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Alternative fuels: SMP system for feeding pasty fuels to cement kilns: Donat Bösch, SID SA (Switzerland)

Filmed at Cemtech Europe 2015, 20-23 September, Intercontinental Hotel, Vienna, Austria.

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When I'm speaking about pasty fuels it means mainly fuels made out of industrial waste and fuels made of hazardous waste. Not working, oh yes it works. I'm CEO of SID group but in my heart I'm an engineer so I participated a lot in the development of the systems I'm presenting you now.

SID has it's headquarters in the Western part of Switzerland close to Neuchatel. It's manufacturing waste treatment system since 1972. The main products are big size reduction machines that means rotary shears and hook shredders but in the mean time we are also manufacturing related products, mixers for raised and also pumps for difficult pumpable materials.

We have also in the meantime subsidiaries in Germany, France, China and India. Production, manufacturing is done in Switzerland, Germany and China. One of the specialties of SID are SMP kiln feeding systems. What means SMP? SMP means systems which has a treading, mixing and pumping step.

The idea is to produce out of different waste of homogeneous slurry only having about hand size foreign objects in the slurry. So how does it look like? We have the possibility to put in bulk waste from a usual bunker. Packed waste. The waste goes in via interlocking door system. The reason is we want to isolate the system from the environment.

Afterwards we have the shredding step, then the mixing step and the pumping step. What you see here is an installation set we delivered to Japan. This installation was not installed in a cement plant but it was installed in a hazardous waste incinerator, but the system are basically very comparable, anyway any system is a bit different because we always have to do some adoptions.

The delivered in the meantime 15 systems in total, SMP systems, shredding mix and pumping systems, four of this 15 system for cement kilns, three in the last two years. So for cement kilns it's a relative or for cement process it's relative new system, but what you see also see here is one of the main activity of SID is related to hazardous waste.

That means we deliver more than hundreds of plants for hazardous waste shredding including a souting[sp?] systems that means a separation system, pumping systems and interlocking door system, and about in the last 20 years more than 500 systems in general for waste treatment or the mainly shredding systems that means our specialties are our very big shredders that means big shredders that can treat more than up to 200 tones per hour.

Hazardous waste, what does it mean? Hazardous waste is waste that cannot be treated in a conventional incineration plant and that cannot be disposed in a normal land field. It's normally characterized that it has a low ignition point, it's very reactive, it's corrosive and it's toxic.

So why using such a material which is more difficult to treat than other materials? First, it is the material which has usually the highest gate fees that means you get highest prices to accept it. Usually holds a good calorific value and for some products it is an effective destruction especially some hydrocarbures due to the high temperatures you have in cement process, it can be, not necessarily, but it can be from an ecological point of view, also a good system. The waste is presented in can come in drums, in containers, can also come as bulk waste, as liquids or as sludge.

The SMP system is able to treat all this kind of waste but you have to make a menu, a menu in order to get it pumpable, that means you need about 50% of liquids otherwise it will stick and of course it must meet the requirements of the cement process, especially for example some substances may be harmful to your process and must be avoided.

So what are the requirements for this system? In the end you need a regular and continuous feeding, that means regular calorific value, regular toxicity and also a the product size. Usually we go down to about hand size but it's also possible to go down further. The product is usually also brought to the pre cosigner you'll see later.

The next thing is,you have, it must be able to treat a wide range of products especially it should not stick when you have some difficult products to treat, it should be robust and it has to be automated, automated means you should avoid as far as possible man waste contact as it's hazardous waste and of course for the economical reasons, you should not have too much manpower.

Once again the flow diagram what you see here, we add usually some nitrogen into the process, this is just to bring down oxygen concentration in order to avoid any explosion and the gases that come of the system are collected and brought to the incineration process. Here you see how it looks like, traditional system, that means you have here the interlocking door system, the shredder, and the mixer.

