Aug 10, 2012
Company finds ways to decrease costs using oxygen enrichmentBack
Allentown|Expertise|Air Products|Cement|CoAL|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|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 Furnaces, Kiln, Ovens and Dryers News
Recent Research Reports
Defence 2014: A review of South Africa's defence industry (PDF Report)
Creamer Media’s Defence 2014 report examines South Africa’s defence industry, with particular focus on the key participants in the sector, the innovations that have come out of the sector, local and export demand, South Africa’s controversial multibillion-rand...
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 road...
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.
This Week's Magazine
The broad-based black economic-empowerment (BBBEE) alignment process in the con-struction sector has begun, dur-ing which the sector codes of the Construction Sector Charter Council (CSCC) will be aligned with the revised Codes of Good Practice (CoGP), which come...
It is second time lucky for Toby Venter. Ten years ago he negotiated to buy the Kyalami racetrack, but “the deal did not materialise”.
Environmental solutions company I-Cat started construction work on its R22-million, 1 949 m2 environmentally sustainable office and warehouse facility, commissioned by I-CAT Environmental Solutions, at a launch event in October. The new sustainable I-CAT campus,...
Effective file synchronisation and sharing across an organisation’s structures can provide the basis for robust mobile-device and document management while maintaining proper backup, version control and content distribution. These are the lessons learned by complex...
Hotel group Carlson Rezidor currently holds the largest hotel pipeline in Africa with 30 hotels and 6 300 rooms under development. The hotel group develops and operates Radisson Blu in the upper upscale segment and Park Inn by Radisson in the mid-market segment. With...