Narogong AFR Platform Support Visit

Conclusion Meeting
October 07-11, 2013

Michael Schmid, HTS/AFR-PF

Including modifications discussed during conclusion meeting.

© 2013 Holcim Ltd

Non-HW Shredding Line
• Primary shredder enclosure
 Complete enclosure (enclosed room like Neue Plastrec AG) is not
necessary.
 A cover to protect mechanical and electrical components is
however recommended.

© 2013 Holcim Ltd 2

Non-HW Shredding Line
• In the current layout loading of trucks and containers occurs in
front the main storage. Although the area is covered wind
spillage has to be expected.
 The length of the hall shall be extended in a way that truck and
container loading happens inside the building.
 Alternatively the a cladding can be provided to the loading area.

© 2013 Holcim Ltd 3

Fire Protection non-HW Shredding Line
• Fire protection system for shredding line
 Currently only the shredders and their discharge conveyors are
protected. Idea: spark extinguishing system prevents fire outbreak.
 In case that spark extinguishing is not realized the entire
shredding line shall be covered with water spray.
 Reduce amount of zones to 2 or max. 3 (alarm valves are
expensive) Zone 3
Spark Extinguishing
System

Zone 1

Zone 2

© 2013 Holcim Ltd 5

Fire Protection non-HW Shredding Line
• It is unclear why three individual sprinkler systems are
considered for the three storage areas.
 The supplier shall revise the calculation and update the offer.
 If possible only one sprinkler system (one alarm valve) shall be
considered to safe costs.
 Special consideration shall be given to the hose stream allowance
(for manual fire fighting). 2m3/min @ 4bar must always be
available (also if the sprinkler system is running a full capacity)

© 2013 Holcim Ltd 6

Fire Protection non-HW Shredding Line
• Building ventilation and smoke release is foreseen via “gable
ventilation”. Sprinklers installed in the ventilation section
exceed the max. allowed ceiling height.
 Installation of ventilation openings at the building sides, just below
the ceiling is recommended
 In any case the dynamics of the air inside the building has to be
take into consideration. The airflow speed must never exceed a
certain value (risk of wrong sprinkler activation and displacement
of sprinkler discharge pattern).
Ventilation openings

>13m
7

© 2013 Holcim Ltd

HW Platform - Alternative Logistics and Layout Proposal
Additional road

Roof to be extended over

entire building

Unloading HW in drums
jumbo bags ect.
Loading of ILC fuel from HW
shredding line
No access for trucks to “dirty
areas”
Gate to be removed to
increase storage capacity
Unloading HW in bulk &
loading of ILC fuel from HW
shredding line
© 2013 Holcim Ltd 10
HW Platform – Shredding Line
• The static hopper on the recirculation belt conveyor will not
work (material will not leave the hopper)
 The basic shredding line arrangement shall be kept as it is.
 In case that an automatic feeder is really needed, a chain belt
conveyor with horizontal loading section can still be implemented.
(unloading onto recirculation conveyor or directly into shredder
hopper)

© 2013 Holcim Ltd 11

HW Platform
• Material passed through the shredder cannot be sent back to
the pit.
 To gain additional flexibility an additional reversible belt conveyor
shall be installed below the shredder.
 This leads to several small modifications of the existing setup
(lifting of shredder, extension of several BC’s)

Additional
reversible belt
conveyor
© 2013 Holcim Ltd 12
HW Platform – Fire Protection
• Currently several zones with individual sprinkler systems are
considered.
 If possible only one sprinkler system (one alarm valve) shall be
considered to safe costs.
 However a sprinkler system for the HW shredding line including
storage must be included.

To be extended

To be included

© 2013 Holcim Ltd 14

HW Platform – Explosion Protection
• The current shredding facility is not suited for operation in
explosion zones.
 If the shredding line will be operated as today (no dusty material)
definition of dust ATEX zones is not necessary.
 However if vapor releasing substances are processed (rags,
solvent based paint sludge) monitoring of the vapor concentration
by gas sensors is necessary at several points.

