1-Jonathan-Forintonx - Ficem

swedishstreakMécanique

22 févr. 2014 (il y a 3 années et 8 mois)

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2012

REDUDUST

A
SYSTEM FOR BYPASS DUST RECOVERY


BY:


ING. JONATHAN FORINTON


ING. PEDRO MONTES DE OCA

2012

REDUDUST

Agenda:


Introduction

Basic Concept

Products

Application

Pilot Plant

Industrial Installation

Summary




2012

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


2012

INTRODUCTION

Properties of Bypass dust:


Very poisonous for the ambient in contact with water


Alkalis (K
2
O,
Na
2
O),


Chlorine
(
Cl
)


Sulfur
(SO
3
)


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


2012

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)

2012

PRINCIPLE

PROCESS

DIAGRAM

Bypass
-
Dust
-


Silo

Mixing

Separation of Brine


and Filter Cake

Brine

Treatment

& Conditioning

Crystallization

Heat Supply

Waste Heat

Source

Salt Products

Filter Cake

Chemicals

2012

MASS

BALANCE
OVERVIEW

DATA
GIVEN

FOR

TYPICAL

EGYPT
BYPASS

DUST

Bypass
Dust

Sewage
water

Chemicals

Cement
Waste Heat

Product

Material

Potable
Water

Salts

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

ReduDust Process Plant

2012

INTERMEDIATE PRODUCTS

Limestone slurry


collected sediments from
CO
2

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)

2012


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

2012

PRODUCT

APPLICATIONS


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 by
p
ass dust

2012

PRODUCT

APPLICATIONS


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


2012

ATEC Technical Center

(AUT)

Pilot Plant

PILOT INSTALLATION

2012

PILOT INSTALLATION

2012

PILOT INSTALLATION

Mixing

Filtration

Drying

Mixing

Crystallizing

Chemical Treatment

2012

PILOT INSTALLATION

By
p
ass dust storage

Slurry rapid mixer

Peristaltic pump

Filter press

2012

PILOT INSTALLATION

Chemical dozing

Sedimentation tank

Crystallizer

Dryer

Process analytics

2012

2012

Holcim Rohoznik

First Industrial
-
Sized
Plant

INDUSTRIAL INSTALLATION

2012

INDUSTRIAL INSTALLATION

DATA
GIVEN

FOR

TYPICAL

EUROPEAN
BYPASS

DUST

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 By
p
ass dust from different plants is
considered

2012

INDUSTRIAL INSTALLATION

DATA
GIVEN

FOR

TYPICAL

EUROPEAN
BYPASS

DUST

Plant capacity


Standard design capacity of 20.000 tpy of By
p
ass dust


4.000 tons of salts per year (approx. 3.000

tons of KCl)


2012

PLANT ARRANGEMENT


Respecting optimal
flow


Bypass dust


Filter cake


Brine


Salt


Chemicals


Dimensions of
footprint


24 m x 36 m

Crystallization


Bypass dust storage,

dosing and transport

Mixing &

Chemical treatment

Tanks

storage

Filtration

KCl

silo

Chemicals

NaCl bags


Filter cake

outlet

2012

MATERIAL

OVERVIEW


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

2012

INDUSTRIAL INSTALLATION

DATA
GIVEN

FOR

TYPICAL

EUROPEAN
BYPASS

DUST

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
1.4

MW


Designed to handle 5
-
15% chlorine content bypass dust


Overall
Cl
-
extraction
e
fficiency >90%


2012

INDUSTRIAL INSTALLATION

2012


SUMMARY


Zero waste



Recycling of raw meal




Production of a saleable Product

2012

Please visit www.atec
-
ltd.com

THANK YOU FOR YOUR ATTENTION