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A TEC’s Mjolnir mill: The future of alternative fuels preparation & burning
By Pedro Montes de Oca andJonathan Forinton
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Agenda
• Background• Mjolnir Features• Plant Flowsheet• Test and industrial results• Link to pyroprocess
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It is possible to substitute common fuels like coal 100% with municipal waste. This is being done in Europe in some plants.
The thermal energy content of municipal waste is interesting at approx. 15…21 MJ/kg depending on the preparation process.
Municipal solid waste breaks down and forms methane which is 21x more potent than CO2 for global warming.
During the fuels preparation process, enhanced recycling can be integrated.
Solid waste as a fuel alternative
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MSW is relatively similar in different parts of America
The % organics and % water depends on the economic profile of the neighbourhood.
MSW make-up
Thermal fraction with calorific value: 17-21 MJ/kg
Recyclables Minerals, dirt
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General Block Diagram for alternative fuels
collection storage transport dosingprocessing
Operation Guidlines & Adjustment
Process Design & Evaluation
Combustion Technology
Standard Alternative Fuel Preparation Technology
ATEC production and process technology for utilization of alternative fuels
There are 2 sections for an alternative fuels plant:1)Mechanical handling, processing and dosing2)Implementation in the cement kiln
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Where Mjolnir product is injected
TAD 4
TAD 3 TAD 2 TAD 1
Bypass
Quench
Main Burner
COMBUSTION CHAMBER
CALCINER
MIXINGCHAMBERCalciner Burner
Kiln Inlet Burner
Particle sizeMain burner: < 20 mmOther burner: < 80 mm
Combustion Gas TemperatureMain burner: > 2000°CCC-burner: < 2000°CKiln inlet burner: < 1200°CCalciner burner: < 900°C
Different sizing is discharged from different points Light fraction for kiln burner heavy fraction for calciner burner
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Industrial Size Test Mill at Sommariva, Italy
The mill is set up similar to a vertical roller mill system Foundation is light because moving parts are light Building footprint approx . L10 x W5 x H6 m
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Mjolnir Test Mill- Main Technical Data
Mill size 2.5
Weight 52‘000 Kg
Drive Unit 2 x 300 kW
Rotor Speed ~ 580 min-1
Capacity 6 t/h <15mm15 t/h <50mm
Feeding 2 x Conveyor screws
Discharge 2 x Conveyor screws
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Industrial Size Test Mill at Sommariva, Italy
The mill allows for a gas throughput, like a vertical roller mill.
This means we can effect drying and grinding in 1 step
The ultra-fines are dedusted and can be separately handled and dosed to kiln system
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Flowsheet
Feed belt conveyor
Bag Filter
Condenser
Outlet Gate 1
Middle Gate
Bin with screw conveyors
Outlet Gate 2
ID Fan
Exhaust
Outlet screw conveyor1
Outlet screw conveyor2
Different sizing is discharged from different points Even metals can be quite reliably separated by density
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Industrial Size Test Mill at Sommariva, Italy
2 Feed belts bring material into each of the 2 shredding chambers
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Mjolnir Design Features
Common feed bin with 2 screw conveyors to each of the 2 mill chambers
Rejects manual outlet gate
Product outlet screens
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Mjolnir View inside the mills
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Mjolnir Features of the grinding tools
The chains are individually adjustable in height and position at the shaft head depending on the input material which has to be grinded.
The change in position can be done in a quick time, if it should come to a request to change the input material.
The same applies if the chains have to be replaced due to wear.
Incoming material < 150 mm Easy to maintain (NO KNIVES) Separated from FE and non FE materials
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Mjolnir 3D Model
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Mjolnir inside the test mill
above, the outlet screens and on the right side the manual outlet gate
left, the chains after the testing period
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Mjolnir Advantages
1) Size reduction from 150mm to 5mm in one grinding step
2) Saves one step of shredding
3) Easy to operate
4) Easy to maintain
5) No knives to keep sharp
6) Drying effect during operation
7) Separation of FE and non FE – materials
8) Different output fuel particle sizes for main burner and
calciner possible
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Feed Product
Feed pre-selection No larger carpets No tyres Reduce large solid beams
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Proper Pyro-Control with FFB Feeder
FFB - Fuel Feeder Burner: Unlike rotary units, this unit:
is easy to operate and maintain is easy to take off-line during operation provides air seal by the fuel material itsself so no moving parts can get stuck
FFB - Fuel Feeder Burner: The hopper feeds to the burner pipe directly An outer pipe carries coal as 10% control fuel Tertiary air ducted tangentially to control flame
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Mjolnir
The future of alternative fuels preparation !
One grinding step does everything Do nt worry about feeding in hard foreign objects Throw the resultant fuel directly to burners
Correct dosing and injection methods Control pyro-process