Waste to Flame

Waste to Flame solution is designed especially to meet the needs of Cement Kilns for recovered fuels production and handling. The turn-key solution includes the complete process from receiving waste to feeding it to the kiln. In Waste to Flame solution BMH Technology’s knowledge of fuel handling and technology of waste processing are combined together as efficient and reliable process solution.

Process overview

TYRANNOSAURUS® Waste Refining Process – the smartest and strongest waste-to-fuel process in the world.

1. Pre-shredding
Optional for low quality waste, Pre-shredding and organic separation
2. Shredding
The heart of the process is the shredder. TYRANNOSAURUS® shredder can handle even as much as 50 tons of waste in hour to as small as 80 mm particle size. TYRANNOSAURUS® shredder protects itself intelligently with MIPS® (Massive Impact Protection System), which automatically rejects unshreddable particles. ZeroCap® hydraulic knive adjustment guarantees right particle size and continuous maximum capacity.
Shredding
3. Preparation

Separation of fines, metals and heavy fraction. Optionally size reduction to main burner size (<25mm)

4. Fuel Storage
Totally closed dust-free, first in - first out automatic storage with adjustable screw reclaimer.
Fuel Storage
5. Receiving

Receiving

TYRANNOSAURUS® Step Feeder works together with the Shredder intelligently. Step Feeder works as both feeder and buffer - therefore it can feed TYRANNOSAURUS® Shredder optimal amount of waste to maximise capacity and shredding result.

6. Organics separation

Organics separation


Wet organic content would decrease the fuel quality. In order to ensure high calorific value the wet organics are separated with Drum Screen from the material after pre-shredding. 

7. Screening

Screening

To assure purity of the fuel it must be screened. First magnet separates ferrous metals from the material. After the magnet, incombustible fines are screened with TYRANNOSAURUS® Fines Screen. Aluminium and other non-ferrous metals are separated with Eddy Current Separator. TYRANNOSAURUS® Air Classifier finalizes the screening process by separating heavy inert material into two or three fractions. 

8. Fine shredding

Fine Shredding

The fuel must burn rapidly in the cement kiln and small particle size increases the flammability of the fuel. TYRANNOSAURUS® Fine Shredder can reduce the particle size of the fuel to 20-25 mm, which makes sure that the fuel is fully prepared for maximum combustion result in the burner.

9. Storages

Storages

The storage systems of BMH Technology are not designed only for storing, but also to homogenize the fuel to ensure uniform quality. Storage system consists of silo distributors, silos and TYRANNOSAURUS® Screw Reclaimers and all equipment work ​together to avoid clogging and enabling required fuel reclaiming.

10. Conveying

Conveying

The location and sites of cement kilns vary and therefore compact and reliable transportation solutions are needed. Belt Conveyors and Tubular Belt Conveyors are used in the process to fit the layout and conveying needs of each plant. Bucker Elevators are available for vertical transportation. Each conveying solution is designed for safe and dust free material transportation.

11. Feeding and dosing

Feeding and dosing


Undisturbed and controlled flow of fuel is enabled by suitable dosing and feeding systems. BMH Technology offers both, pneumatic and mechanical solutions. The pneumatic feeding system includes a dosing hopper with accurate flow control. The fuel is fed into a Rotary Valve Feeder from where it is injected to into the pneumatic system and further into the burning process. The mechanical system includes receiving bunkers, silos, dosing and flow monitoring designed for wide range of alternative fuels. 

Key equipment

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TYRANNOSAURUS® Feeders

TYRANNOSAURUS® Feeders enable optimal feeding to the shredder/crusher ensuring continuous maximum capacity.

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TYRANNOSAURUS® Feeders are an excellent solution for optimizing feeding process to the shredder when continuous flow of material is needed.  Feeder works as a buffer and a feeder for the process and lengthens the loading intervals.  The feeding capacity of the Feeder is adjusted according to the level of measurement taken from the shredders hopper. TYRANNOSAURUS® Feeders are designed to have high reliability and low maintenance costs, in addition TYRANNOSAURUS® Feeders are easy to install and safe to use.
 Product name  Width (m) Length (m) 
 TYRANNOSAURUS® Feeder 2412  2.4  12
 TYRANNOSAURUS® Feeder 2418  2.4  18
 TYRANNOSAURUS® Feeder 2424  2.4  24
 TYRANNOSAURUS® Feeder 3212  3.2  12
 TYRANNOSAURUS® Feeder 3218  3.2  18
 TYRANNOSAURUS® Feeder 3224
 3.2  24
 TYRANNOSAURUS® Feeder 4012  4.0  12
 TYRANNOSAURUS® Feeder 4018  4.0  18
 TYRANNOSAURUS® Feeder 4024  4.0  24
 TYRANNOSAURUS® Feeder 6012  6.0  12
 TYRANNOSAURUS® Feeder 6018  6.0  18
 TYRANNOSAURUS® Feeder 6024  6.0  24
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TYRANNOSAURUS® 6600 Pre-shredders

TYRANNOSAURUS® Pre-shredders are ideal for preparation of challenging waste to increase the capacity of the entire process or as a main shredder for grate fired boiler.

