Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ......
Transcript of Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ......
![Page 1: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/1.jpg)
![Page 2: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/2.jpg)
Beneficial Recovery of Metal Contaminated Soils in a Cement Kiln
•Cement manufacturing process•Lafarge’s Beneficial Resource Recovery Program – use of Metal Contaminated Soils•Summary and Questions
![Page 3: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/3.jpg)
3
Subsidiary of Lafarge (since 1986)
Works with Cementos Argos to continue supplying alternative fuel for two cement plants that were purchased from Lafarge in 2011 - Harleyville, SC and Calera, AL
Works with Eagle Materials Inc. which purchased the Tulsa, OK and Sugar Creek, MO facilities from Lafarge in 2012.
• Lafarge SA had over $19 billion in sales in 2011 and is:– a global Fortune 500 company– the world’s largest cement and construction materials manufacturer– a world-wide user of waste by-products– on most recent list of: “Global 100 Most Sustainable Corporations in the World”
• Cementos Argos ‒ has facilities in Columbia, the U.S. and the Caribbean ‒ had $2.0 billion in sales in 2011
‒ Eagle Materials, Inc.‒ has six cement plants, all based in the United States (also has other construction
materials divisions)‒ had revenue of $495 million in 2012.
![Page 4: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/4.jpg)
Richmond
Exshaw
Fredonia
Sugar Creek Paulding
BrookfieldAlpena
Calera
St. Constant
Kamloops
Davenport
Harleyville
Woodstock
Sparrows Point(grinding facility)
Tula
Vito
Systech’s Coverage Areaand other cement partner locations
- Cementos Argos (nonhaz fuels)
Tulsa
-“ w/Systech (haz/nonhaz FQW)
-“ w/Systech (nonhaz byproduct /fuels)+ Ecuador and Honduras
- Lafarge Cement plant
- w/Systech (nonhaz byproduct fuels)
- w/Systech (haz/nonhaz FQW)
Whitehall
Ravena
Bath
Joppa
Buda
Reno
- Eagle Mat’l Cement plant
![Page 5: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/5.jpg)
Cement Manufacturing Process
![Page 6: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/6.jpg)
Cement vs Concrete – There is a difference!
Cement Concrete
Water + Rocks +Sand
![Page 7: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/7.jpg)
Cement Manufacturing Process
Step 1. Create a raw mixStep 2. Burn the raw mix in a kiln to produce
“clinker”Step 3. Pulverize the clinker to make the powder
known as cement
![Page 8: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/8.jpg)
Step 1. Creating a raw mix• Raw materials are combined in exact
proportions to create a chemically correct raw mix– Silica (sand, clay, shale)– Alumina (clay, shale, low grade bauxite)– Iron (mill scale, smelter slag)– Lime (limestone)
• Raw mix is pulverized in a mill
![Page 9: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/9.jpg)
Step 2. Burning the raw mix in a kiln• Raw mix is burned in a kiln• Material temperatures >1450 0 C• End product is cooled to form
pellet size material “Clinker”• Alternate fuels are introduced
here
![Page 10: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/10.jpg)
Step 3. Pulverizing the Clinker
• Clinker is combined with a small percentage of gypsum and ground in a mill to produce the powder know as cement
![Page 11: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/11.jpg)
Richmond Cement Kiln
![Page 12: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/12.jpg)
Richmond Cement Kiln
![Page 13: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/13.jpg)
1. Creating a raw mix
Clinker
Alumina: Ash, Shale
Silica: Sand, soilLime: Limestone
1450oCChemical
Transformation
Iron: Steel slag
How Cement is Manufactured – 3 Step Process
2. Burning the raw mix
3. Final Grind Cement
![Page 14: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/14.jpg)
Lafarge’s Beneficial Resource Recovery Program
![Page 15: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/15.jpg)
Resource Recovery Opportunitiesat Cement Plants
1) Replacement of conventional raw materials with byproduct streams originating primarily from industrial and commercial sources.
2) Replacement of conventional fuels with by-product streams originating from industrial, commercial, institutional and residential sources.
![Page 16: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/16.jpg)
Beneficial Recovery of Metal Contaminated Soil Materials
• Cement plants consume large quantities of conventional raw materials such as sand, shale and limestone.
• Industrial by-products can off-set usage of natural raw materials
• A large number of cement kilns around the world consume a wide variety of by-products containing silica, alumina, iron and/or lime.
![Page 17: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/17.jpg)
Contaminated Soil Utilization Criteria
• Non hazardous soils only• Chemically compatibility• Physical characteristics, handling and
process introduction• Environmental considerations and impact
on emissions• Health and safety factors• Financial considerations
![Page 18: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/18.jpg)
Typical Alternative Raw Materials
• Aluminum catalysts • Fluid cracking
catalysts• Boiler ash• Silica Desiccant• Metal impacted
soils
• Spent abrasives• Spent foundry sands• Flyash• Lime Sludge• Alumina Sludges
![Page 19: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/19.jpg)
Lafarge Cement Kiln Beneficial Recovery
• Lafarge cement kilns can provide complete and safe destruction for a variety of byproducts including contaminated soil while recovering their inherent value.
• Beneficial recovery is aligned with the concept of sustainable development through the replacement of fossil fuels and conventional materials with byproducts.
• Proven use of byproducts at many of Lafarge’s plants worldwide.
![Page 20: Beneficial Recovery of Metal · 2016-01-22 · Creating a raw mix Clinker Alumina: Ash, Shale ... Chemical Transformation Iron: Steel slag How Cement is Manufactured – 3 Step Process](https://reader030.fdocuments.in/reader030/viewer/2022041004/5ea8a10f1d91983f413c4a40/html5/thumbnails/20.jpg)
Cement Kiln Beneficial Recovery Differs from Incineration Conventional raw materials are replaced by the
by-products Conventional fuels are replaced by the by-
products for energy use No residual materials to landfill – NO ASH
Ash is incorporated into final product