Schenck Process Americas S.A.S / FCT Combustion Pty

1. Schenck Process Americas S.A.S / FCT Combustion Pty FICEM APCAC COSTA RICA 2012

2. CONTENTS 1 Schenck Process Americas S.A.S Presentation 2 FCT Combustion Pty Ltd Presentation

3. Efficient and Optimum Cement Production with Alternative Fuels By SanjivDhanjal (FCT Combustion, USA) and Fernando Garcia (Schenck Process Americas S.A.S, Colombia)

4. Your partner in cement Industry Products: Clay Sand Crusher relief screen • Belt weigher • Weighfeeder • Loss in weigh feeder MECHATRON • Flowmeter • MULTISTREAM • Bin weighing • Mass flow feeders MULTICOR • Screens • Truck and train scales • Loading automation • Alternativefuels. Limestone Sand Clay Apron feeder Limestone crusher Reclaimer wheel Return grits Lime- stone Sand Clay Separator Homogeni- zation Alternative: Raw mill SCHENCK Fuel Master Feeding of Alternative Fuels Flow gates Bucket elevator MECHATRON FE2SO4 Bucket elevator Return grits Separator Additive Belt weigher to be installed in apron conveyor Clinker Gypsum Store Blaine value Measurement Cement- mill Cooler Kiln MULTICOR-K - Feeding of pulverized coal (10 bar pressure proof) Cement Cement Cement SCHENCK Fuel Master Feeding of Alternative Fuels

5. Feeding systems FUEL-Mastersolutions for alternative fuels The goal: Reduce the operation costs in cement kilns by substituting of: More expensive primary fuels (Coal, Oil, Gas) for alternative low cost fuel. ... Giving the less impact on: • Clinker quality • Production capacity • stability of kiln • and atmosfericemisions.

6. Feeding systems FUEL-Mastersolutions for alternative fuels Design requirements for fuel systems: • They must feed a wide range of materials. • Hi accuracy and high feeding constancy. • High reliability and high availability. • Capacity of manage very big sizes of material. • Easy integration on existing installations. • Easy maintenance • Cheap return cost

7. Feeding systems FUEL-Mastersolutions for alternative fuels 3 golden rulesfor design of alternative fuels plants: • Specifying robust equipment despite low density! Ensure high availability of systems. • Avoid bottleneck - Alternative fuels tries to create bridges.  Avoid dead times for plugging. • Design a wide range of densities and flow properties.  Makes sure high flexibility using several materials.

8. Feeding systems FUEL-Mastersolutions for alternative fuels Reception Storing and transport Weighing and feeding

9. FCT Turbu-JetFor Regular and Alternative Fuel

10. Fuel Combustion • Gaseous • Nozzle design is based on flow and pressure. Typically multiple holes • Liquid • Atomization required for efficient combustion • Pressure atomization requires up to about 40 barg (600 psig) • Air and steam also used for atomization, typically at about 6-8 barg (90-120 psig) • Solid • Grind coal or coke to about 90% through 75 micron sieve • Final size depends on volatile fraction • Purpose is to facilitate fuel and air mixing

11. Alternative Fuels come in all shapes and sizes Rice Husks Wood Waste Paper and Plastics Tire Shreds Diapers Cherry Stones

12. Testing and Modeling to determine best way to fire alternatives

13. FCT Alternative Fuel Nozzle

14. Kiln Mineralogical Reactions • C3S • C2S • C3A, • C4AF

15. FCT Modeling for Burner Design Physical Modelling Water Bead Acid/Alkali Mathematical

16. Example – Problem • 1650 TPD kiln firing coal/coke/gas can only fire 30% coke before high CO and build up • Model shows • The burner provides incorrect momentum to entrain the combustion air. • The burner position and angleinthekiln cause flame impingement. • The kiln is operated with too little excess air. • Flame length is excessive at all reasonable excess air levels.

17. Example - Solution • Model used to design new burner • New burner • Shorter flame length at all excess air levels, can operate at 2% oxygen • Performs best when aligned with the kiln axis • Has correct burner momentum for short flame.

18. Example - Benefits • The benefits to the plant are • Petcoke usage has now increased to 100% - previously 30% • Clinker quality has improved dramatically, with 28 day strengths increasing by 10% • Almost no build up has been experienced in the kiln and riser duct, where previously build up was restricting kiln performance even with 30% petcoke • A fuel saving of about 45 kcal/kg cli was seen by the plant, partly attributable to a change in the coal dosing system and partly to the new burner

19. FCT Gyro-Therm BurnerFor Gas and Coal

20. COSMA Output in Real Time • On-Line X-Ray Diffraction Analyzer • Measures mineral phases directly, like alite, belite, gypsum de-hydration and free lime • Data sent to process control system for automatic quality control and process optimization • Continuous mineral analysis in Real Time • Control quality continuously • Increase limestone or pozzolan addition • Reduce free lime variability, lower fuel, reduce NOx, less grinding energy • Ensure clinker quality, especially when burning alternatives

21. SUMMARY MATERIAL HANDLING COMBUSTION EFFICIENCY PRODUCT QUALITY CONTROL

22. THANK YOU VERY MUCH.