Pub Date : 2013-04-11DOI: 10.1109/CITCON.2013.6525275
S. Ziegler, J. Bittner
A company operates fly ash beneficiation facilities that produce high quality pozzolan from poor quality fly ash. A patented electrostatic separation process reduces the carbon content of fly ash to produce a low loss on ignition (LOI) product used as a portland cement replacement in concrete products. Additionally, a high carbon content product stream is produced and is returned to utilities to recover fuel value or to cement kilns as a fuel and raw material. Two processing facilities have been commissioned in Florida; one in Tampa and another in Jacksonville. Both installations also include a patented ammonia removal process that reduces ammonia content on the fly ash from levels of greater than 2000 ppm to levels less than 75 ppm. The Tampa facility includes three separators, an ammonia removal process, two concrete slip-form product silos and a 25,000-ton dome. The plant is capable of processing 350,000 tons of fly ash per year. The Jacksonville installation contains two separators and an ammonia removal process capable of processing 300,000 tons per year. Twelve (12) ash beneficiation facilities have been commissioned in North America, the United Kingdom and Poland along with two mineral processing facilities in Europe and Canada.
{"title":"Fly ash carbon separation and ammonia removal in Florida","authors":"S. Ziegler, J. Bittner","doi":"10.1109/CITCON.2013.6525275","DOIUrl":"https://doi.org/10.1109/CITCON.2013.6525275","url":null,"abstract":"A company operates fly ash beneficiation facilities that produce high quality pozzolan from poor quality fly ash. A patented electrostatic separation process reduces the carbon content of fly ash to produce a low loss on ignition (LOI) product used as a portland cement replacement in concrete products. Additionally, a high carbon content product stream is produced and is returned to utilities to recover fuel value or to cement kilns as a fuel and raw material. Two processing facilities have been commissioned in Florida; one in Tampa and another in Jacksonville. Both installations also include a patented ammonia removal process that reduces ammonia content on the fly ash from levels of greater than 2000 ppm to levels less than 75 ppm. The Tampa facility includes three separators, an ammonia removal process, two concrete slip-form product silos and a 25,000-ton dome. The plant is capable of processing 350,000 tons of fly ash per year. The Jacksonville installation contains two separators and an ammonia removal process capable of processing 300,000 tons per year. Twelve (12) ash beneficiation facilities have been commissioned in North America, the United Kingdom and Poland along with two mineral processing facilities in Europe and Canada.","PeriodicalId":400797,"journal":{"name":"2013 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2013-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114454170","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2013-04-11DOI: 10.1109/CITCON.2013.6525260
L. Blahous, C. Potocan, F. Kolb, E. Gallestey, T. Marx
The optimum quantitative addition of gypsum to clinker prior to cement grinding is an optimization opportunity for cement manufacturing, which has not yet been extensively used. Near Infra-Red identifies complex chemical molecular structures of minerals. The drawback of this method is that it measures on the material surface only. Since the gypsum additive is statistically homogeneous, it is a suitable material for Near Infra-Red On Line analysis. This paper presents calibration results of SO3 in gypsum. It also describes how this analysis can be used as input to an optimization algorithm software suite, which is based on model predictive control to arrive at an optimum cement quality within complex plant and cement type specific constraints. This optimization software solution implements closed loop quality control at the minimum overall production costs.
{"title":"Optimizing cost and quality of finished cement using near Infra-Red gypsum on line analysis and model predictive control","authors":"L. Blahous, C. Potocan, F. Kolb, E. Gallestey, T. Marx","doi":"10.1109/CITCON.2013.6525260","DOIUrl":"https://doi.org/10.1109/CITCON.2013.6525260","url":null,"abstract":"The optimum quantitative addition of gypsum to clinker prior to cement grinding is an optimization opportunity for cement manufacturing, which has not yet been extensively used. Near Infra-Red identifies complex chemical molecular structures of minerals. The drawback of this method is that it measures on the material surface only. Since the gypsum additive is statistically homogeneous, it is a suitable material for Near Infra-Red On Line analysis. This paper presents calibration results of SO3 in gypsum. It also describes how this analysis can be used as input to an optimization algorithm software suite, which is based on model predictive control to arrive at an optimum cement quality within complex plant and cement type specific constraints. This optimization software solution implements closed loop quality control at the minimum overall production costs.","PeriodicalId":400797,"journal":{"name":"2013 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"218 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2013-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114682019","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2013-04-11DOI: 10.1109/CITCON.2013.6525268
J. Tomanovich, J. Knotts
NESHAP standards have been finalized and enforcement dates set. In terms of Particulate Matter (PM), there will be significant reductions in the emissions limits allowed by federal legislation. The new standards of less than 0.07 lb/ton of clinker in existing baghouses (and 0.02 lb/ton in new sources) will stretch the performance limits of current filters. To achieve these new limits it will be important to identify all potential sources of PM emissions. For the fiberglass-backed membrane filter bags typically used in cement kiln baghouse applications, the seam area of the bag can be a significant source of PM leakage. The purpose of this paper is to share results of recent field trials in which membrane filter bag seams have been sealed to achieve lower PM emissions levels. A model for predicting filter bag failure modes is offered to assist cement producers in identifying which baghouses may benefit the most from this technology development.
