Objective
To recycle non hazardous wastes (industrial and municipal) and fluff (refuse material generated by sorting centres) as fuel to the Cement Industry.
To use the cheapest preparation way : rough shredding and compression as bales (80 to 120 kg)
To implement on the rotary part of two (wet process) cement kilns (length : 202 m/227 m; diameter : 6.8 m/7.16 m) at CIMENTS D'OBOURG (Belgium):
* a mid kiln feeding port for these conditioned bales (in the rotary part of the furnace at the level of the calcining zone, at about 1200 deg. C) and, if necessary, an associated tertiary air injection port,
* evaluation, if necessary, of a gas by-pass line, around the drying zone of the kiln, equipped with a cooler and a condenser for alkaline chloride removal.L%
A substantial reduction of the fossil fuel consumption (and cost) of Ciments d'Obourg (15% to 20% of Energy saving)
* A cheap and environmentally sound route for eliminating between 100 ktons/year of non hazardous wastes, which otherwise would be landfilled or incinerated, at much higher price and environmental impact.
* No "fatal waste" (incineration ash)to be dumped at high price and substantial environmental impact.
* An operation of a cement kiln, using non hazardous waste as non crushed fuel, in full compliance with EU legislation on emissions and effluents.
* The possibility to mix further the dust collected at the electrostatic filter with the clinker, without affecting the composition of the product, that remains below acceptable standards
* An economy of raw materials for clinker (up to 40 ktons/year), and associated costs.
* A complete separation of the waste and the cement chemistry, by collecting, separately volatile chlorinated compounds.
* A specific extraction of volatiles from wastes (alkalis, some heavy metals) without distributing the cement process, leading to an improved quality of the final product.
CIMENTS D'OBOURG is owner of a plant in OBOURG (Belgium) producing 1.5 1000000 tons/year of clinker (2.5 1000000 tons/year of cement) and consuming 200.000 TOE/year. Since 4 years, this plant is fed partly with waste fluxes, blended by SCORIBEL, a Joint Venture between OBOURG and SCORI (France). The blended waste is pastly or pulverulent and is injected in the main flame. The operation has no adverse effect so far, neither on the environmental impact of the plant, nor on the product quality.
On the other hand, WATCO operates several municipal sorting centres, including the one of Brussels. This kind of unit generates from 30% to 50% of refuse (fluff), not recyclable. This refuse has so far been sent to landfill, but dumping will be strongly restricted in 2002, and becomes progressively very expensive.
The present project consists in :
1. compressing this refuse in bales (80 to 120 kg; 650 kg/m3), using a very specific press, with high compression ratio.
2. delivering the bales tothe cement plant, using a handling system and transport by truck
3. feeding two cement kilns (for flexibility and at least 50% availability in case of operational problem), mid kiln, at baout 1200 deg. C, in the rotating part of the kiln. This injection point provides enough residence time at high temperature, to destroy almost completely the organic volatile matters. Air will be injected, if necessary, at the same level to dampen out volatile peaks that could appear during bale injection.
4. improving the flexibility of the composition of the bales with regard to chlorine content, a gas by-pass line being installed, if necessary, also in the rotating part of the kiln, for that purpose
5. analysing the influence of these modifications on the operability, maintenance, product quality, energy efficiency, profitability and environmental impact, as support to further duplication and dissemination measures.
The project presents several innovative characters: it is indeed focused on a new technology (mid kiln feeding of waste bales), for a new application (valorisation of fluff from sorting centres, landfilled up to now):
* the preparation and the feeding of conditioned waste bales, at mid kiln level of a (wet process) cement kiln, under normal operating conditions, is innovative, at a worldwide level
* the by-pass line has so far been installed on some dry cement kilns, equipped with a fixed pre-calciner. This kind of process allows the by-pass line to be located in the fixed part of the process.
* in the present case, the by-pass line will be located in the moving part of the furnace, the inclusion of a condenser, for alkaline salts, in the by-pass line, is also innovative, on a global level.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques.
- natural scienceschemical sciencesinorganic chemistryhalogens
- engineering and technologyenvironmental engineeringenergy and fuels
- engineering and technologyenvironmental engineeringwaste managementwaste treatment processes
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Call for proposal
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DEM - Demonstration contractsCoordinator
7034 Obourg
Belgium