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TYRANNOSAURUS® Pre-shredders are ideal solution for rough shredding. They are especially designed to open plastic bags, to prepare waste for organics separation and to increase the capacity of the entire process. TYRANNOSAURUS® Pre-shredders are also available for main shredding of waste in grate fired incinerators. TYRANNOSAURUS® Pre-shredders can work in demanding conditions for rough shredding and with high water content materials. The knives of the shredder are easily exchangeable and therefore maintenance is fast.
Product name    Power (kW)   Length 
TYRANNOSAURUS® 6603   220  1900
TYRANNOSAURUS® 6604  264  2500
TYRANNOSAURUS® 6605  320  3200
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TYRANNOSAURUS® 9900 Main Shredders

TYRANNOSAURUS® 9900 main shredders are the World's biggest and strongest waste shredders.

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TYRANNOSAURUS® 9900 shredders are the most strongest, robust and smartest waste shredders. They are able to shred any combustible material  to uniform particle size in one single phase. TYRANNOSAURUS® 9900 shredders have advanced automatic MIPS® (Massive Impact Protection System) which protects the shredder from damages due to unshreddable items. The material is cut into pieces and wear of knives is limited thanks to unique ZeroGap® technology. TYRANNOSAURUS® 9900 shredders represent most advanced technology and strongest design in the market.
Product name Power (kW)  Rotor length 
 TYRANNOSAURUS® 9903  365  2400 
 TYRANNOSAURUS® 9904  525  3200
 TYRANNOSAURUS® 9905  685  4000
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TYRANNOSAURUS® 8800 Main Shredders

TYRANNOSAURUS® 8800 main shredders are designed to process mixed Municipal Solid Waste on high capacity.

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TYRANNOSAURUS® 8800 shredders are designed to handle Municipal Solid Waste with superior usability, easy maintenance and low running costs.  Intelligent control system chooses an optimal shredding speed according to the waste type. Through large service hatches the knives are easily replaceable without any welding or grinding and the screen of the shredder is easily changeable for optimized particle size. Hydraulic power transmission ensures high torque and availability.
Product name  Power (kW)   Rotor length (mm)
 TYRANNOSAURUS® 8804  264  2200
 TYRANNOSAURUS® 8805  320  2700
 TYRANNOSAURUS® 8806  400  3200
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TYRANNOSAURUS® 1500 Fines Screens

TYRANNOSAURUS® Fines Screen separates fines, for example, sand, glass, soil from the material.

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TYRANNOSAURUS® Fines Screens separates sand, soil and other fines from the material, and also reduces the content of ash, humidity, chlorine and heavy metals. The shape and material of the stars enable high screening precision and durability. Throughput of the TYRANNOSAURUS® Fines Screen is adjustable with speed and star gap.
Product name  Power (kW)   Shafts
 TYRANNOSAURUS® Fines Screen 1501   5.5  12
 TYRANNOSAURUS® Fines Screen 1502   11  24
 TYRANNOSAURUS® Fines Screen 1503   16.5  36
 TYRANNOSAURUS® Fines Screen 1504   22  48
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TYRANNOSAURUS® 2500 Air Classifiers

TYRANNOSAURUS®2500 Air Classifiers produce light and clean fraction to maximize the fuel quality.

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TYRANNOSAURUS® 2500 Air Classifiers produce clean light fraction by separating inert material, such as glass, stones and ceramics. TYRANNOSAURUS® Air Classifiers can separate the material into two or three fractions and they are easily adjustable. Operation costs of TYRANNOSAURUS® Air Classifiers are low and they work seamlessly as a part of the process.
 Product name Power (kW)   Width (m)
 TYRANNOSAURUS® Air Classifier 2502  90  2.5
 TYRANNOSAURUS® Air Classifier 2503  90  2.5
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TYRANNOSAURUS® 1200 Fine Shredders

TYRANNOSAURUS® Fine Shredders are used to ensure the combustibility of the fuel by reducing the particle size as small as 25 mm.

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TYRANNOSAURUS® Fine Shredders are used to reduce the particle size of SRF to even small as 25 mm fraction to increase the  combustibility of the fuel. TYRANNOSAURUS® Fine Shredders are robust and have low operating and maintenance costs. They operate flawlessly with entire process to produce SRF on high capacity.
Product name    Power (kW)  Rotor length 
TYRANNOSAURUS® 1203  255  2400
TYRANNOSAURUS® 1204   350  3200
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TYRANNOSAURUS® Rotating Screw Reclaimers

TYRANNOSAURUS® Rotating Screw Reclaimers are suitable to discharge solid fuels from silos or round open-air storages.