{"title":"Filter bag seams as a source of particulate matter (PM) emissions","authors":"J. Tomanovich, J. Knotts","doi":"10.1109/CITCON.2013.6525268","DOIUrl":"https://doi.org/10.1109/CITCON.2013.6525268","url":null,"abstract":"NESHAP standards have been finalized and enforcement dates set. In terms of Particulate Matter (PM), there will be significant reductions in the emissions limits allowed by federal legislation. The new standards of less than 0.07 lb/ton of clinker in existing baghouses (and 0.02 lb/ton in new sources) will stretch the performance limits of current filters. To achieve these new limits it will be important to identify all potential sources of PM emissions. For the fiberglass-backed membrane filter bags typically used in cement kiln baghouse applications, the seam area of the bag can be a significant source of PM leakage. The purpose of this paper is to share results of recent field trials in which membrane filter bag seams have been sealed to achieve lower PM emissions levels. A model for predicting filter bag failure modes is offered to assist cement producers in identifying which baghouses may benefit the most from this technology development.","PeriodicalId":400797,"journal":{"name":"2013 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"118 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2013-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134445620","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2013-04-11DOI: 10.1109/CITCON.2013.6525263
A. B. Amin, J. Kutz
This paper describes the function and operation of hydraulic drive systems for modern Clinker Coolers and related components. Based on the most recent technological developments, tremendous progress has been made in regards to this critical application for the cement industry. Provided is a functional description in regards to the clinker cooler drive, Hydraulic and Electric schematic as well as the drive mechanism. Some of the important features and challenges involved with maintaining uptime and reliability of this very critical part of the clinker production will be explained. As well as providing helpful hints to avoid potential failure, share experience and discuss maintenance practices to improve the reliability of the cooler drive.
{"title":"Hydraulic drive systems for Clinker coolers","authors":"A. B. Amin, J. Kutz","doi":"10.1109/CITCON.2013.6525263","DOIUrl":"https://doi.org/10.1109/CITCON.2013.6525263","url":null,"abstract":"This paper describes the function and operation of hydraulic drive systems for modern Clinker Coolers and related components. Based on the most recent technological developments, tremendous progress has been made in regards to this critical application for the cement industry. Provided is a functional description in regards to the clinker cooler drive, Hydraulic and Electric schematic as well as the drive mechanism. Some of the important features and challenges involved with maintaining uptime and reliability of this very critical part of the clinker production will be explained. As well as providing helpful hints to avoid potential failure, share experience and discuss maintenance practices to improve the reliability of the cooler drive.","PeriodicalId":400797,"journal":{"name":"2013 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"18 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2013-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124566992","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2013-04-11DOI: 10.1109/CITCON.2013.6525267
K. Poulsen, S. W. Miller
Proposed NESHAP (National Emissions Standard for Hazardous Air Pollutants) emission regulations in the US include the reduction of THC (Total HydroCarbons) and particulate matter to lower limits than what is required today. A single-step technology has been developed for dealing with both of these emissions. In the laboratory as well as at a US cement plant, results and knowledge from slip stream pilot tests have been gained. The promising results show it is possible to obtain very high removal efficiencies of the THC, especially organic HAPs (Hazardous Air Pollutants) and at the same time stay well below the dust emission limits.
