Shredded Tires feeding Line 1

and Line 2
*Tire feeding protocol version_01 is susceptible to changes during commissioning process.

Contents
Section 1: Introduction..................................................................................................................................................3
Section 2: Guideline for tire storage, fire and emergency preparedness......................................................................4
2.1 Mitigation of ignition risk....................................................................................................................................4
2.2 Stocks Pile Management.....................................................................................................................................5
2.3 Fire risk assessment.............................................................................................................................................6
Section 3: TDF feeding process layout Line 1 and Line 2...............................................................................................7
3.1 Common storage.................................................................................................................................................7
Section 4: Feeding and burning inside the kiln............................................................................................................13
4.1 TDF feeding to kiln.............................................................................................................................................13
4.2 Procedure for feed stop....................................................................................................................................14
4.3 Heat input in the system...................................................................................................................................15
4.4 CRO training and reviewing operational interlocks...........................................................................................15
Section 5: Clinker Quality............................................................................................................................................16
Section 6: Reporting....................................................................................................................................................17
6.1 TDF area power consumption...........................................................................................................................17
6.2 Feasibility vs. actual...........................................................................................................................................17
6.3 Benchmarking....................................................................................................................................................17
Section 7: Maintenance plan.......................................................................................................................................18

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Section 1: Introduction

 This protocol covers the guideline for TDF fuel system successful commissioning and utilization at Line # 1 and
Line # 2. Total feeding capacity per line is 7.5 TPH which will supply 248 MJ/hr (12 % wires with heating value
37.6 MJ/ton) to the kiln system.
 TDF is a very high quality fuel about the same as of superior quality coal, with sulfur range from 0.5 – 2.0 %.
Comparison among conventional fuel and TDF is shown in figure 1:

Figure 1: Comparison of TDF with other fuels

 Below table summarizes typical composition of HFO and TDF (tires)

Composition HFO (%) Tire (%)

Carbon 83.8 78.2
Hydrogen 11.2 7.1
Sulfur 3.9 1.6
Nitrogen 0.1 0.2
Zince Oxide 0 0.9
Steel 0 12
Thermal value 41.7 (MJ/kg) 37.6 (MJ/kg)

 Note: Thermal value of tire per kg reduces with respect to reduction in weight as approximately 12 % is the
amount of wires by weight.

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Section 2: Guideline for tire storage, fire and emergency preparedness

 The most hazard associated with amounts of TDF outdoors is the potential for large fires, once a large
pile catches fire, it is very hard to extinguish due to high calorific value of tires (37,600 KJ/kg).
 Tires piles are difficult for fire fighters to penetrate with water or foam; since tires are designed to
repel water. Burning is with black smoke as shown in the Figure 1.

Figure 2: Fire incident of tires

 TDF are chopped and grinded to produce a low density, porous material through which air may
percolate. The total surface area of tire chips may also be large compared with the volume occupied.
The combination of permeability to air-flow and a high exposed surface area means that a
combustible material such as rubber is potentially susceptible to spontaneous combustion.
 Tire contain some chemicals and they burn in uncontrolled way they represent significant risk to
human health by producing thick and hazard smoke. This limits the access to control fire from near to
the stock pile

2.1 Mitigation of ignition risk

Risk Control Actions Responsible Risk Index
Minimize TDF stock at site not more than 30 days
Mitigation of Daily sub surface temperature monitoring.
fire ignition Production High
risk Storage area should be clean with no organic
content (soot).
Turning of piles at risk of spontaneous heating.

2.2 Stocks Pile Management

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 Risk Control Actions Responsible Risk Index
Max 20m long (followed by 5m gaps at ends)
3m high (to avoid heating & spontaneous combustion)
Stock piles
management Width of base 5m (approximate maximum) 6m Production High
between rows (to permit movement of earth moving
equipment to create fuel break)
No closer than 10m to structures (either same lot or
neighboring)

