Aug 10, 2012
Company finds ways to decrease costs using oxygen enrichmentBack
Allentown|Expertise|Air Products|Cement|CoAL|Flow|Gas|Industrial|Resources|System|Waste|United States|Cement Kilns|Cement Manufacturing Process|Cement Producers|Energy|Equipment|Flow|Manufacturing|Nitrogen Oxide Monitoring Equipment|Products|Recycled Rubber|Rubber|Rubber Recycling|Rubber Recycling Processes|Speciality Gas|Power|Sachin Kulkarni|Waste|Early Technologies
© Reuse this
The company has developed methods to save energy, reduce pollution and lower costs by using oxygen enrichment in cement kilns and cryogenics in rubber recycling processes.
Air Products bulk gases sales manager Sachin Kulkarni says the evolution of oxygen enrichment for cement kilns and cryogenics for rubber recycling is extremely beneficial to industry.
“Oxygen enrichment evolved when cement producers sought alternative fuels to expend- able and nonrenewable natural resources, such as coke, coal and rubber, for use in cement kilns.
“The fumes that resulted from heating these substances in kilns using traditional methods, were considered detrimental to the environment and humans,” he says.
In the late 1980s, oxygen enrichment was adopted as a suitable method of achieving full combustion when reusing rubber as a fuel in cement kilns.
Oxygen enrichment allows high temperatures to be reached very quickly, which greatly reduces emissions, while also producing the required amount of heat for the cement manufacturing process.
While oxygen enrichment is now commonly used in cement kilns that use recycled rubber as a fuel, Air Products’s burner system has developed to such an extent that the design allows for complete process stabilisation and increased output.
“Operational teams require a stable kiln operation, as the stability of the kiln can, over time, contribute to higher production volumes. The burner design and system provide shorter flames and better control of the burning zone, which assists in stabilising processes,” says Kulkarni.
He points out that companies that adopt the oxygen-enrichment methodology will require an oxygen burner, an oxygen flow meter and nitrogen oxide monitoring equipment, which monitors flue gases to adequately decrease or increase the oxygen flow.
The system not only reduces the carbon footprint but also increases the production of clinker by between 5% and 30%. Documented results also include a 30% to 80% increase in the use of alternative fuels.
Kulkarni explains that the cryogenic recycling of rubber was one of the early technologies that was considered as a means to counter the impact the industry was having on the environment and to find alternatives for the use of nonrenewable resources.
Cryogenics refers to the science and technology of producing a low-temperature environment for applications.
As the demand for more finely ground recycled rubber had increased, the incentive to find more productive and economical ways of achieving alternative uses for nonrenewable resources gained momentum.
The application of cryogenic principles to the handling of the rubber has resulted in the form of the rubber being altered, which makes it brittle and easy to break and grind.
The first step in the process is the removal of foreign objects, such as wire and nylon, from rubber tyres and other waste rubber.
Thereafter, the rubber is chopped into manageable chunks and placed on a sealed system conveyor. Liquid nitrogen is then sprayed on the rubber until it reaches glass transition temperature levels. At this stage, the rubber can be removed for fine grinding.
The powder can then be used as an additive by tyre manufacturers and rubber parts suppliers, as well as for the manufacture of sound- absorbent rubber mats for use at airports.
Cryogenic technology, in this application, increases the use of waste products and reduces the negative impact on the environment.
Research on waste fuels has been done in Allentown, in the US. A Solid Fuel Laboratory has been installed to conduct tests on various fuels and associate burners.
Edited by: Chanel de Bruyn© Reuse this Comment Guidelines (150 word limit)
Other Foundries, Forges and Die-Casting News
Recent Research Reports
Road and Rail 2014: A review of South Africa's road and rail infrastructure (PDF report)
Creamer Media’s Road and Rail 2014 report examines South Africa’s road and rail transport system, with particular focus on the size and state of the country’s road and rail network, the funding and maintenance of these respective networks, and the push to move...
Real Economy Year Book 2014 (PDF Report)
This edition drills down into the performance and outlook for a variety of sectors, including automotive, construction, electricity, transport, steel, water, coal, gold, iron-ore and platinum.
Real Economy Insight: Automotive 2014 (PDF Report)
This four-page brief covers key developments in the automotive industry over the past 12 months, including an overview of South Africa’s automotive market, trade figures, production and the policies influencing the sector.
Real Economy Insight: Construction 2014 (PDF Report)
This five-page brief covers key developments in the construction industry over the past 12 months. It provides an overview of the sector and includes details of employment in the sector, infrastructure and municipal spending, as well as insight into companies’...
Real Economy Insight: Electricity 2014 (PDF Report)
This five-page brief covers key developments in the electricity industry over the past 12 months, including details of State-owned power utility Eskom’s generation activities, funding and tariffs, independent power producers and prospects for the sector.
Real Economy Insight: Road and Rail 2014 (PDF Report)
This six-page brief covers key developments in the road and rail industries over the past 12 months, including details of South Africa’s road and rail network and prospects for both sectors.
This Week's Magazine
South African State-owned defence industrial group Denel has announced its fourth consecutive year of profits. The group's results for the financial year 2013/2014 were recently announced at its head office in Centurion, south of Pretoria. Revenues grew by 17%, net...
There is little opportunity for JSE-listed infrastructure company Group Five to grow shareholder value in the domestic market, says CEO Mike Upton. He says value can still be found in the private sector, in the renewable and industrial power sector, as well as in...
The National Association of Automobile Manufacturers of South Africa (Naamsa) has announced the event dates of the 2015 Johannesburg International Motor Show (JIMS). The event will take place from October 14 to October 25, 2015, at the Johannesburg Expo Centre, Nasrec.
UK engineering support services provider Babcock is set to deliver the largest order of global truck manufacturer DAF’s truck tractors in Southern Africa to bulk carrier road-based logistics company Ngululu Bulk Carriers (NBC), with 133 trucks to be delivered in...
Digital radio communications in the African local government space can open up the world, but have many challenges to overcome, notes integration and migration of legacy radio communications infrastructure with digital mobile radio company Emcom Wireless head of...