Cement Manufacturers Association (CMA)

10 Figure 1: Flowsheet of the proposed design The system’s design for tyre chip injection into the calciner is based on a CFD study. The tyre chip bulk density is considered between 0.5 t/ m³ for equipment sizing and 0.6 t/m³ for drive selection. The system can also handle other fuels like Refused derived fuels and wood chips independently. The step by step system working of the installed system is explained below: Receiving and Unloading Tyre chips are delivered to cement plant via self-tipping trucks. These trucks are managed using signal lights, barriers, and roller shutter doors. The green signal light indicates when the crane is not operating, allowing the truck to safely unload the material into either an underground pit or an over ground pit. Handling and Storage Material handling is completely automated with the help of a fully automated Grab crane. This crane efficiently transfers tyre chips from the underground pit to the over ground storage area, and to the feeding hopper for further processing. The system is designed to operate around the clock, ensuring a continuous supply of tyre chips to the calciner. Feeding Process The tyre chips are then discharged from the storage hoppers to an apron weigh feeder, a crucial component that controls the feed rate based on specific process requirements. The material is discharged to a flexible belt conveyor via a discharge chute, equipped with jamming sensors for smooth operation. The flexible conveyor lifts the material vertically and feeds it to a conventional belt conveyor, which ultimately conveys the material to a small hopper in the existing preheater building. Feeding into the Calciner At this stage, apron weigh feeder takes over to control the feed rate into the calciner. An electric double flap valve, along with a pneumatic safety shutoff gate, is responsible for conveying the material from apron weigh feeder to the calciner, ensuring a controlled and efficient feeding process.