{"title":"Catalytic Ceramic filter reduces emission of organic air pollutants from a cement plant","authors":"K. Poulsen, S. W. Miller","doi":"10.1109/CITCON.2013.6525267","DOIUrl":"https://doi.org/10.1109/CITCON.2013.6525267","url":null,"abstract":"Proposed NESHAP (National Emissions Standard for Hazardous Air Pollutants) emission regulations in the US include the reduction of THC (Total HydroCarbons) and particulate matter to lower limits than what is required today. A single-step technology has been developed for dealing with both of these emissions. In the laboratory as well as at a US cement plant, results and knowledge from slip stream pilot tests have been gained. The promising results show it is possible to obtain very high removal efficiencies of the THC, especially organic HAPs (Hazardous Air Pollutants) and at the same time stay well below the dust emission limits.","PeriodicalId":400797,"journal":{"name":"2013 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"59 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2013-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114759294","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2013-04-11DOI: 10.1109/CITCON.2013.6525270
G. Kaelin
Traditional baghouse control and sensing devices for the cement industry have progressed into the era of intelligent automation. Instrumentation solutions now integrate high-efficiency baghouse control technologies with state-of-the-art particulate emissions monitors, non-clogging differential pressure sensors and compressed air sensors to optimize filtration and provide a reliable and justifiable Return-on-Investment (ROI). This paper reviews how these innovative yet field-proven systems provide financial savings that reduce baghouse operating and maintenance costs. Smart baghouse control and monitoring systems assure EPA Regulatory Compliance and simultaneously minimize compressed air and energy use, reduce labor costs, extend filter life and minimize down-time. A perceived government regulatory cost is converted into a viable and unexpected investment offering a reasonable payback worth investigating.
{"title":"Reduce operating and energy costs and simultaneously assure EPA regulatory compliance with integration of intelligent baghouse control and sensing","authors":"G. Kaelin","doi":"10.1109/CITCON.2013.6525270","DOIUrl":"https://doi.org/10.1109/CITCON.2013.6525270","url":null,"abstract":"Traditional baghouse control and sensing devices for the cement industry have progressed into the era of intelligent automation. Instrumentation solutions now integrate high-efficiency baghouse control technologies with state-of-the-art particulate emissions monitors, non-clogging differential pressure sensors and compressed air sensors to optimize filtration and provide a reliable and justifiable Return-on-Investment (ROI). This paper reviews how these innovative yet field-proven systems provide financial savings that reduce baghouse operating and maintenance costs. Smart baghouse control and monitoring systems assure EPA Regulatory Compliance and simultaneously minimize compressed air and energy use, reduce labor costs, extend filter life and minimize down-time. A perceived government regulatory cost is converted into a viable and unexpected investment offering a reasonable payback worth investigating.","PeriodicalId":400797,"journal":{"name":"2013 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2013-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129347255","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2013-04-11DOI: 10.1109/CITCON.2013.6525284
C. Wester, T. Smith, T. Fahey
Microprocessor-based protective relays are being used throughout industrial facilities and offer the benefits of extensive metering and monitoring, which include sequence components and waveform capturing. There are two types of relay testing which is performed on microprocessor-based protective relays: (1) commission testing and; (2) routine or periodic testing. Commission testing is extensive and exhaustive and its role is to completely test the design and installation of the protective system. Routine or periodic testing is used to validate that a protective system will perform its task by verifying the relay is measuring correctly, set correctly and that it will operate its output contacts for a fault or alarm condition. This paper will first review the differences and functions of commission testing and routine/periodic testing. Secondly, the paper will review methods to use the “smarts” of the microprocessor-based protective relay to detect issues during startup or during normal operation. These methods include protective relay setting comparison, minimal negative sequence current and voltage, verification/recognition of contact inputs, manual operation of contact outputs, complete control circuitry (trip, close, start, stop functions), lack of device self-test alarms, device date & time, and phasor diagrams provided by protective relay. Examples will be reviewed on the methods including an overview of symmetrical components. The paper will discuss options of installing test switches for AC current & AC voltage isolation and use of spare relay case or chassis for bench tests/verifications. In addition, the paper will discuss the periodic tests that should be performed on protective relay spares that are stored in an industrial facility's warehouse.
