RCA Kiln Nar2 Due To Analyzer
RCA Kiln Nar2 Due To Analyzer
RCA Kiln Nar2 Due To Analyzer
HIL / CE
© Holcim Group Support Ltd 2011
HIL TSR Journey 2006 – 2012 and Aspiration
Target 2016 :
TSR NAR-1 : 24.13%
Actual Projection TSR NAR-2 : 19.81%
TSR CIL-2 : 7.35%
Actual 2011 TSR HIL : 16.12%
TSR NAR-1 : 10.7%
TSR NAR-2 : 9.4%
TSR CIL-2 : 1.4%
TSR HIL : 7.0 %
Geocycle Asia Network Meeting, Singapore, 29 Feb 2008 © 2012 Legal entity 2
Way forward : 2012 to 2016 HIL Journey planned
Incoming waste/AFR
Fine solid SLC
- Drilling cuttings
KI fuel NAR-2
- Contaminated Soil
AR with - WWT Sludge
Organic - Foundry Sand
- Fly ash 5
© Holcim Group Support Ltd 2011 26.09.2011/SCE
AFR Preparation Sites – Basic Concept
Solid
ISW
Solid
Shredding line
Consumer phase 3 Coarse ILC fuel
Products NAR-1
Sorted Plastic
Waste from Fine solid SLC
MSW fuel NAR-2
KI fuel NAR-2
NAR-2
(non CV AF)
7
© Holcim Group Support Ltd 2011 26.09.2011/SCE
Platform Capacity
• Solid preparation plant: 135’000 t/a
• Sludge preparation plant: 25’000 t/a (Sludge 18’000 t/a
and AR with Organic 7’000 t/a)
• Total Capacity : 160’000 t/a
8
© Holcim Group Support Ltd 2011 AFR Turntable India 2011 04.08.2011/MAI
Location
(proposal)
9
© Holcim Group Support Ltd 2011
Proposed new location Solid and Sludge Platform
New proposed
location for
AFR platform
10
© Holcim Group Support Ltd 2011
Proposed new location Solid and Sludge Platform
New
proposed
location for
AFR
platform
12
© Holcim Group Support Ltd 2011
New shredding line
• Phase 3: Production of ILC fuel (<150mm) for NAR1&2
and SLC fuel (<30mm) for NAR2
67‘500t/y ISW/RDF (<150mm)
67‘500t/y ISW/RDF (<30mm)
400k
Primary Second.
Table Screen Air SLC fuel (2D
Shredding Fe Shredding 2D
Feeder (50 mm) Classifier <30mm)
< 150mm <30mm
Manual sorting of
heavy fraction
13
© Holcim Group Support Ltd 2011 Inert 26.09.2011/SCE
Flow sheet Solid AFR Platform
14
© Holcim Group Support Ltd 2011
Lay out Solid AFR Platform
15
© Holcim Group Support Ltd 2011
Lay out Solid AFR Platform
Star screen
Primary shreeder
Air Classifier
Secondary shreeder
16
© Holcim Group Support Ltd 2011
Solid AFR Platform – Basic Design
Basic design :
Roofed Storage cap. for receiving material 525 t
Dimension 60x25x4, eff storage 60% 3500 m2
Est. BD : 0.15 t/m3
Main equipment
Walking floor feeder
Primary shredder (Max capacity 30 tph)
Star Screen
Magnetic separator
Air classifier
Secondary shredder (Max Cap 15 tph)
Conveyor systems
Facilities :
Water pond for fire suppression : 1000 m3
Water pond for rain polluted water (roofed): 300 m3
AFR Office
Access concrete road (wide 10 m)
17
© Holcim Group Support Ltd 2011
Sludge AFR Platform
18
© Holcim Group Support Ltd 2011
Flow sheet Sludge AFR Platform
Sludge Platform
74x38 = 2812m2
19
© Holcim Group Support Ltd 2011
Basic design Sludge AFR Platform
Storage capacity :
• Total est receiving 17.875 t/y
• Receiving area 2430 m2 (450 t)
• Total drum 900 (180t); jumbo bag 270
(270t)
• Stock capacity 7 day operation
Production capacity :
• Max production 2.5 tph (60 tpd)
Handling material :
Static crane Jonsered
Mixer
Sludge Pump (existing)
Shreeder (M&J 1000)
20
© Holcim Group Support Ltd 2011
Lay out Sludge AFR Platform
Mixer
Existing
Sluge pump
Shreeder
21
© Holcim Group Support Ltd 2011
2013
Sludge platform
• Operating principle of the sludge platform: Production of
pumpable sludge
Hydraulic arm for
Four unloading pits for material handling
low viscosity sludge
and pasty material in
drums, jumbo bags Collection pit or
and bulk container for solids
Contaminated
soil
Material transport
into PH tower by
contruction elevator
Pasty material
24
© Holcim Group Support Ltd 2011 AFR Turntable India 2011 04.08.2011/MAI
Roadmap – NAR-2
2013
• Improvement of
existing solid feeding
installation at NAR-2
for contaminated soil
feeding
• Mixing of cont. soil
and pasty/solid oil
sludge by loader
Sludge
TSR (sludge): <2%
2013
25
© Holcim Group Support Ltd 2011
2013
AFR feeding NAR-2
• As light (RDF) and heavy (solid sludge & contaminated
soil) material shall be dosed with the same system, it is
suggested to install a belt weigh feeder which contorls
the speed of the extractor.
• The density of the two materials differ by factor 10. This
cannot be handled with the same belt weigh feeder.
• Design of extraction hopper and belt weigh feeder shall
be for RDF.
• In case of feeding of heavy material, only one extraction
screw shall be running and the signal of the belt weigh
feeder shall be ignored (only volumetric dosing as feed
rate is small).
26
© Holcim Group Support Ltd 2011
2013
AFR feeding NAR-2
• Flowsheet
27
© Holcim Group Support Ltd 2011
2013
AFR feeding NAR-2 – Screw Extraction Hopper
• Double screw extration hopper design
„Funnel“ to
facilitate jumbo Length of hopper:
bag emptying 4000mm
Height of hopper:
2000mm
Pitch of screw at Pitch of screw at Pitch of screw at
beginning of hopper: end of hopper: after hopper:
200mm (cont. 300mm 350mm (avoid
increasing) blockages)
Width of hopper:
1000mm
29
© Holcim Group Support Ltd 2011
2013
AFR feeding NAR-2 - Screw Extraction Hopper
• Capacity estimation for one extraction screw (CS)
30
© Holcim Group Support Ltd 2011
2013
AFR feeding NAR-2 - Screw Extraction Hopper
• Feeding capacities and buffer time estimation
Light Material (0.1t/m3, both screws running): 0.3 – 1.8t/h
Buffer time in case of 1.8t/h RDF: 20min*
Heavy Material (1.2t/m3, one screw running): 1.8 – 11t/h