Aug 10, 2012
Company finds ways to decrease costs using oxygen enrichmentBack
Allentown|Expertise|Air Products|CoAL|Design|Environment|Flow|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|Solutions|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
Steel 2015: A review of South Africa's steel sector (PDF Report)
Creamer Media’s Steel 2015 report provides an overview of the key developments in the global steel industry and particularly of South Africa’s steel sector over the past year, including details of production and consumption, as well as the country's primary carbon...
Projects in Progress 2015 - First Edition (PDF Report)
In fact, this edition of Creamer Media’s Projects in Progress 2015 supplement tracks developments taking place under the Renewable Energy Independent Power Producer Procurement Programme, which has had four bidding rounds. It appears to remain a shining light on the...
Electricity 2015: A review of South Africa's electricity sector (PDF Report)
Creamer Media’s Electricity 2015 report provides an overview of State-owned power utility Eskom and independent power producers, as well as electricity planning, transmission, distribution and the theft thereof, besides other issues.
Construction 2015: A review of South Africa’s construction sector (PDF Report)
Creamer Media’s Construction 2015 Report examines South Africa’s construction industry over the past 12 months. The report provides insight into the business environment; the key participants in the sector; local construction demand; geographic diversification;...
Liquid Fuels 2014 - A review of South Africa's Liquid Fuels sector (PDF Report)
Creamer Media’s Liquid Fuels 2014 Report examines these issues, focusing on the business environment, oil and gas exploration, the country’s feedstock supplies, the development of South Africa’s biofuels industry, fuel pricing, competition in the sector, the...
Water 2014: A review of South Africa's water sector (PDF Report)
Creamer Media’s Water 2014 report considers the aforementioned issues, not only in the South African context, but also in the African and global context, and examines the issues of water and sanitation, water quality and the demand for water, among others.
This Week's Magazine
Today’s organisations execute projects within increasingly complex environments – particularly in the engineering sector. The ability to successfully execute these projects is what drives the realisation of successful projects and, ultimately, the achievement of...
South Africa’s distribution grid is a twentieth-century relic, which must be changed to serve the country’s modern electricity needs, says South African National Energy Development Institute (Sanedi) Smart Grid Programme manager Dr Minnesh Bipath. “What we are...
There is a disparity in government funding provided to integrated transport networks – bus rapid transit (BRT) networks ¬¬– and that given to conventional bus services, says Putco executive director Thys Heyns. “We have neglected and strangled conventional bus...
The Johannesburg Social Housing Company (Joshco) is building 502 rental housing units, valued at R200-million, in Dobsonville, Soweto, which are scheduled for completion in June 2016.
Automotive component manufacturer and distributor Metair is centralising its research and development (R&D) work in Turkey, in an attempt to bolster the company’s ability to produce affordable start/stop batteries. The new R&D centre is part of an expansion plan in...