{"title":"Commissioning and periodic maintenance of microprocessor-based protection relays at industrial facilities","authors":"C. Wester, T. Smith, T. Fahey","doi":"10.1109/CITCON.2013.6525284","DOIUrl":"https://doi.org/10.1109/CITCON.2013.6525284","url":null,"abstract":"Microprocessor-based protective relays are being used throughout industrial facilities and offer the benefits of extensive metering and monitoring, which include sequence components and waveform capturing. There are two types of relay testing which is performed on microprocessor-based protective relays: (1) commission testing and; (2) routine or periodic testing. Commission testing is extensive and exhaustive and its role is to completely test the design and installation of the protective system. Routine or periodic testing is used to validate that a protective system will perform its task by verifying the relay is measuring correctly, set correctly and that it will operate its output contacts for a fault or alarm condition. This paper will first review the differences and functions of commission testing and routine/periodic testing. Secondly, the paper will review methods to use the “smarts” of the microprocessor-based protective relay to detect issues during startup or during normal operation. These methods include protective relay setting comparison, minimal negative sequence current and voltage, verification/recognition of contact inputs, manual operation of contact outputs, complete control circuitry (trip, close, start, stop functions), lack of device self-test alarms, device date & time, and phasor diagrams provided by protective relay. Examples will be reviewed on the methods including an overview of symmetrical components. The paper will discuss options of installing test switches for AC current & AC voltage isolation and use of spare relay case or chassis for bench tests/verifications. In addition, the paper will discuss the periodic tests that should be performed on protective relay spares that are stored in an industrial facility's warehouse.","PeriodicalId":400797,"journal":{"name":"2013 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"86 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2013-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124830683","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2013-04-11DOI: 10.1109/CITCON.2013.6525273
R. Bohan, J. Kline
Particle size reduction is one of the most energy intensive and inefficient processes in use today. Traditional means for calculating energy requirements used for sizing equipment rely on empirically derived formulas and indices. The standard work indices of Kick, Bond and Von Rittinger each work within specific particle size ranges based on empirically derived factors. To date the true energy required for size reduction alone is still unknown. Because of this the true efficiency of size reduction processes are also unknown. Fundamental research at the Massachusetts Institute of Technology's (MIT) Concrete Sustainability Hub (CSH) is taking a closer look at the theoretical power required for particle size reduction on the micro scale. This work has the potential to greatly reduce the power required for cement manufacture. This paper reviews the MIT research and discusses the possible implications and next steps for that work.
{"title":"Breakthrough in Clinker grinding","authors":"R. Bohan, J. Kline","doi":"10.1109/CITCON.2013.6525273","DOIUrl":"https://doi.org/10.1109/CITCON.2013.6525273","url":null,"abstract":"Particle size reduction is one of the most energy intensive and inefficient processes in use today. Traditional means for calculating energy requirements used for sizing equipment rely on empirically derived formulas and indices. The standard work indices of Kick, Bond and Von Rittinger each work within specific particle size ranges based on empirically derived factors. To date the true energy required for size reduction alone is still unknown. Because of this the true efficiency of size reduction processes are also unknown. Fundamental research at the Massachusetts Institute of Technology's (MIT) Concrete Sustainability Hub (CSH) is taking a closer look at the theoretical power required for particle size reduction on the micro scale. This work has the potential to greatly reduce the power required for cement manufacture. This paper reviews the MIT research and discusses the possible implications and next steps for that work.","PeriodicalId":400797,"journal":{"name":"2013 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"3 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2013-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129645225","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2013-04-11DOI: 10.1109/CITCON.2013.6525282
W. Finley, M. Loutfi, B. Sauer
Vibration problems in large induction motors can be extremely frustrating and may lead to greatly reduced motor reliability. It is imperative, in all production operations that downtime be avoided or minimized. If a motor problem does occur, the source of the problem needs to be promptly identified and corrected. With proper knowledge of the sources of motor vibration, proper vibration measurement and diagnostic procedures, it is possible to more quickly identify the root cause of motor vibration. This paper intends to assist the operators of cement plants in avoiding erroneous conclusions that may be reached as a consequence of not understanding the root cause of the vibration; conclusions that may result in trying to fix an incorrectly diagnosed problem, wasting time and money in the process. By utilizing the proper data collection and analysis techniques, the true source of the vibration can be more accurately determined: This analysis includes, but is not limited to vibration related to: · Electrical imbalance - stator, rotor bar · Mechanical unbalance - rotor, coupling, driven equipment · Resonance and critical speeds · Mechanical effects - looseness, rubbing, bearings · External effects - base, driven equipment, misalignment. This paper includes a diagnostic guide (Table I) listing of the causes of electrically and mechanically induced vibrations in large motors, along with the characteristics of these vibrations. In addition, a field example is provided from a cement plant facility wherein a vibration problem was discovered, the root cause was determined and the vibration issue was solved.
