Decrease fossil CO2 emissions using 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
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.
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.