Alternative Fuel Systems Projects

Alternative Fuel Systems Projects

Whole Tire Fuel Feed System
NATAL PORTLAND CEMENT (NPC), Simuma Plant, South Africa

The Whole Tire Feed system designed to automatically feed whole tires to the preheater feed shelf of kiln using a Double Gate Airlock Valve with weight-based feed rate control as the fuel injection method providing a maximum feed rate of 480 tires per hour.

Whole Tire Hook Elevator with Centering Conveyor
Votorantim Cement, Minas Gerais, Brazil

Automatic tire feed system designed to transport tires ranging in size from 590 mm to a 750 mm diameter, with a feed rate of 480 tires per hour.  The Hook Elevator includes a Centering Conveyor to properly position tires for pick up by the Hook Elevator.

Main Frame Mover for the Skewer Suspension Burner
TXI, Midlothian, TX, USA

Main Frame Mover for the Skewer Suspension Burner fully designed with a pulling capacity of 10,500 lbs in either direction.

Whole Tire Triple Gate Airlock Valve with Weighing System
Holcim, Moscow, Russia

Whole Tire Feed System which includes an airlock valve with top and bottom gate, designed to feed whole car and truck tires onto the feed shelf of a 4 or 5 stage preheater/precalciner kiln.  The airlock valve mounts to a customer-supplied duct, which will be attached to the riser duct of the kiln. Weighing system consisted of a gravity roller conveyor mounted on a platform scale with a structural steel support frame and a locally mounted display/controller.

Whole Tire Feed System
Lafarge Ciment, Medgidia, Romania

Whole Tire Fuel Feed System designed to accept tires manually loaded on a conveyor at ground level and automatically feed them to the feed shelves of the kilns using double gate airlock valves.  Components include roller conveyors, hook elevator, belt conveyor and inline transfer device, airlock valve and inline weight scale.

Phase II added additional airlock valve and weigh-feed into a second kiln from the same loading point.

Whole Tire Suspension Burner Test System
CEMEX, Balcones, TX USA

Whole Tire Test Burn System which includes a suspension burner system (nozzle, hot gate, airlock chamber, suspension fork with auto-clean, automatic ram).  Controls: PLC with programming.  System provides automatic tire feeding to the calciner from the manually loaded weight scale conveyor, with weigh-based feed rate control.

Whole Tire Feed System
Lafarge Ciment, Hogiz, Romania

Automatic tire fuel system with hook elevator and airlock valve.  System designed to automatically feed whole tires to the feed shelf of a through an airlock valve mounted to the back side of the riser duct of the kiln.  Feed rate capacity of 480 tires per hour (8 tires per minute).

Whole Tire Feed System
American Cement, Sumterville, FL USA

System designed to feed whole  to , includes custom-designed live bottom hopper, tire separator, separation refinement with inline expansion joint, inspection/rejection, vertical lift conveyor system, refractory lined chute, airlock valve with weight scale conveyor.

Whole Tire Feed System
Florida Rock, Newberry, FL USA

TDF system designed to feed to precalciner kiln and includes trailer tipper, live bottom hopper, tire separator, separation refinement, inspection/rejection, modification of existing elevator, freestanding 100’ structural steel tower. Phase II modified conveyor system and controls to feed to airlock valve of a second kiln.

Staging Fork and Cam Actuator
Lehigh Cement (Heidelberg), Evansville Plant, Fleetwood, PA USA

Duplicate AFS system comissioned to second kiln.  Includes weight-based feed rate system, tire staging fork with cam, and mid-kiln cadence valve.

CEMEX Test Burn Equipment
Multiple locations including plants in California, Alabama, Florida, Georgia, Kentucky

Designed and fabricated equipment for use in a series of test burns.

Whole Tire Feed System for Electric Utiity Boilers Geneva Energy
Ford Heights, IL USA

System designed to feed multiple airlock hoppers and includes manual unloading dock, conveyor system with pop-up belt transfers, tire accumulation system.  Integrated with existing shredded-tire feed system.

Staging Fork and Cam Actuator
Lehigh Cement (Heidelberg), Evansville Plant, Fleetwood, PA USA

System includes weight-based feed rate system, tire staging fork, and mid-kiln actuator valve.

Mid Kiln Whole Tire Feeding System Modifications
St. Lawrence Cement (Holcim), Hagerstown, MD USA

Modifications include relocation of mid-kiln tower, mid-kiln valve, and mixing air.

