ReduDust A System for Bypass dust recovery By: Ing ReduDust A System for Bypass dust recovery By: Ing. Jonathan forinton ing. Pedro montes de Oca

Redudust Agenda: Introduction Basic Concept Products Application Pilot Plant Industrial Installation Summary

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

Properties of Bypass dust: Introduction Properties of Bypass dust: Very poisonous for the ambient in contact with water Alkalis (K2O, Na2O), Chlorine (Cl) Sulfur (SO3) 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

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)

Principle process diagram Chemicals Bypass-Dust- Silo Brine Treatment & Conditioning Separation of Brine and Filter Cake Mixing Filter Cake Waste Heat Source Crystallization Heat Supply Salt Products

ReduDust Process Plant Mass Balance Overview Data given for typical Egypt bypass dust Bypass Dust Sewage water Chemicals Cement Waste Heat 5,0 t/h Product Material 6,0 t/h 6,0 t/h Potable Water 4,0 t/h ReduDust Process Plant 1,0 t/h Salts 2,0 t/h 10 MW

Intermediate Products Limestone slurry collected sediments from CO2 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)

Lime hydrate filter cake Salt 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

Filter cake (low chlorine) –approximately 35% of residual moisture 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

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

Pilot Installation Pilot Plant ATEC Technical Center (AUT)

PILOT INSTALLATION

Pilot Installation Drying Crystallizing Chemical Treatment Filtration Mixing Mixing

Pilot Installation Bypass dust storage Slurry rapid mixer Peristaltic pump Filter press

Pilot Installation Chemical dozing Crystallizer Sedimentation tank Process analytics Dryer

First Industrial-Sized Plant Industrial Installation First Industrial-Sized Plant Holcim Rohoznik

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

Industrial Installation Data given for typical European bypass dust Plant capacity Standard design capacity of 20.000 tpy of Bypass dust 4.000 tons of salts per year (approx. 3.000 tons of KCl)

Mixing & Chemical treatment 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

MATERIAL OVERVIEW Bypass dust 20k t/y Filter cake 16k 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

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%

Industrial Installation

Summary Zero waste Recycling of raw meal Production of a saleable Product

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