Aug 10, 2012
Company finds ways to decrease costs using oxygen enrichmentBack
Allentown|Air Products|Flow|Gas|United States|Cement Kilns|Cement Manufacturing Process|Cement Producers|Energy|Flow|Nitrogen Oxide Monitoring Equipment|Recycled Rubber|Rubber|Rubber Recycling|Rubber Recycling Processes|Speciality Gas|Sachin Kulkarni|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
Other Furnaces, Kiln, Ovens and Dryers News
A new modular oven and operator panel with a colour display is being offered by global technology group Siemens’ Industry Automation Division for its Maxum Edition II gas chromatograph, used to separate and analyse gas by chromatography.
British technology company Dyson says its patented Airblade hand dryer is the first hand dryer to earn the Carbon Reduction Label from nonprofit organisation Carbon Trust.
Recent Research Reports
Steel 2014: A review of South Africa's steel sector (PDF Report)
Creamer Media’s Steel 2014 report provides an overview of 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 steel and stainless...
Projects in Progress 2014 - First Edition (PDF Report)
This publication contains insight into progress at the delayed Medupi and Kusile coal-fired projects, in Mpumalanga and Limpopo respectively, as well as at the Ingula pumped-storage scheme, which is under construction on the border between the Free State and...
Automotive 2014: A review of South Africa's automotive sector (PDF Report)
The report provides insight into the business environment, the key participants in the sector, local construction demand, geographic diversification, competition within the sector, corporate activity, skills, safety, environmental considerations and the challenges...
Construction 2014: A review of South Africa's construction sector (PDF Report)
Construction data released during 2013 hints at a halt to the decline in the industry during the last few years, with some commentators averring that the industry could be poised for recovery. However, others have urged caution, noting that the prospects for a...
Electricity 2014: A Review of South Africa's Electricity Sector (PDF Report)
This report provides an overview of the state of electricity generation and transmission in South Africa and examines electricity planning, investment in generation capacity, electricity tariffs, the role of independent power producers and demand-focused initiatives,...
Defence 2013: A review of South Africa's defence industry (PDF Report)
Creamer Media’s 2013 Defence Report examines South Africa’s defence industry, with particular focus on the key players in the sector, the innovations that have come out of the defence sector, local and export demand, South Africa’s controversial...
This Week's Magazine
The Electronic Systems Laboratory (ESL) of the Department of Electrical and Electronic Engineering at Stellenbosch University is strongly reaffirming its position as one of South Africa’s leading centres for satellite technology and expertise. It is currently...
The world’s lowest-cost diesel-electric locomotive is not made in China, but in Pretoria, at RRL Grindrod Locomotives’ newly upgraded 30 000 m2 plant. The company’s locomotive pricing is “more competitive than any other original-equipment manufacturer (OEM)...
The South African Defence Review 2012, released to the public at the end of last month (despite the year given in its title) recommends the creation of the post of Chief Defence Scientist. This official would be responsible for the management of defence technology...
AltX-listed engineering technology company Ansys has been awarded an R188-million contract by Transnet to supply integrated dashboard display systems to the freight rail utility’s locomotives. Black-owned and controlled Ansys developed the bespoke integrated system...
South Africa’s sole nuclear power station Koeberg, which is located in the Western Cape, breached a major operations milestone on April 4, which marked the thirtieth anniversary of Unit 1 having been connected to the grid. Eskom, which operates the two-unit plant,...