Pile 1 Pile 2

Pile 3 Pile 4

Figure 2: TDF stacking method

2.3 Fire risk assessment

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 Risk Control Actions Responsible Risk
Index
Document all possible fire hazards and scenarios site, the
likelihood that they will cause a fire and severity of the potential
fire
Ignition source control to incorporate in emergency response, no
Fire Risk smoking signs and installation of lightning rods
assessment All team Extreme
Fire hydrant system at storage location and pre-heater feeding
point
Fire hydrants at all floors for emergency response
Emergency contact details for key personnel
Appointment and organization of fire wardens
Emergency Safety High
The location of all fire safety and emergency equipment, and
plan
training of all staff in their use. Demarcation of assembly point
with all boards

Fire risk assessment (Example)

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Section 3: TDF feeding process layout Line 1 and Line 2

TDF feeding system is divided into three main categories, which are mentioned as under;

3.1 Common storage

Common storage design storage capacity is 800 m3 equivalents to 384 Tons TDF (Density 480 Kg/m3).
However in operation all the shed cannot be used for storage as approximate 30 % space shall be utilized
for the unloading of new receiving trucks.

Figure 3 : Common receiving and feeding

1. Truck unloading
 TDF trucks entry shall be same traffic plan as of soot bulkers to reach the unloading point.
 Before unloading site supervisor shall ensure enough space and area cleaning.
 01 truck at a time shall be allowed for unloading inside the shed, remaining trucks shall wait
 Unloading of the truck is through jack system, truck driver shall be instructed to slowly unload the vehicle
to avoid un-balance.
 Unloading of fresh TDF shall be done approximately 3 meter away from the main heap for visual inspection.
 Truck shall be sent out of yard after unloading completed.
 TDF truck exit shall use the same traffic plan as of soot bulkers.
 In event of unloading yard is already filled with material and no space is available send the truck to second
designated place for unloading of TDF.

2.Visual inspection:
The area supervisor for unloading shall do the visual inspection for the unloaded truck.
a. Optimum size of the shredded tire :

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  TDF chips size range: 2 inch to 4 inch.
 Over size chips shall result in chute blockages and reduce combustion efficiency.
 Check the size the TDF chips by meter tape as shown figure below. During inspection wear gloves to avoid
hand injury from the TDF wires.

Figure 4 : Measuring dimensions of TDF chips

 Visual inspection of the TDF wires so that they are properly cut. Long wires inside the heap may cause
material agglomeration at the chutes of the belt conveyors.
 Over size material shall be reported to shift leader before mixing of the vehicle in the heap.
b. Foreign material :
 Check for any foreign material inside i.e. grease, metal pieces etc.
3.Material pushing by top loader
 Unloaded truck material is pushed by using top loader which have 02 motors
 (1)Lifting motor shall give the angle to the top loader and (2) travel motor moves material.
 Top loader shall feed the material in the common feeding hopper for both lines.
4.Common feeding hopper and conveyor
 Design capacity of the feeding hopper is 20 m3 equivalents to 9.6 tons TDF (Density 480 Kg/m3).
 Common feeding conveyor design capacity is 15 TPH operated with variable speed motor.
 Below picture briefly describes the feeding system of common storage section

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 Common storage

Common conveyor
Feeding hopper
Figure 5 : Common storage

 DOES HORSE have a feeding hopper of 5 m3 to store ~ 3 ton material for smooth feeding, diverter is used
for selection at line # 1 and Line # 2, process flow as under;

Figure 6 : Process layout common storage

 DOSE HORSE feeding hopper of capacity 5 m3 is shown in the picture below.

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 5 m3 intermediate storage in
dose-meter

Figure 7: Dose Horse receiving hopper

3.2 Feeding Line # 1

Total feeding capacity of the line # 1 feeding system is 7.5 TPH; equipment detail with process flow sheet
is mentioned as under;

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3.3 Feeding Line # 2

Total feeding capacity of the line # 2 feeding system is 7.5 TPH; equipment detail with process flow sheet
is mentioned as under;

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Line # 2

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 Section 4: Feeding and burning inside the kiln
4.1 TDF feeding to kiln
 TDF transport system feed the TDF in the Calciner of the Kiln; controlled feeding is imported to
avoid normal condition inside kiln. Schematic shown as under;

