Waste to Flame
Cement production is a very energy intensive process. A typical medium sized cement line can consume over 600 tons of coal every day. The good news is that it can be fully replaced by SRF (Solid Recovered Fuel).
The TYRANNOSAURUS® Waste to Flame solution from BMH Technology customises the SRF process and its implementation to individual cement plant processes and chemical characteristics.
Why choose BMH ?
We deliver all the needed equipment and know them inside out. This makes a smoothly running system with comprehensive guarantee and easy maintenance.
Robust construction and high level of automation, including MIPS® (Massive Impact Protection System), guarantee the best availability.
COMPACT DESIGN &
LOW OPERATING COSTS
BMH layouts come in compact size and fit into limited spaces. ZeroGap®shredding means high capacity and accurate separation.
Cement plants can indeed be huge off-takers for SRF, benefitting both the plant and the local community. In co-processing, SRF is used both as energy and as raw material. With BMH’s unique approach in Waste to Flame application, up to 100% Thermal Substitution Rates (TSR) are reachable, using SRF in both calciner and main burner. Simultaneously, the cement process safely binds the ash into cement, reducing the need for mined raw materials and eliminating the need for ash landfilling.
In addition to economic benefits, substituting fossil fuels by SRF will also lead to reduction in NOx as well as fossil CO2 emissions.
A Waste to Flame project begins with a thorough feasibility analysis, consisting of a waste study, process analysis including CFD (Computational Fluid Dynamics) as needed and plant engineering. Careful waste analysis is the foundation of all subsequent studies. After the waste analysis, the SRF quality options can be evaluated.
In order to define the customers’ need, their objectives are carefully mapped. Such objectives can be for example annual coprocessing capacity, TSR targets or focusing
on either calciner or main burner. These customer-specific targets are combined with waste study results and BMH’s understanding of global wastes and possible SRF qualities. This sets the scope for the project, which in principle can target up to 90% annual TSR and 10% raw material replacement.
The TYRANNOSAURUS® Waste to Flame co-processing uses mostly existing cement plant infrastructure. The BMH fuel handling equipment, needed for co-processing, requires only a small layout to integrate into existing processes.
The scope of each project will be determined together with the customer according to their needs. SRF production plant, cement plant fuel handling system, as well as dosing and feeding equipment can be delivered by BMH on a turnkey basis. The suppliers for above mentioned engineering and process study options are also found in our network.
The next step, preliminary process study, evaluates the current process and estimates boundaries for SRF quality factors, such as moisture content, chlorine level, alkaline content and particle size distribution. Simultaneously, the impact of local conditions, feed rates, bypass or ID fan capacity, preheating tower cyclones’ pressure drop etc. are considered as part of the plant design and engineering.
The main process study with a CFD analysis can be started once the above mentioned boundaries have been determined and agreed on. The goal for the main process study is optimising the co processing to enable up to 100% TSR to be achieved on a best day basis.
After CFD, optimised feed rates and locations are used to finalise the cement plant technical solution, which is then completed with silos and conveyors. Correct feeding and dosing equipment are also chosen according to the process study.
Watch TYRANNOSAURUS® Waste to Fuel Process Video
Waste to Flame references
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