With concern growing over the consumption of fossil fuels, an increasing number of cement plants are turning to alternative fuels. At the same time, tougher environmental legislation presents cement plants with the challenge of lowering emissions without sacrificing plant perfor-mance. FLSmidth is working with plants all over the world to provide better, more efficient operations while meeting and often exceeding emission standards.
Replacing traditional fossil fuels with refuse derived fuels (RDF), tyre derived fuels (TDF) and biomass is not only economical; it’s also an environmentally friendly solution for many cement plants. However, plants firing alternative fuels while using traditional equipment for monitoring and reporting are faced with several potential challenges, such as variations in burning and emissions. FLSmidth’s cost-effective solutions meet these challenges and reduce emissions in plants that burn alternative fuels.
With leading technologies, including the Selective Non-Catalytic Reduction system (SNCR) and ECS/StackGuide, an innovative continuous emission monitoring system, FLSmidth has all the equipment and know-how needed for firing with alternative fuels.
SNCR – the solution for reducing NOx emissions
Reducing NOx emissions is a challenge for many plants, particularly when burning alternative fuels. And in some cases, NOx emission limits for alternative fuels have even fallen below levels achievable with traditional equipment and operating techniques. The answer could be FLSmidth’s complete Selective Non-Catalytic Reduction (SNCR) system – a customisable and comprehensive emission solution for dry kiln systems. So how does SNCR work?
SNCR selectively reduces NOx emissions through an aqueous ammonia solution (< 25 [% w/w]). The high ammonia utilisation results in negligible emission by-products. An SNCR system comprises a number of ammonia reagent storage tanks with unloading and supply pump units, control and measuring modules, injection modules, and specially engineered spray lances with nozzles for optimum spray coverage in the duct. Based on a solid theoretical framework and field test results, SNCR systems are tailored so that NOx reduction is not replaced by other harmful by-products, such as carbon monoxide or ammonia slip. Fully compliant in safety and quality standards, SNCR is designed for optimum operating efficiency. And, when combined with FLSmidth’s industry-leading low-NOx calciner, SNCR is easily the most cost-effective secondary method of minimising NOx emissions.
New fuels require new analyses
A European cement plant recently partnered with FLSmidth to reduce production costs by burning RDF and TDF. But continually meeting emissions standards with alternative fuels isn’t always easy as they burn with far greater variation than traditional fossil fuels. So, this plant needed reliable process equipment, complete control over the combustion process and gas analysis in the kiln and calciner. They chose FLSmidth Airloq’s KilnLoq probe system for simple, reliable gas analysis at the kiln inlet.
KilnLoq improves kiln performance and energy through its patented, easy to clean and maintain ‘One Pipe’ design. Kiln gas analysis hinges on stable kiln combustion, and the innovative KilnLoq probe is the only probe on the market capable of consistently achieving this – with minimum maintenance and an unprecedented high run factor. KilnLoq can lead to a possible energy reduction of around 8-15 kcal/kg of clinker, compared to an identical kiln running without an oxygen analyser. The One Pipe design also minimises undesirable kiln stops to increase plant safety and reduce emissions by eliminating costly, wasteful heat-ups.
Cleaner air through emission monitoring and reporting
Cement plants all over the world are facing increasing demands on their emission reporting. In response, FLSmidth Airloq and FLSmidth Automation developed ECS/StackGuide – now the industry’s most cost-efficient analysis tool, supporting all emission monitoring and reporting requirements.
ECS/StackGuide is a continuous emission monitoring system (CEMS), a complete system of reporting equipment that spans system configuration, monitoring roles, data validation methods and reporting types. ECS/StackGuide summarises the results from the combustion and calcination process in the kiln. But analysis and reporting by itself is not capable of reducing emissions, so FLSmidth Automation’s ECS/ProcessExpert system can be added to optimise any process in the cement kiln’s entire operation. The better use of resources leads to a reduction in plant emissions through increased production along with lower fuel consumption.
FLSmidth’s ECS/ProcessExpert system can also be used to connect various emission reducing technologies, such as burners, SNCR, filters and other installations, for the greatest possible emission reduction.
FLSmidth – the complete package
FLSmidth is working with its cement partners all over the world to provide cost-effective solutions that minimise emissions when firing alternative fuels. Many plants want to modernise their facilities so they comply with regulations and meet increasing environmental demands – and they are turning to FLSmidth because it has the know-how and technology to handle the entire process, from planning and feasibility studies to complete delivery. FLSmidth is leading the industry in creating the next generation of clean, high-performance cement plants.
Related links:
Go to FLSmidth Alternative Fuels