C5

C4
CO %
C3

C2

Gas Temp

C1 TDF feeding point inside Pre-heater

Meal Temp

Figure 8: Feeding point of TDF

 Controlled feeding of TDF shall be started from 2.0 TPH and increased by gradual reduction in HFO
 Validation of C1 meal temperature, C1 Gas temperature, C3 gas analyzer and Dopol fan outlet
 Initially in the start TDF C5 meal temperature increase rapidly and expected CO until Parameter
adjusted through reduction of HFO and normal feed of TDF stable condition shall be achieved.
 TDF chips shall follow the loop duct trajectory to enter into cyclone C1.
 Combustion zone temperature > 850 degrees shall be maintained to ensure complete combustion
of TDF chips with respect to residence time inside the calciner.
 System sulfur input shall increase therefore oxidizing atmosphere is essential with C3 O2 >2.8%.

4.2 Procedure for feed start and stop manually

Line # 2 (Feeding 3 TPH locally):

1. Double flaps valve operation shall be start from CCR by operator.

2. Vibrator screen shall be stated on local command from site

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3. The elevator and belt conveyor total speed is 0.8 m/s to deliver 7.5 TPH and shall be adjusted to run at 0.7
m/s with respect to system abnormality.
4. The feed belt setting of initial feeding of 3.0 TPH shall be based on following estimation with respect to the
design of the conveyor.

Sr # Belt Speed (m/sec) Estimated feed (TPH) Remarks

1 0.8 7.5 Designed
2 0.7 6.5
3 0.6 5.6
4 0.5 4.6
5 0.4 3.7
6 0.3 2.8
7 0.2 1.8
8 0.1 0.93

The above chart provides the amount of feed going in the system with respect to the speed of the conveyor
set. This table shall be replaced with respect to site actual measurement.

5. Cross check of belt feed TPH with respect to above table shall be done by adjusting the belt speed at 0.3
m/sec and then following the procedure as mentioned under;
 Stop the loaded belt by emergency and take sample from 01 meter length.
 Weight the sample amount of TDF on the weigh scale for the TPH with respect to the adjusted speed.
 Modify the above table accordingly with respect to the found weight as per TDF density.
 Measure belt length from dose horse to feed pulley and with help of stop watch find m/sec.
6. The dose horse and the diverter adjustment shall be done by manual patroller at site.
7. The common feeding system have a capacity of 15 TPH, the adjustment of the speed shall be done as per
following assumptions.

Sr # Common conveyor Estimated feed (TPH) Remarks

(m/sec)
1 0.2 15 Designed
2 0.1 7.5
3 0.05 3.75
8. Adjust conveyor speed as per VFD than ok; if not available then we use the same procedure through
measuring the total length and marking a spot. This shall give the speed in m/sec.

9. Adjustment of speed at the common conveyor should respect the material level inside the dose horse
which can maximum take 3.0 TPH. Therefore the patroller adjusts the speed through looking in the local
hopper of the dose horse.

10. Stoppage procedure:

 Empty the system completely; the patroller shall be given clearance for empty.
 Change the diverter position to the other line if in working/ stop the feed.

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  Stop the belt conveyor manually from site as empty.
 Stop the elevator and vibrator manually as empty.
 Upon all system empty and clearance from the site the patroller shall give clearance to the CRO to
stop the double flap gate.
11. Procedure for heat substitution of HFO:

With respect to tire feeding in the system, HFO substitution shall be done. Following table summarizes the
expected reduction of HFO with respect to the feed rate of TDF

Net Heat Expected HFO

TDF Total heat
(Excluding wire) Substitution
(TPH) (MJ)
(MJ/Kg) Kg/hr
1 31 31,450 763.91
2 31 62,900 1,528
3 31 94,350 2,292

 Feed start of the system shall take place with increase from 1.0 TPH to 3.0 TPH. HFO fuel reduction
should be gradual in the system to maintain the temperature and CO formation
 The primary and secondary pressure of the HFO firing in the PC had to be adjusted by the manual
patroller for proper atomization of HFO fuel.
 CO formation shall be kept under observation to avoid EP tripping at high CO level inside the system
 Theoretically total combustion air required for HFO and TDF is 13 NM3/kg and 11.5 Nm3/kg.
Combustion table shall be revised with respect to actual conditions.
 During stoppage and tripping of TDF system, operator shall notice reduction in C1 meal temperature
and C1 gas temperature. HFO of the system shall be increased to achieve the temperature back.