{"title":"Motor vibration problems — Understanding and identifying","authors":"W. Finley, M. Loutfi, B. Sauer","doi":"10.1109/CITCON.2013.6525282","DOIUrl":"https://doi.org/10.1109/CITCON.2013.6525282","url":null,"abstract":"Vibration problems in large induction motors can be extremely frustrating and may lead to greatly reduced motor reliability. It is imperative, in all production operations that downtime be avoided or minimized. If a motor problem does occur, the source of the problem needs to be promptly identified and corrected. With proper knowledge of the sources of motor vibration, proper vibration measurement and diagnostic procedures, it is possible to more quickly identify the root cause of motor vibration. This paper intends to assist the operators of cement plants in avoiding erroneous conclusions that may be reached as a consequence of not understanding the root cause of the vibration; conclusions that may result in trying to fix an incorrectly diagnosed problem, wasting time and money in the process. By utilizing the proper data collection and analysis techniques, the true source of the vibration can be more accurately determined: This analysis includes, but is not limited to vibration related to: · Electrical imbalance - stator, rotor bar · Mechanical unbalance - rotor, coupling, driven equipment · Resonance and critical speeds · Mechanical effects - looseness, rubbing, bearings · External effects - base, driven equipment, misalignment. This paper includes a diagnostic guide (Table I) listing of the causes of electrically and mechanically induced vibrations in large motors, along with the characteristics of these vibrations. In addition, a field example is provided from a cement plant facility wherein a vibration problem was discovered, the root cause was determined and the vibration issue was solved.","PeriodicalId":400797,"journal":{"name":"2013 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"18 26","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2013-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"120824756","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2013-04-11DOI: 10.1109/CITCON.2013.6525279
J. Forinton
A new process has been developed for processing chlorine-bypass-dust into new materials that can be sold or used in the cement kiln. Bypass dust is the dust that is rejected from a kiln system in order to lower the chlorine or alkali content of the produced clinker. Many cement plants have routinely landfilled this dust over many years. The strategic concept of "zero waste" is the basis for this system, but other smaller reasons also exist for its development: · The landfill disposal costs are high in some areas. · Bypass dust, which is typically wasted, has a unit cost of 20-30% of the cost per ton of producing clinker - depending on the cement making process type - and this cost can be recuperated. · For environmental reasons it may be beneficial to reduce the landfill area within the overall plant site area. · An increase in alternative fuels may cause an increase in bypass dust that needs to be extracted, thereby, causing higher disposal specific production costs. · The sales price of salt runs at approximately 350 USD/t which is potentially a new income stream for the plant. The dust reduction system is made up of the following sections: 1. Washing of bypass dust with water; 2. Filtration to obtain a salt solution (brine); 3. Chemical treatment (purification and conditioning of the brine); 4. Evaporation of this clean-neutralized brine to obtain the alkali-salts. The products of the system are: 1. Raw meal, low in alkalis and chlorine, that can be directly used as kiln feed. 2. High purity salts that can be used for food, de-icing roads, or making fertilizer. 3. Heavy metals sludge that can be treated separately to obtain valuable metals. A pilot plant has been installed with positive results and now the first industrial-sized plant is under construction.
{"title":"Recycling kiln bypass dust into valuable materials","authors":"J. Forinton","doi":"10.1109/CITCON.2013.6525279","DOIUrl":"https://doi.org/10.1109/CITCON.2013.6525279","url":null,"abstract":"A new process has been developed for processing chlorine-bypass-dust into new materials that can be sold or used in the cement kiln. Bypass dust is the dust that is rejected from a kiln system in order to lower the chlorine or alkali content of the produced clinker. Many cement plants have routinely landfilled this dust over many years. The strategic concept of \"zero waste\" is the basis for this system, but other smaller reasons also exist for its development: · The landfill disposal costs are high in some areas. · Bypass dust, which is typically wasted, has a unit cost of 20-30% of the cost per ton of producing clinker - depending on the cement making process type - and this cost can be recuperated. · For environmental reasons it may be beneficial to reduce the landfill area within the overall plant site area. · An increase in alternative fuels may cause an increase in bypass dust that needs to be extracted, thereby, causing higher disposal specific production costs. · The sales price of salt runs at approximately 350 USD/t which is potentially a new income stream for the plant. The dust reduction system is made up of the following sections: 1. Washing of bypass dust with water; 2. Filtration to obtain a salt solution (brine); 3. Chemical treatment (purification and conditioning of the brine); 4. Evaporation of this clean-neutralized brine to obtain the alkali-salts. The products of the system are: 1. Raw meal, low in alkalis and chlorine, that can be directly used as kiln feed. 2. High purity salts that can be used for food, de-icing roads, or making fertilizer. 3. Heavy metals sludge that can be treated separately to obtain valuable metals. A pilot plant has been installed with positive results and now the first industrial-sized plant is under construction.","PeriodicalId":400797,"journal":{"name":"2013 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2013-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129919907","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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