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TYRANNOSAURUS® Rotating Screw Reclaimers are suitable for reclaiming material from silos and round oper-air storages automatically. They are ideal for handling biomass fuels, such as wood chips, bark, sludge and pellets, peat and solid recovered fuel.  Service and maintenance is easy through service points and the TYRANNOSAURUS® Screw Reclaimers are easily adjustable to fit the process and material requirements. 
Type Max Capacity
 (m3/h)
TYRANNOSAURUS® Rotating Screw Reclaimer 1005  70
TYRANNOSAURUS® Rotating Screw Reclaimer 2007  250
TYRANNOSAURUS® Rotating Screw Reclaimer 2507  350
TYRANNOSAURUS® Rotating Screw Reclaimer 3012  700
TYRANNOSAURUS® Rotating Screw Reclaimer 3514  700
TYRANNOSAURUS® Rotating Screw Reclaimer 4016  800
TYRANNOSAURUS® Rotating Screw Reclaimer 5025  900
TYRANNOSAURUS® Rotating Screw Reclaimer 5527  900

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Drag Chain Conveyors

Drag Chain Conveyors are ideal for safe and reliable transportation of bulky materials in various industrial processes.

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Drag Chain Conveyors are safe and reliable solution for handling bulk materials in a continuous and even material flow. They can be used for instance in receiving the material and transporting it to intermediate storage, filling storage silos, discharging from storage, and in intermediate transportation in TYRANNOSAURUS® SRF production process. Drag Chain Conveyors are customized for variety of materials in terms of composition and temperature for instance there is a possibility to include water-cooling designs and heatproof structures. Materials such as wood chips, bark, agro biomass, pellets, peat, SRF, coal, ash, cement, lime and minerals can be transported with Drag Chain Conveyors. BMH Technology customizes the Drag Chain Conveyor solution to fit the individual needs of each process.
 Width (mm)  Capacity m3/h 
 650  150
 800  200
 1000  300
 1200  400
 1400  500
 1600  700
 2000  1000
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Screw conveyor

Screw Conveyors are economical ways to transfer bulk materials over short distances.

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Screw conveyors are made according to the required measurements of the customer.
Your measurement define the size and material best for your purposes.
Diameters can be:
  315 mm
  400 mm
  500 mm
  630 mm
  710 mm
  800 mm
  900 mm
 1000 mm
 1120 mm
 1250 mm
 1400 mm
 1600 mm
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Bucket Elevators

Bucket Elevators are an ideal choice for vertical transportation of different bulk materials.

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Bucket Elevators of BMH Technology provide an excellent choice for vertical transportation up to 70 meters high. Enclosed construction provides dust-tight operation and special design of the buckets ensure clean discharge. There are two option available Belt Bucket Elevator and Chain Bucket Elevator. Belt Bucket elevators are ideal for handling wood chips, bark, agro biomass, pellets, peat, solid recovered fuel etc and Chain Bucket Elevators are suitable for handling cement, lime and ash. Bucket Elevators of BMH Technology are always custom designed to meet specific requirements of the customer and the transported material. 
 Belt Bucket Elevators   Chain Bucket Elevators
 Belt Width (mm) Max Capacity (m3/h)   Casing size (mm)
Max capacity (m3/h)
 500  100    400 x 1000
40
 650  150    720 x 1000
80
 800  250    900 x 1250
120
 1000  400      
 1200  600      
 1400  900      

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Rotary Valve Feeders

Rotary Valve Feeders are optimal solution for feeding and dosing variety of different fine-grained or dusty materials.

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Rotary Valve Feeders are used in feeding and dosing fine-grained and dusty materials. Rotary Valve Feeders feed the material into a power boiler and at the same time prevent the backflow of gases and flames. In addition, they act as a dosing feeder at the silo outlet to prevent uncontrolled discharge of material out of the silo. Rotary Valve feeders are reliable and safe in use, easy to install and the structure is totally enclosed and dust-tight. Rotary Valve Feeders are ideal for handling wood chips, bark, agro biomass, pellets, peat, SRF, coal, Sludge, ash sand and sticky materials. Rotary Valve Feeders are always customized to fit the needs of each process and handled material. 
 Type LSF for biomass and SRF    Type LSC for coal, sludge, sticky materials and biomass 
 Size  Capacity(m3/h)    Size
Capacity (m3/h) 
 40/60  40    40/40  20
 50/60  60    40/50  30
 50/80  85    40/60  40
 63/50  100    50/60  60
 63/80  140    63/50  60
 80/80  200    63/80  100
 63/120  230      
 80/120  300      


Type LSAR for ash and sand    Type LSA for ash and sand  
 Size  Capacity (m3/h)      Size  Capacity (m3/h)
 20/20  5    20/20  5
 30/30  15    30/30  14
 40/40  40    40/50  40
 50/50  80    40/60  50



Waste to Flame success stories

  • BMH Technology reference Cimpor Alhandra small
    Success Stories

    Waste to Flame solution delivered to Cimpor - Alhandra, Portugal

    Waste to Flame project. A full turnkey solution for handling alternative fuels at a cement mill, including receiving, screening, storages, dosing and feeding systems, designed and installed by BMH.Read more about the project

  • pikku
    Success Stories

    Waste to Flame solution delivered to Cimpor - Souselas, Portugal

    Waste to Flame project. A full turnkey solution for handling alternative fuels at a cement mill, including receiving, screening, storages, dosing and feeding systems, designed and installed by BMH.Read more about the project