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2012 REDUDUST A SYSTEM FOR BYPASS DUST RECOVERY BY: ING. JONATHAN FORINTON ING. PEDRO MONTES DE OCA.

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Presentation on theme: "2012 REDUDUST A SYSTEM FOR BYPASS DUST RECOVERY BY: ING. JONATHAN FORINTON ING. PEDRO MONTES DE OCA."— Presentation transcript:

1 2012 REDUDUST A SYSTEM FOR BYPASS DUST RECOVERY BY: ING. JONATHAN FORINTON ING. PEDRO MONTES DE OCA

2 2012 REDUDUST Agenda: Introduction Basic Concept Products Application Pilot Plant Industrial Installation Summary

3 2012 INTRODUCTION Many plants have implemented a bypass for removing chlorine from the pyrosystem Main Advantage: – Stable operation despite Cl input Main challenges today: – Clean disposal of bypass dust – Recuperation of raw material – Winning of byproducts

4 2012 INTRODUCTION Properties of Bypass dust: – Very poisonous for the ambient in contact with water – Alkalis (K 2 O, Na 2 O), – Chlorine (Cl) – Sulfur (SO 3 ) – Mercury, heavy Metals Use today: – Limited addition to cement – Rest landfilled Use with REDUDUST: – Economically friendly solution: conversion to marketable products: salts + clean raw meal

5 2012 BASIC CONCEPT Before leaching – particles covered with Micro Crystals of Chlorine based salts Water dissolves the Micro Crystals - uncovered particles are now able to react with water Blue areas indicate free lime Free lime reacts to Lime Hydrate (orange)

6 2012 PRINCIPLE PROCESS DIAGRAM Bypass-Dust- Silo Mixing Separation of Brine and Filter Cake Brine Treatment & Conditioning Crystallization Heat Supply Waste Heat Source Salt Products Filter Cake Chemicals

7 2012 MASS BALANCE OVERVIEW DATA GIVEN FOR TYPICAL EGYPT BYPASS DUST Bypass Dust Sewage water Chemicals Cement Waste Heat Product Material Potable Water Salts 5,0 t/h 6,0 t/h1,0 t/h 10 MW6,0 t/h4,0 t/h2,0 t/h ReduDust Process Plant

8 2012 INTERMEDIATE PRODUCTS Limestone slurry – collected sediments from CO 2 precipitation Heavy metal sludge – collected sediments from heavy metal treatment process Both are usually not leaving the process !! Limestone slurry (dry) Heavy metals sludge (dry)

9 2012 FINAL PRODUCTS Lime hydrate filter cake – Desalted bypass dust released from filter press Salt – Crystallized mixture of all salt contained in brine – Separation and purification of main elements possible e.g. Potassium chloride (KCl) Filter cake Salt

10 2012 PRODUCT APPLICATIONS Filter cake (low chlorine) –approximately 35% of residual moisture – Reintroduce back to process into cement mill due to low Cl content (<1%) – SO2 Trap Preheater Tower and/or Filter Equipment – Recycling as Raw Material: Calcining at 580°C, Energy 1.99MJ/kg CaO instead of 3.17 MJ/kg CaO – Additive for Cement Blends – No need for new material licenses, because it is considered as bypass dust

11 2012 PRODUCT APPLICATIONS Salts – Valuable product on market (e.g. fertilizer production at around 300 €/t market price) – Valuable Raw Material for various processes in the chemical Industry – Meets all European laws for chemical products

12 2012 ATEC Technical Center (AUT) Pilot Plant PILOT INSTALLATION

13 2012 PILOT INSTALLATION

14 2012 PILOT INSTALLATION MixingFiltrationDrying Mixing CrystallizingChemical Treatment

15 2012 PILOT INSTALLATION Bypass dust storageSlurry rapid mixer Peristaltic pump Filter press

16 2012 PILOT INSTALLATION Chemical dozing Sedimentation tank Crystallizer Dryer Process analytics

17 2012

18 Holcim Rohoznik First Industrial-Sized Plant INDUSTRIAL INSTALLATION

19 2012 INDUSTRIAL INSTALLATION DATA GIVEN FOR TYPICAL EUROPEAN BYPASS DUST Basic design principles – Utilization of waste heat from the cement plant – Installation must follow chemical installation requirements especially for environmental and safety reasons – Automatic operation – Reception of Bypass dust from different plants is considered

20 2012 INDUSTRIAL INSTALLATION DATA GIVEN FOR TYPICAL EUROPEAN BYPASS DUST Plant capacity – Standard design capacity of tpy of Bypass dust – tons of salts per year (approx tons of KCl)

21 2012 PLANT ARRANGEMENT Respecting optimal flow – Bypass dust – Filter cake – Brine – Salt – Chemicals Dimensions of footprint – 24 m x 36 m Crystallization Bypass dust storage, dosing and transport Mixing & Chemical treatment Tanks storage Filtration KCl silo Chemicals NaCl bags Filter cake outlet

22 2012 MATERIAL OVERVIEW Bypass dust 20k t/y – CKD 8 – 15 % of Chlorine Filter cake 16k t/y – Washed bypass dust <1% of Chloride – moisture <30% Brine 20k t/y – Saturated salty water >10% of Chlorine Chemicals used – 4 common industrial chemicals available on the market Salt – KCl >95% purity – NaCl salt >98% purity

23 2012 INDUSTRIAL INSTALLATION DATA GIVEN FOR TYPICAL EUROPEAN BYPASS DUST Operational data – 3 operators full time operation in 3 shifts working days – depending on kiln operation due to its heat demand (important for design of the storage capacity) – Heat need for crystallization and drying is around 1.4 MW – Designed to handle 5-15% chlorine content bypass dust – Overall Cl-extraction efficiency >90%

24 2012 INDUSTRIAL INSTALLATION

25 2012 SUMMARY Zero waste Recycling of raw meal Production of a saleable Product

26 2012 Please visit THANK YOU FOR YOUR ATTENTION


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