Decrease fossil CO2 emissions using alternative fuels

No oil, gas or coal – with polysius® fuel substitution, your cement plant can run on up to 100% alternative fuels

Preserving scarce resources is becoming increasingly critical in the cement industry. thyssenkrupp offers the right solutions and process engineering know-how to support cement producers in implementing new solutions that substitute fossil fuels with up to 100% alternative fuels, without compromising cement quality and while ensuring emission limits. The polysius® fuel substitution solution enables the use of biomass, residual materials and waste, for example, as primary energy sources in the kiln, riser duct and precalciner.

One-stop solutions for alternative fuel: polysius® fuel substitution

As a full-liner for cement plant technology, thyssenkrupp offers an integrated range of products and services to easily implement the entire waste-to-energy chain: From waste delivery, to storage and feeding, and thermal utilization. This includes:
  • Customer plant audits to identify the most suitable fuel substitution solution
  • Easy-to-implement solutions for plant owners that focus on cement quality and ensure compliance with emission limits
  • Modular approach from startup measures to advanced solutions – the simple conversion of a calciner up to 100% independence from fossil fuels
  • Focus on the use of a wide range of alternative fuels – from high to low-quality substitute fuels such as domestic or commercial waste.
  • Cost savings on CO2 emission certificates and through replacing increasingly scarce and expensive fossil fuels with biomass, residual materials and waste
  • Sustainability improvements, for example, by avoiding waste such as plastic being disposed in landfills and having a negative environmental impact

Solutions that fit both individual and regional needs

Alternative fuel availability, waste infrastructure, recycling rates, landfill costs and local regulations are just a few factors that impact the choice of the best-fitting alternative fuel substitution solution. Our solutions offer maximum flexibility and allow a stepwise increase in the share of alternative fuels: From high-waste pre-processing efforts using the polflame® burner, to zero pre-processing with the step combuster prepol® SC. Our solutions allow the incineration of fuels directly in the calciner or in a separate combustion chamber and meet regional and client-specific needs.

With the polflame® VN burner, alternative fuels can be incinerated easily in the kiln. It allows for maximum flexibility, and even incinerates challenging pulverized fuels thanks to an outer fuel channel, while alternative fuels flow through the center tube into the combustion zone. With its adjustable nozzles, fuels and primary/secondary air are perfectly mixed to ensure highly efficient and low emission combustion. Additional satellite tubes enable the alternative fuels rate to be pushed up to 100% at the kiln – with no costly burner modifications needed.

When it comes to very low fuel qualities that are characterized by a high moisture content as well as ultra-coarse particle sizes, it is preferable to incinerate substitute fuels in a combustion chamber. Here, thyssenkrupp offers two solutions: prepol® SC and prepol® SC-S. Generally, installing a step combustor is beneficial in the overall cement production process as it allows everything to be burned using one technology, in an economical and environmentally friendly way. Furthermore, it enables significant savings in fuel preparation and in terms of the fuel itself.

What makes the difference? The top 6 reasons to choose prepol® SC/S

1. Patented air blast transporting, with no moving parts in the hot zone

2. Separation of coarse and fine fuel particles on the grate, leading to the highest combustion efficiency in the market and less grate area required for combustion

3. Highest fuel flexibility thanks to the fuel separation effect on the grate – “burn what you get”

4. Constant agitation of the fuel on the grate for a superior oxygen supply and fewer CO peaks

5. Maximum reliability, proven in six years of operation with lowest maintenance costs and several step combustors in operation

6. Calorific dosing for maximum utilization of alternative fuels’ potential
 

prepol® SC-S combustion chamber

The prepol® SC-S allows the incineration of alternative fuels in a step combustor that is either mounted at the riser duct, at integrated line calciners, or even at separate line calciners. It is an efficient solution for increasing the residence time of coarse alternative fuels of up to 150 mm, boosting (cost) efficiency. This easy-to-implement technology does not require tertiary air.  


prepol® SC combustion chamber

The prepol® SC enables the incineration of even large amounts of very coarse and wet alternative fuels of up to 300 mm. This translates into significant savings in fuel preparation thanks to minimum waste pre-processing efforts and allows for the flexible sourcing of alternative fuels.

Extracting chlorine can be easily managed with the new designed polysius® chlorine bypass system, which guarantees low heat losses and the extraction of minimal dust amounts. It is the best solution for mastering the challenge posed by high chlorine concentration with high alternative fuel rates in the cement plant.

Benefits of polysius® fuel substitution

  • Achieve 100% independence from fossil fuels, without compromising on cement quality and while meeting CO2 emission standards
  • Save costs on CO2 emission certificates and by replacing increasingly expensive fossil fuels with biomass, residual materials and waste
  • Take advantage of our comprehensive support for implementing new processes along the waste-to-energy chain: waste delivery, storage and feeding, and thermal utilization
  • Benefit from easy-to-implement solutions from a single source that will significantly increase your plant’s profitability through the incineration of high volumes of alternative fuels
  • Enjoy maximum flexibility to incinerate multiple fuels and maximize alternative fuel rates in your cement plant

Contact

Worldwide

Leo Fit
Technology Innovation Sustainability
thyssenkrupp Industrial Solutions AG
Business Unit Cement Technologies

References

Germany
90% AF rate total
AF core products: polflame® VN, prepol® calciner, chlorine bypass

Germany
90% AF rate total
AF core products: prepol® calciner, chlorine bypass

Germany
90% AF rate total
AF core product: polflame® VN

Germany
80% AF rate total
AF core products: prepol® calciner, chlorine bypass

Germany
75% AF rate total
AF core products: prepol® calciner, prepol® SC, chlorine bypass

Germany
90% AF rate total
AF core product: polflame® VN

Germany
90% AF rate total
AF core products: polflame® VN, prepol® calciner, prepol® SC, storage

Mexico
2 x 70% AF rate at calciner
AF core products: polflame® VN, prepol®calciner, prepol® SC, storage and conveying, chlorine bypass

South America
20% AF rate total
AF core product: prepol® SC-S

Thailand
3 x 80% AF rate at calciner
AF core products: prepol® SC, storage and conveying, chlorine bypass

Take a look at our other solutions