Whole Tire Feed System Test Burn
CEMEX, Fairborn, OH USA

Initial phase of tire fuel system installation.  Includes airlock valve, refractory lined chute, inclined chain flight conveyor, weight-based feed rate system.  loading platform built to allow direct transfer from trailer to conveyor.

Whole Tire and Chipped Tire Feed System
CEMEX, Ponce, Puerto Rico USA

System design and equipment for feeding , which includes two trailer tippers, two-stage live bottom hopper 80' long, sealed live bottom hopper 40' long, tire separator, tire separation refinement, rim detector, inspection/rejection system, screw conveyors, inclined belt conveyors, bridge truss frame, accumulation conveyors, venturi eductors, programming logic, electrical design.

Mid Kiln Whole Tire Feed System
TXI Midlothian, TX USA

A complete turnkey whole tire fuel handling system to feed existing long dry kiln. The equipment includes a trailer tipper, live-bottom hopper, tire separator, separation refinement system, tire inspection and rejection, conveying system with accumulation control, mid kiln valve for car and truck size tires, above kiln valve actuator, weight-based feed rate controls, all electrical equipment, all mechanical, electrical and civil installation, PLC programming, control room interface, startup and commissioning.

Whole Tire Suspension Burner
Lafarge, Cemento Melon, La Calera, Chile

Project added a second suspension burner to the precalciner.

Tire Elevator System
Rinker Materials (Cemex), Brooksville, FL USA

System included 100’ hook elevator, centering conveyor, discharge conveyor. Engineering for large platform at 100’ elevation and loading dock platform.

Tire Feed Chutes and Cam Actuator
Cadence / Lafarge Seattle, USA

Tire feed chute and cam actuator which feeds 4 tire per revolution per minute

Tire Feed Chutes and Cam Actuator
Lafarge Ravena, NY, USA

Tire feed chute and cam actuator which feeds 8 tires per revolution per minute for Ravena kilns Mid Kiln Fuel System Engineering and Equipment Akmenes Cementas AB, Lithuania Provided engineering design services to build semi-automatic whole tire feed system to mid kiln valve. Also provided special cam actuator to open and close cadence valve.

Whole Tire Feed System for two 4-Stage Preheater kilns
Cemex, Brooksville, FL USA

In conjunction with Dover Conveyor, provided system design and equipment for feeding whole tires to two 4-stage preheater kilns, which included trailer tipper, two stage live bottom hopper 80' long, tire separator, tire separation refinement / inspection / rejection system, (2) inclined belt conveyors, bridge truss frame, directional conveyor, accumulation conveyors, double gate airlock valves, programming logic, basics for electrical design.

Whole Tire Feed System to one 4-Stage Preheater Kiln
Cemex - Demopolis, AL USA

Consulting work. In conjunction with Dover Conveyor, provided system design and equipment for feeding whole tires to one 4-stage preheater kiln, which included trailer tipper, two stage live bottom hopper, tire separator, tire separation refinement / inspection / rejection system, inclined belt conveyor, double gate airlock valve, programming logic, basics for electrical design.

Projects designed and managed by company President, John Tiernan, prior to the founding of AFS Technology:

Mid Kiln Feed System – Turnkey
Lafarge - Midwest Joppa Plant, Grand Chain, IL USA

A complete turnkey whole tire fuel handling system to feed two existing long dry kilns. The equipment includes a trailer tipper, live-bottom hopper, tire separator, tire accumulator, tire inspection and rejection, conveying system, two hook elevators with gravity feed chutes, mid kiln valves for car and truck size tires, above kiln valve actuators, weight-based feed rate controls, all electrical equipment, all mechanical, electrical and civil installation, PLC programming, control room interface, startup and commissioning.

Live-Bottom Hopper, Tire Separator and Airlock Valve
Holcim (Deutschland) AG, Hannoversche Straße

System redesign / upgrade - Provided a live-bottom hopper (21 meters long), tire separator, airlock valve, and engineering to upgrade their existing tire feeding system.

Whole Tire Suspension Burning System
Lafarge, Cemento Melon, La Calera, Chile

This was phase two of a three phase project for a whole tire suspension burning system for a precalciner of the plants existing cement kiln. This included a hook elevator, conveying system, and automated ram for the suspension burner. Phase one included a manual suspension burner and weight-based feed rate control system. Phase three of this project will include a trailer tipper, live-bottom hopper, tire separator and conveying system to make the tire feed system completely automated.

