Integrated solutions for alternative fuels

Alternative fuels can reduce both fuel costs and greenhouse gases; two very common goals in the cement industry. As a result, more and more producers desire the capability to burn a wide variety of alternative fuels. Such capabilities require a comprehensive approach for the design of the entire plant; the receiving, sorting, shredding, handling, and dosing of fuels as well as the combustion must be considered to maximise fuel substitution.

In May 2007, FLSmidth introduced the Alternative Fuels group to focus on selecting and applying the optimum technology and systems to maximise fuel substitution. The group has the capability to assess the impact to the process from a quality, chemistry, corrosion, and emission perspective regardless if your application is a new installation or an upgrade of an existing line.

Comprehensive product portfolio
Alternative fuels (in shredded or bulk form) generally have much larger particle size and substantially longer burn-out times than traditional pulverised fuels. FLSmidth offers products that are well-suited to support these attributes. For example, the complete line of calciner solutions allows for the customisation for plant specific considerations – as well as to the properties of the intended fuels. The proper residence time can be accommodated, or if needed a bypass can be included to alleviate possible chlorine loading in the kiln system.

The DUOFLEX^TM G2 kiln burner can fire multiple alternative fuels, both liquids and small solids, as well as traditional gases. The burner can accommodate liquids with relatively high viscosity (300 CST), liquids that contain solid particles up to 5-6 mm, or even chemically aggressive and corrosive liquids. If bulky waste or biomass fuels are also desired, the system can be designed to include a HOTDISC reactor for the calciner. Furthermore, products such as the Pfister rotor weighfeeders support the process by providing an accurate dosage system.

Material handling of alternative fuels is facilitated by the FLSmidth KOCH closed pipe conveyors which enable the safe and reliable mechanical conveying of solids. FLSmidth KOCH and Pneumatic Transport also supply silo extraction systems specifically designed to eliminate bridging phenomena, thereby ensuring reliable fuel feed. Furthermore, FLSmidth Pneumatic Transport offers abrasion-resistant products which have been successfully incorporated in alternative fuel applications.

FLSmidth Automation supplies the multi-fuel controller, which ensures stable operation when firing a number of alternative fuels simultaneously.
Furthermore, Automation’s StackGuide, an on-line continuous emission monitoring system, can be used to ensure compliance for emission requirements and overall process stability.

Leveraging experience
FLSmidth’s years of experience in the cement industry minimises the risks and unknowns inherent in projects that convert from conventional to alternative fuels in pyroprocessing lines. Thereby, fast project implementation and increased certainty on the investment payback is achieved. For new lines, FLSmidth can ensure your plant will have the flexibility to burn a wide range of fuels from the initial commissioning, or position your plant for simplified future upgrades to burn alternative fuels.

Related links:
Go to FLSmidth Alternative Fuels