Line # 1 (Feeding 3 TPH locally):

1. Double flaps valve operation shall be start from CCR by operator.

2. Vibrator screen shall be stated on local command from site
3. The elevator and belt conveyor total speed is 0.8 m/s to deliver 7.5 TPH and shall be adjusted to run at 0.7
m/s with respect to system abnormality.
4. The feed belt setting of initial feeding of 3.0 TPH shall be based on following estimation with respect to the
design of the conveyor.

Sr # Belt Speed (m/sec) Estimated feed (TPH) Remarks

1 0.8 7.5 Designed
2 0.7 6.5
3 0.6 5.6
4 0.5 4.6
5 0.4 3.7
6 0.3 2.8

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 7 0.2 1.8
8 0.1 0.93

The above chart provides the amount of feed going in the system with respect to the speed of the conveyor
set. This table shall be replaced with respect to site actual measurement.

5.

6. After adjustment of speed of belt at 0.4 meter/sec the next step is to start the feed of the system.
7. Cross check this material by stopping belt at load and taking 01 meter sample from the loaded belt
8. This sample shall be weighted on the manual weigh scale for cross check.
 Feed stop group shall be followed to completely empty the system including belts and the
vibrating conveyor before stopping feed.
 During planned stoppage the hopper of the Dose horse shall also be emptied to ensure no
material present inside the hopper.
 In case of breakdown, the closing the flaps shall be ensured to avoid positive pressure of hot gas
leaving the system from the flap portion. This is critical activity as hot gasses coming out is a
potential fire hazard at preheater.
 Alarm indication shall be available with operator if double flap valve is not closed.
 CO generation in the system may also lead to the tripping of EP system; CRO shall reduce TDF
consumption during CO formation at C3 and dopol gas analyzer.

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 TDF feeding point
in calciner

Figure 9 : Feeding point of TDF

4.3 Heat input in the system

 Heat input in the system shall be obtained from the counters of TDF consumed at kiln.
 QC team shall provide the heating value for TDF normal range 31.4 to 35.5 MJ/ton. Net heating value for
the TDF shall be included for moisture and wires impact.

4.4 CRO training and reviewing operational interlocks

CRO training shall be conducted for the new system with respect to all operational interlock. This
operational SOP shall be signed by all CRO.

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Section 5: Clinker Quality

5.1 Sulfur:
 According to high concentration of sulfur in tire composition, and tendency of production of volatile
alkaline salts in this environment, Solid layer form in inlet and outlet of cement kiln.
 Expected increase in clinker SO3 and accordingly adjustment of gypsum input at cement mill.

5.2 Iron:

 Iron contained in tire melts and reacts with aluminum in cement kiln. This results in decreasing
concentration of aluminum in cement composition. So it would be necessary to add aluminum compounds
to the raw materials.
 Iron input in the raw meal also needs to be adjusted.
 Clinker AM to be checked at different substitution rates of TDF.

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 5.3 Cement strength:
 Cement strength to be checked at different substation of TDF with respect to zinc, chlorine, chromium and
other heavy metals present in TDF.

Section 6: Reporting
6.1 TDF area power consumption
 Total power consumption of the TDF area is as under
Common storage 25.45 KW
TDF system L1 30 KW
TDF system L2 30.8 KW
Total KW 85 KW
 Total KWH shall be reported as KWH per ton clinker for the line running.
 During both lines in operation the consumption TDF KWH shall be on the basis of TDF consumed in
percentage.

6.2 Feasibility vs. actual

 Feasibility vs. actual analysis shall be done for different substitution of TDF.

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  Payback period calculation shall be finalized on decided substitutions rate and submitted to the
management.

6.3 Benchmarking
 Target setting for the TDF substation rate.
 Target setting for the TDF power consumption

Section 7: Maintenance plan

General actions are mentioned to be cross checked and modified by maintenance team

 Inspection schedule preparation

 Lubrication schedule preparation
 List of critical spare parts
 Project left over and forecasted requirement
 Annexure equipment list attached as under.

63948 - Equipment
list_revD.xls

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