 Gas sensors shall be installed inside the building close to ground

level and also on mobile equipment (loader, fork lift) which is
operating in the HW platform. (Possible supplier: Dräger)
 In addition sufficient natural ventilation openings shall be provided
close to ground level (e.g. lowest 2m of cladding = mesh or grid)

© 2013 Holcim Ltd 17

HW Platform - Potentially Polluted Areas
• The road within 3m distance from the HW platform shall be
defined as “potentially polluted area”.
 Rain water from this area shall be sent to the “potentially polluted
water pit”.
 To minimize the amount of water that needs to be treated, a
canopy covering at least the loading and unloading areas (better
the entire area) shall be foreseen.
 Within this area a washing station mainly for mobile equipment
leaving the inside of the HW platform (especially material handler)
shall be foreseen.
 A procedure must be in place which ensures that the tires of all
mobile equipment which needs to leave the HW platform or the
potentially polluted area (material handler, loader, fork lifts) have
been cleaned.

© 2013 Holcim Ltd 18

HW Platform - Potentially Polluted Areas

Potentially polluted area. To

minimize potentially polluted
rain water this area should be
covered by a canopy

Drainage of potentially
polluted water close to the
building wall
Possible location for (tire)
washing station.
© 2013 Holcim Ltd 19
Spillage and Water Management – Proposed Alternative
Polluted Area
Clean Water
Polluted Area Residual Fire Truck water Domestic water
from Roof and
(inside building) Fighting basin, truck deep well
Road
cleaning

Note 3

Spillage
Pit Building Internal usage
Collection Pit

Rain Water
Pond for Fire Sanitation Water
Water Reserve treatment
Cap 600 M3

Polluted Water
Sampling point
Basin
Cap 20 M3
Normally Flow Meter
Close 2)

F
20 M3 /day

Normally drainage
Fire Water Waste Water Open 2)
Retention Basin Treatment drainage
F
Cap 600 M3 Cap 20 M3/day
Flow Meter
Sampling point

© 2013 Holcim Ltd 20

Material Reception and Extraction for SLC fuel
• Main issues of the current solution are.
Just in time delivery can lead
to emptying of buffer storage

No possibility to load hopper

from the side

4.5m deep pit necessary

(CAPEX)

Buffer storage not big enough

to absorb one entire truck
load.

Inclination of hopper walls

with 55° low. Risk of buildups
and reduced life volume
© 2013 Holcim Ltd 21
 Material Reception and Extraction for SLC fuel
• Proposed modifications
Chain belt conveyor with
inclined section (35°) and
dosing drum

Placing conveyor on floor

level avoids pit

Buffer volume approximately

90m3 (around 40min @
10t/h)

Truck would dump on the

Ceiling ground inside the building.
height to be Filling of hopper by front end
checked loader. Direct unloading into
buffer hopper not possible
anymore.
© 2013 Holcim Ltd 22
Feedpoint SLC (NAR-2)
• Gravimetric dosing is foreseen to be done inside the current
rice husks building. On the other hand for the ILC feedpoint a
Multiflex is foreseen.
 The foreseen Multiflex shall be used for the SLC feedpoint since
the equipment cannot cope with heavy material (e.g. contaminated
soil) going to the kiln inlet.
 Additional advantages are a shorter reaction time for the SLC and
more accurate dosing.
SLC NAR-2
ILC NAR-2

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New Feeding System to SLC (NAR-2)
• The possibility of installing one Sicon conveyor instead of two
individual conveyor was further investigated.
 It looks like the required height can be reached however the
clearance where it crosses the road is only 4m.
 Access by truck to the area behind is still possible however trucks
would have to pass right in front of the PH tower elevator.
 Considering these restrictions it is recommended to go for the
proposed solution with two conveyors.
Alternative - Sicon
Proposed solution

© 2013 Holcim Ltd 24

Feedpoint ILC (NAR-2)
• For the ILC feedpoint two simple screw floor hoppers with a
subsequent conveying system to the feed chutes shall be
foreseen.
 For ILC fuel (shredded solids) a subsequent belt weigh feeder
shall be foreseen.
 For low calorific AFR (contaminated soil, etc) volumetric dosing is
considered as sufficient.
 Two completely separated feed chutes shall be foreseen to allow
feeding of both AFR streams at the same time.

© 2013 Holcim Ltd 25

Feedpoint ILC (NAR-2)
• Example Saraburi 3, Thailand

© 2013 Holcim Ltd 26