A platform for research: civil engineering, architecture and urbanism
A platform for research: civil engineering, architecture and urbanism
Several obstacles must be overcome for any industry with the objective of sustainability. Two major hurdles are: radical improvement in energy efficiency and zero waste. To realise this, a step change improvement is required from current strategies of energy optimisation and waste minimisation. TXI (Texas Industries Incorporated) and Hatch have found several solutions to waste and energy problems by applying the practice of By-Product Synergy. TXI's cement division and Chaparral Steel developed the STAR (Systems and Technologies for Advanced Recycling) project focusing on the respective cement and steel works with the aim of eliminating waste. Several innovative ideas emerged ranging from the consumption of alternative fuels to recycling of auto shredder fluff. This was the genesis of the CemStar technology. Research began in 1994. By 1995 the technology was patented and incorporated into TXI's Hunter pre-calciner kiln. Initially all 280000 TPA of air cooled slag from Chaparral's North Texas EAF was utilised. Acceptance has grown and by 2002 approximately 340000 tonnes of air cooled slags were consumed by the CemStar process in the USA. This technology provides the opportunity to radically increase the consumption of slags in the cement industry, and enables the cement industry to lower their CO2 emissions. It eliminates a steel making waste problem and provides cement makers with the benefit of pre-calcined feed. CemStar requires no major upfront investment in capital equipment, technology or processes by the steel mill. As the process uses air cooled slags it is ideal for reducing old stockpiles and even mining legacy heaps from defunct operations. Almost all iron and steel slags can be viably used within the broader region provided the economics of supply and transport are feasible. CemStar allows slag products to compete on a level playing field alongside quarried products such as Limestone and Shale. It has been proven that both old and new slags are totally compatible with the process.
Several obstacles must be overcome for any industry with the objective of sustainability. Two major hurdles are: radical improvement in energy efficiency and zero waste. To realise this, a step change improvement is required from current strategies of energy optimisation and waste minimisation. TXI (Texas Industries Incorporated) and Hatch have found several solutions to waste and energy problems by applying the practice of By-Product Synergy. TXI's cement division and Chaparral Steel developed the STAR (Systems and Technologies for Advanced Recycling) project focusing on the respective cement and steel works with the aim of eliminating waste. Several innovative ideas emerged ranging from the consumption of alternative fuels to recycling of auto shredder fluff. This was the genesis of the CemStar technology. Research began in 1994. By 1995 the technology was patented and incorporated into TXI's Hunter pre-calciner kiln. Initially all 280000 TPA of air cooled slag from Chaparral's North Texas EAF was utilised. Acceptance has grown and by 2002 approximately 340000 tonnes of air cooled slags were consumed by the CemStar process in the USA. This technology provides the opportunity to radically increase the consumption of slags in the cement industry, and enables the cement industry to lower their CO2 emissions. It eliminates a steel making waste problem and provides cement makers with the benefit of pre-calcined feed. CemStar requires no major upfront investment in capital equipment, technology or processes by the steel mill. As the process uses air cooled slags it is ideal for reducing old stockpiles and even mining legacy heaps from defunct operations. Almost all iron and steel slags can be viably used within the broader region provided the economics of supply and transport are feasible. CemStar allows slag products to compete on a level playing field alongside quarried products such as Limestone and Shale. It has been proven that both old and new slags are totally compatible with the process.
CemStar revolutionises slag disposal
CemStar revolutioniert die Schlackenbeseitigung
Gale, Stephen (author)
2003
8 Seiten, 2 Bilder, 1 Tabelle, 8 Quellen
Conference paper
English
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