The idea to bring hazardous waste or to transform hazardous waste or industrial waste to transform it into a pumpable slurry is not a new idea. The first test were made more than 25 years ago, but at that time especially pumping technology was not so developed. So it was in all cases a two stage shredding was necessary, and reliability and especially availability was not very high.

In the mean time, we have some system which have 99% availability. So I would like to go to the different components. The system can be fed alongside by bulky waste, on the other side a pelletized waste, or by waste in containers by sludges and by liquids. The pelletized waste or drum waste is usually transported by a fully automatic system, including horizontal and all the hoist system to an interlocking door system.

The bulk waste is usually stored in a normal bunker and then taken by a conventional crane. Before it goes into the system, it passes through an interlocking door system. The interlocking door system serves to isolate the system from the environment but also to inject some nitrogen.

In some cases we also measure directly the oxygen concentration. What you see here is a typical system to bring drums into the shredder. In front of the shredder, we have the hopper but it's not only a usual hopper but it's equipped but it's equipped with a pushing device which pushes the product before it turns into the shredder, it's also equipped with some over pressure busting discs.

So what you see here, here the hopper, here the ram feeder which presses the product into the shear and sets the rotary shear or the size redox to equip on itself. We are producing different size reduction machines but for hazardous waste or for this kind of system we always use rotary shears, they have advantages that they are low speed shredders running at about 15 RPM, they give the required granule limitry and also it's possible to remove relatively easy unshaveable objects.

Here you see the cutting principal, you cut here at the edges of each shaft. In order to have a nice home organization you need a mixer, you'll see our usual mixers be falling between five and ten meters cubed, we can go up also higher if required. The mixer is equipped with a weir. It's a one shaft mixer, hydraulically driven, and what you also see here, different flanges where you can add all kinds of liquids in order to make the product pumpable or to adjust the calorific, the toxic or all those values.

From the mixture we go into a piston pump. This piston pump is a very special pump in a way that it's able to pump even when you have a quite big quantity of foreign objects. So if you shred for example here, all the chairs and tables and you put some liquid sludges we leave, you can pump it with this pump, it has a cutting force of nearly a hundred tones.

The pump itself is fed by a double screw feeder which presses the product in the pump. So here you see the pump, here you see the double screw feeder, the hydraulic gauge of the pump. After the pump, according to the the consistency of the product, we can go up to about 150 meters, so you should not be further away from the pre cosigner via piping, usually a piping of 350 millimeters, and from that you go into the lance.

You see here where it goes in, it's a standard lance which is usually air cooled for hazardous waste incinerators for example, we also made what we call lances. In order to reduce the danger of explosion the installation is equipped with a nitrogen blanketing system which brings down oxygen concentration to about 5%, and also we have a gas recuperation system, what you see here is the interlocking chamber where we blow in some nitrogen after all the exhaust air goes out is recuperated here, and brought back to the incineration process. To increase safety we in stall O2 measurement systems, these are paramagnetic, electrochemical or laser system, each system has it 's advantages.

Inside the shredder there is no danger of explosion as it's in a ticed[sp?], except when you have some substances like peroxide which explodes without oxygen, but outside there shredder or in case you have a failure in the systems you might have fire, so the installations are usually equipped with a fire extinction system and the shredder itself is an X proved construction, resisting to about one bar power pressure.

In the installation we have nearly 200 different measurement points which we take into consideration, for example the mixer is on weight cells, we can also measure oil pressure in the pump, in the feeding screws, in the mixer in order to determine in which direction the system is going if you might have a problem, if it risked to go to stick in the field and what the whole system is finally entirely automised requiring or allowing a relatively easy operation.

In some cases an SMP system is not enough because the customer has some additional requirements, in that case the SMP system can for example combined with a separation system for iron, it can also separate liquids, we can add liquids which results in the end, sometimes in quite complicated system, this diagram was not made for cement it was made for hazardous waste incineration.

It's mainly the same. That means the system are usually customized to the request of the customer, and we add what the customer needs. Okay, this was it.

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