System technology for alternative fuels (AFR)

Using alternative fuels

Pre-processing of waste into a high grade alternative fuel and its application is becoming increasingly attractive to reduce production costs and CO2 emissions – especially for energy-intensive areas like the cement and lime industry. Furthermore, all organic pollutants will be destroyed in the kiln at temperatures of approximately 2,000 °C and will be absorbed by the surplus of finely ground limestone. The use of different types of alternative fuels is governed by the availability in a given region and especially the economic aspects.

Our AFR systems are designed to meet the particular requirements of functionality and performance under the strain of daily operation. In addition to a comprehensive supply of reliable systems for handling alternative fuels, we also focus on planning of logistics and customized conveying and warehouse systems, including crane halls, steel structures and of course turnkey deliveries of mechanical part. Due to the modular system of all design groups and system components, each project is engineered and designed individually.

The importance of flexibility and reliability

The alternative fuel markets are still developing. It is in the interests of the plant operator to prefer solutions which could be continually and easily customised to use the of most efficient and economical fuel.

The thermal substitution rate (TSR) also has a significant effect on the overall design of the system and the components used. The higher the required and achieved TSR, the greater the need for reliable equipment, because the substitution of primary fuel is very difficult due to technological and economical aspects.

System technology for scrap tires as alternative fuel

Scrap tires that cannot be recycled are best for co-processing: Natural rubber and textile carcass can be used as a fuel, whilst the steel carcass donates iron to the required clinker composition. BEUMER Group has many years of expertise and sophisticated technologies for feeding whole tires as well as chipped tires as tire derived fuel (TDF).

Chipped tires as tire derived fuel (tdf)

Our system technology is flexible and also designed for conveying and feeding TDF for a continuous and smooth kiln operation. TDF can constantly be fed on the same path as RDF and biomass, when the longer retention time of tire chips is taken into account for proper coprocessing. All modules and system components, as well as each entire project, are planned individually according to the specific process requirements.

From delivery to co-processing

After the scrap tires are unloaded, they are handled primarily by a wheel loader or gantry crane with a polygon gripper for storage and discharge. The size of the stock area has to be adapted to the kiln consumption and works as a compensation between discontinuous supply and continuous consumption.

Official permission must be obtained for setting up and operating the storage as well as for building the tire handling system, and the corresponding local regulations regarding fire-fighting and water management should be followed.

Once the tires have passed the storage and separating line, control station and weighing system, steeply inclined conveyors transport them from ground level to the defined inlet height at the preheater. The capacity and size of the incline conveyor are specifically designed in accordance with each particular project.

The whole tires can be fed through a swivel valve or triple flap. The upper and central steps open and close in order to protect the pyroprocess against heat loss and unwanted air entry. The lower step acts as a shutoff device for malfunctions. The metallic parts are protected by a highly heat-resistant coating.