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Presentacion ATEC Holcim Apasco Ago 2008

The document outlines the upgrade of Holcim Apasco's Orizaba plant, focusing on the installation of a new Calciner Loop and Rotary Calciner to process petrochemical waste, specifically drilling cuttings. The project aims to improve kiln performance, increase thermal substitution rates, and enhance combustion efficiency, with a total investment of $10 million. Achievements include increased clinker capacity and reduced thermal consumption, demonstrating that older kiln technologies can be effectively upgraded.

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Edgardo Cardozo Meyer
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183 views18 pages

Presentacion ATEC Holcim Apasco Ago 2008

The document outlines the upgrade of Holcim Apasco's Orizaba plant, focusing on the installation of a new Calciner Loop and Rotary Calciner to process petrochemical waste, specifically drilling cuttings. The project aims to improve kiln performance, increase thermal substitution rates, and enhance combustion efficiency, with a total investment of $10 million. Achievements include increased clinker capacity and reduced thermal consumption, demonstrating that older kiln technologies can be effectively upgraded.

Uploaded by

Edgardo Cardozo Meyer
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 18

Upgrading Holcim Apasco's Orizaba

plant with a new Calciner Loop


and Rotary Calciner for
Petrochemical waste

Ing. Jonathan Forinton Ing. Armando Cruz


Initial Kiln Information

Equipment Capacity
• Preheater 4 stages Polysius
• Length 72 Meters
• Diameter 4.2 Meters
• Planetary Cooler ( 10 Cooler tubes)

Performance
• BDP (Best practice) 1580 Ton/day Ck
• TSR 5 % ( Preheater, basically whole tyres )
• Thermal Consumption 3850 MJ/Ton
Drilling cuttings (Petrochemical waste)

The material is the product residue of the drilling process in


the oil exploration, is a mix of clay, limestone and diesel.

Material H2O HV SiO2


(%) (MJ/kg) (%)
Drilling Cuttings 15 3.3 28
Project Objectives

• Disposal 50,000 Ton/Year of drilling cuttings


• Increase the % of Oxygen in the kiln inlet to improve
the kiln combustion
• Increase of thermal substitution ( with more
capacity for disposal of alternative fuels )
Project approach

• New Calciner Loop with more of 3 seconds of residence time.


– To ensure total Hydrocarbons destruction
– To reduce the thermal load in the kiln , using a petcoke burner for new
calciner
• Design of heat gases extraction system in the kiln hood, using a
Booster Fan.
• Installation of a burner in the rotary calciner (for diesel or alternative
liquid fuels )

Note: Until now no one had experience in the installation of rotary


calciner with a Planetary Cooler Kiln, our unique experience was the
installation of the rotary calciner with a grate cooler kiln.

This was the big challenge!!


Project Stages

Stage I New Calciner Loop designed by ATEC


• Split 40% - 60 % ( Ratio Calciner/Main Burner)
• 20% TSR
• Residence time > 4.0 Sec

Stage II Rotary Calciner system designed by Holcim Apasco


• Rotary Calciner Capacity 10 Ton/Hour
• Rotary Cooler system
• Hot gases extraction in the kiln hood and booster fan
• Burner using diesel or liquid alternative fuels.
Stage I Calciner Loop design

Inlet hot gases


from rotary calciner
Stage I Calciner Loop
Rotary Calciner-Kiln (hot gases system)

Hot gases from


New Calciner the rotary calciner
Loop Hot gases from the kiln
Rotary calciner

Rotary Cooler
Stage II Rotary Calciner

New Riser Duct

Drilling Cuttings Transport


4 Stage

Booster Fan

Kiln No 3
Calcinator

Kiln No 2

Cooler Tube

Ciclon

Clinker Transport Dust Discharge


Project achievements

Before After
Clinker Capacity 1,580 T/d 1,720 T/d
Thermal consumption 3,850 MJ/T 3,750MJ/T
Thermal substitution rate (by rotary calciner) 5% 13-15 %
Thermal substitution rate (complete system) 5% 30 %
O2 Kiln Inlet < 1.0% > 4.0 %
Sulfur % in Stage IV ( Hot meal) > 5.0 % ~ 4.0 %
Residence time 1.2 sec 4.2 Sec
Rotary Calciner capacity 9.0 T/H
Next steps

To reach design capacity in the rotary calciner (10 Ton/h)


• Increasing gas flow in riser duct ~ 24 meter/second

To reduce use of Diesel in rotary burner (actual 2 lts/sec)


• Idem
Investment

Resume :

2.0 Mio USD Calciner Loop

6.0 Mio USD Rotary Calciner

2.0 Mio USD Waste handling

10.0 Mio USD Total Investment


Conclusions

• The project accomplished the objectives and even in some


cases exceeded them.

• The project show us that kilns with old technology are able to
be upgraded.
Project Schedule

12 month
Assembly process
Final view of the rotary calciner
Final view of the Calciner

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