Cement Americas

SUM 2019

Cement Americas provides comprehensive coverage of the North and South American cement markets from raw material extraction to delivery and tranportation to end user.

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28 CEMENT AMERICAS • Summer 2019 • www.cementamericas.com FEATURE T he manufacture of cement is particularly energy-inten- sive. To reduce the use of valuable primary fuels like coal, HeidelbergCement is opting for alternative fuels, such as waste tires. The calorific value of rubber is comparable to that of hard coal. And because the iron from the armour- ing can be incorporated mineralogically into the cement, it reduces the need to add ferrous corrective substances. BEUMER Group supplied the fully-automated system that sorts, separates and regulates the tires of different sizes and weights, and then feeds them to the rotary kiln inlet. The system supplier also took over the installation and pro- vided the steel structure. Thanks to the new system, the kiln of the cement plant is now fed with a constant stream of material. "With every ton of waste tires that we're using, we're replacing the same amount of valuable hard coal," explained Michael Becker. He is the director of the Heidel- bergCement plant in Lengford, a small town in Germany. The company, headquartered in Heidelberg, is one of the largest cement manufacturers in the world. "Waste tires have a high heat content, meaning that they are the ideal fuel for our production," said Becker. About 20,000 tons of hard coal are used in the plant annually to produce circa 20% of the overall heat we require, this cor- responds to 20 million tires. "This is how we can substitute the primary fuel with the tires as secondary fuel." The tires that are used are production waste coming from the manufacturers as well as waste tires from trucks and cars. This also means that they vary greatly: their diame- ters vary between a minimum 300 and maximum 1,600 mm, their widths between 100 and 400 mm. The average weight is at 8 kg for the car tires and around 60 kg for the truck tires. Only One System Instead of Two To feed the different tire material to the rotary kiln inlet, HeidelbergCement used to operate two systems: one line transported the smaller and lighter car tires and the oth- er one, the larger and heavier truck tires. "We didn't think that this solution was efficient enough," said Becker. "Our employees hung the tires individually by hand into the hook lift and then transported into the kiln inlet. The heavy truck tires were handled by an excavator before they were fed into the transport stream. "With the new fully automatic system we were able to not only improve this process with regard to occupational safe- ty, but also optimise the working conditions for our employ- ees in combination with an increased performance. We An Energy-Efficient Alternative A Fully Automated Tire Transport System at HeidelbergCement Ensures Continuous Feed of Waste Tires as Secondary Fuels. By Mark S. Kuhar BEUMER Group supplied HeidelbergCement with the ful- ly-automated system that sorts, separates and regulates the tires of different sizes and weights and feeds them to the rotary kiln inlet. The plant recycles about 10 million tires per year.

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