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Reliable energy supplier – Part 2

World Cement,

To read part one of this report please click here.

Solution for the calciner

With the second system, the calciner can be fed with more coarse alternative fuels, such as tyre derived fuel or the fuels described above, but in a more coarse state. They are generally less processed, contain three-dimensional particles and therefore require more time to burn out than for example the more intensively processed, exclusively two-dimensional secondary fuels for the main burner.

The coarse calciner fuel is delivered in moving-floor trailers or tippers. The secondary fuels are quickly unloaded and stored temporarily in a dust-proof way. Another storage serves as a flow buffer, which can hold the overall capacity of 900 cubic metres of the preceding bunker. From here, the Pipe Conveyor transports the material to the calciner in the preheater tower. Here, the secondary fuel is weighed and dosed. During the feed towards the hearth in the calciner, there is often the risk that the material or the conveying system can catch fire due to thermal radiation or pulsations. For this reason, the valveless special feed was developed, so the material can be safely fed to the calciner.

In order to ensure safe and automatic fuel supply after successful testing, BEUMER Group provides systems for permanent operation with high thermal substitution rates. The systems consist of the receiving area and a storage system, where the crane system can store material of different quality into different storage zones and boxes. Experiences so far have shown that you always have to calculate with disruptives or quality deficits in the fuel. This is why the entire storage and conveying technology in the hall can be provided with equipment that is able to separate metal, wet and three-dimensional disruptives from the fuel for the main burner and keep disrupting oversized grains from the calciner fuel.

Equipped with the necessary sensor technology, the operation runs automatically. The crane can be used independently for homogenisation, in order to minimise quality variations or feed the lines towards the main burner and the calciner.

Pipe Conveyor stands the test

Schwenk Zement AG's product diversity and production capacity make their plant in Bernburg one of the largest and most efficient cement plants in Germany.

In order to reduce energy costs, the cement plant is increasingly using secondary fuels that are engineered in external processing plants into high-quality fuels with defined product parameters.

Until now, the manufacturer had been using drag chain conveyors. After almost a decade of use and numerous modifications however, more and more maintenance was required. The fuel quality also improved over time, so that, due to its density of 0.2 t/m3, the existing technology was no longer sufficient to convey the required quantities towards the main burner. This created the need for a reliable, eco-friendly and low-maintenance solution. In addition, the new conveyor needed to be optimally adapted to the curved routing in the plant.

Schwenk Zement KG opted for the BEUMER AFR system with its Pipe Conveyor to feed the main burner with alternative fuels. The system works almost completely automatically, from receiving to the feeding system of the rotary kiln. Cranes pick up the engineered secondary fuels in the storehouse and fill them into the discharge bunkers with their discharge equipment. From there, a chain belt conveyor transports the fuel continuously towards the Pipe Conveyor, which conveys it to the weigh feeders before the main burner.

The curved Pipe Conveyor at the core of the system requires little maintenance and its enclosed design and quiet operation protect against emissions and the wind-blown dispersal of the fuel. It is able to connect long distances without interruption and navigate tight curve radii that adapt to the individual conditions of the plant.

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