Whole Tire Injection Airlock Valves
Cemex Plants:  Guadalajara Mexico, Monterrey Mexico, Tamuin Mexico, Yaqui Mexico and Barrientos Mexico.

2002-2003 Mid-Kiln Whole Tire Feeding System
St. Lawrence Cement (Holcim), Hagerstown, MD USA

Turnkey fully automated mid-kiln whole tire feeding system for one long dry kiln. This system includes a trailer tipper, live-bottom hopper, tire separator, tire separation refinement system, tire inspection and rejection system, 145’ inclined trussed-framed belt conveyor with nose-over, accumulation conveyors, tire weighing system with feed rate control, mid-kiln equipment support tower, over-the-kiln tire feeding chute, mid-kiln valve, mechanical and electrical installation, along with all PLC programming and system commissioning.

Preheater Kiln (4-Stage), Whole Tire Feed System
CEMEX, Balcones Plant, New Braunfels, TX USA

Turnkey fully automated whole tire feeding system for a 4-stage preheater kiln. This system includes a trailer tipper, live-bottom hopper, tire separator, tire separation refinement system, tire inspection and rejection system, 290’ inclined trussed-framed belt conveyor, support steel and platforms in preheater building, accumulation conveyors, tire weighing system with feed rate control, airlock valve, mechanical, electrical, and civil installation, along with all PLC programming and system commissioning.

Mid-Kiln Whole Tire Feeding System
Blue Circle Cement (Lafarge), Tulsa, OK USA

Turnkey system project, installed in 2001.
Provided all equipment and installation, including - mechanical, electrical, civil, and control room interface aspects. The system was designed to feed whole tires to mid-kiln valves mounted on the plants two long dry kilns. Major equipment includes a rotary disk tire separator with live-bottom hopper, trailer tipper, a belt and roller conveying system, and two hook type elevators.

Preheater Kiln (4-Stage), Whole Tire Feed System
“HISALBA” Hornos Ibericos ALBA (Holcim), S.A. Spain

Installed in 1999 and 2000. This system included our first rotary disk whole tire separator. The system also included a live-bottom hopper, separation refinement conveyors, tire inspection system, tire weighing system and a triple gate air-lock valve mounted to the riser duct of the preheater of the kiln.

Mid-kiln Whole Tire Feed System
“HISALBA” Hornos Ibericos ALBA (Holcim), S.A. Spain

Installed In 1999. This system was designed to feed whole tires to one long dry kiln with a 2-stage preheater. The system included all mechanical and electrical engineering, all mechanical and electrical equipment (including the control room interface). Installation supervision was provided. This system utilized a new mid-kiln feed method whereas all of the feeding equipment is located under the kiln at pier elevation and the gate is opened by a cam designed for that specific kiln size and speed.

Precalciner Kiln, Whole Tire Feed System with Iron Waste Feed Provisions
Texas Lehigh Cement (Heidelberg), Buda, TX USA

Turnkey system designed to feed whole tires and iron waste products to a precalciner cement kiln. Our project scope included all engineering, all mechanical and electrical equipment, system programming, mechanical and electrical installation, and building structures to enclose the equipment, as well as, storage of tires and iron waste material.

Mid-Kiln Whole Tire Feed System For Two Kilns
Essroc Materials, Inc. (Italcementi), Bessemer, PA USA

Mid-kiln feed system in which all mechanical and electrical engineering, all mechanical and electrical equipment (less the PLC, MCC, and MMI equipment) were provided. Essroc provided electrical installation. This system feeds two kilns from above the mid-kiln location. This system also incorporates a truck dumper to unload tires from trailers into the walking floor hopper.

Mid-kiln Whole Tire Feed System
Blue Circle Cement (Lafarge), Atlanta Plant, Atlanta, GA USA

Provided mid-kiln tire feeding equipment to conduct a test burn on one of the two kilns at the plant. The equipment provided included one under-the-kiln tire staging forks, one under-the-kiln cam actuator for the Cadence mid-kiln gate, and a staging platform.

Precalciner Kiln, Whole Tire Feed System
Hercules Cement, Inc., Stockertown, PA USA

Provided a double gate air-lock valve to test the viability of TDF in an existing precalciner kiln.