Mixing Mixing

  15. Pilot Installation Bypass dust storage Slurry rapid mixer Peristaltic pump Filter press

  16. Pilot Installation Chemical dozing Crystallizer Sedimentation tank Process analytics Dryer

  17. Industrial Installation First Industrial-Sized Plant Holcim Rohoznik

  18. Industrial Installation Data givenfortypical European bypassdust • Basic design principles • Utilization of waste heat from the cement plant • Installation must follow chemical installation requirements especially for environmental and safety reasons • Automatic operation • Reception of Bypass dust from different plants is considered

  19. Industrial Installation Data givenfortypical European bypassdust • Plant capacity • Standard design capacity of 20.000 tpy of Bypass dust • 4.000 tons of salts per year (approx. 3.000tons of KCl)

  20. Respecting optimal flow Bypass dust Filter cake Brine Salt Chemicals Dimensions of footprint 24 m x 36 m KClsilo Crystallization Chemicals NaCl bags Mixing & Chemical treatment Tanks storage Filter cake outlet Filtration Bypass dust storage, dosing and transport PLANT ARRANGEMENT

  21. Bypass dust 20k t/y CKD 8 – 15 % of Chlorine Filter cake 16k t/y Washed bypass dust <1% of Chloride moisture <30% Brine 20k t/y Saturated salty water >10% of Chlorine Chemicals used 4 common industrial chemicals available on the market Salt KCl >95% purity NaCl salt >98% purity MATERIALOVERVIEW

  22. Industrial Installation Data givenfortypical European bypassdust • Operational data • 3 operators full time operation in 3 shifts working days • depending on kiln operation due to its heat demand (important for design of the storage capacity) • Heat need for crystallization and drying is around 1.4MW • Designed to handle 5-15% chlorine content bypass dust • Overall Cl-extraction efficiency >90%

  23. Industrial Installation

  24. Summary • Zero waste • Recycling of raw meal • Production of a saleable Product

  25. Thank you for your attention Please visit www.atec-ltd.com

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