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Cardox Technology for the Lime Industry

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ATD-Pressure Gas System

This document describes Cardox technology for removing material buildup using pressurized carbon dioxide gas tubes. It is presented by John Stulack of ATD Pressure Gas Systems. The technology has been used safely for over 60 years to clear blockages in industrial processes like lime production, pulp/paper, cement, and bulk material storage. It works by detonating a sealed tube containing liquid carbon dioxide, which expands into an inert gas that blasts away deposits through a discharge nozzle. Key advantages are improved safety, reduced downtime, and preventing problematic buildups from occurring.

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ATD Pressure Gas System Presents: Cardox Technology for the Lime Industry. Safe, Fast and Effective Material Build-up Removal Presented by John Stulack
ATD Pressure Gas System has been safely removing material build–up and blockages in industrial processes and bulk storage for over 60 years.
ATD Provides Cardox Technology to over 300 customers in 50 Countries  Lime Industry  Pulp and Paper Industry  Cement Industry  Steel Manufacturing  Waste Industry  Power Industry  All Types of Bulk Storage  Chemical Industry
Applications Examples:  Pyroprocessing/Calcining – Rotary Kilns – Riser Duct -Preheater – Chimney/Cassette - Ceiling/Roof - Cyclones – Feed Pipes – Feed shelf - Transfer Chute – Riser Duct - Downcomer – Cooler.  Incinerators – Combustion Chamber – Duct Work – Grate Cooler.  Power Industry – Super Heater Tubes – Economizer – Electrostatic Precipitator – Boiler Ash Hoppers – Lime silos –Flyash silos.  Steel Industry - Slag Pot Ladles – Coke Battery – Coal Feeders – Preheater Box.  Bulk storage/ Silos, Feeders and Rail Cars – Lime – Coal – Gypsum - Finished Cement - Iron Ore - Fly-ash - Raw Meal - Soda Ash – DDG - Bone Meal - Grain etc.
How does a Cardox Tube Work? The Cardox Tube is loaded with a chemical Pressure Gas Generator and is then sealed with the Tube Head. The Discharge side of the tube is loaded with a Copper Washer and Shear Disc, followed by the operator’s choice of Discharge Head. After the tube is loaded it is then filled with liquid CO2.
Loading the Tube with Generator, Copper Washer and Shear disc. This takes about two minutes with our Loading Table. Filling The Tube with liquid CO₂. This takes about 30 seconds with our Wall-mount Filling Station. Loading & Filling Equipment
Three Main Components Cardox Tube Base Socket Gripcase The Base Socket is installed on the outside of the vessel wall in the location where the internal material build-up is to be removed. The Gripcase safely holds the tube in place while it is activated. The Cardox Tube removes the unwanted build-up with a high pressure blast of inert gaseous C0₂.
When the Tube is Activated The operator detonates the Tube from a safe predetermined location. When detonated, the Chemical Generator creates heat, converting the liquid CO2 to Gaseous CO2 in 20 milliseconds. It expands at over 500 times its original volume and the gas ruptures the shear disc at 37,000 psi, producing traverse forces up to 15 tons. The CO2 discharge is deflected by the Discharge Head (type depending on application) removing the build-up from the refractory/vessel wall.
Remove Material Build-up while on line Preheater Rotary Kiln Cooler Bulk Material Storage Cassette/Chimney Transfer ChuteCeiling Feed Shelf Hoppers/Silos
“We were experiencing funnel flow (vs. mass flow) which leads to rat-holes putting the site at operational risk. We originally brought in a firm, that will remain nameless to clear the rat- hole in an alternate way than yours. This was costly, ineffective, and frankly I believe that firm was milking the job. When we contacted John Stulack he responded to our needs quickly and professionally with his mind on safety. His use of the Cardox System has kept the coal flowing in our silos and has relieved a great deal of stress for the people working in this power plant, not the least of which is mine. John is experienced, courteous and direct which is refreshing. He has helped us numerous times and without his dedication I have no doubt we would have process interruptions.” – Utilities Manager from Pennsylvania Pulp and Paper Industry ATD-Pressure Gas System – Because experience matters. We are your Cardox experts!
Lime Preheater Build-up Examples Keep your Preheater clean and your Kiln running by using ATD Cardox. Our equipment and training is specifically designed for use in high heat applications. Material Build-up is safely removed from the outside of the vessel wall in minutes while keeping your work staff safe. Base Sockets can be installed with the assistance of our Technical Advisors in key areas from the Preheater to the Cooler allowing safe access to clear the unwanted build-up. Using Cardox proactively can prevent build-up from becoming problematic.
Remove Build-up from Feed Inlet to Cooler Build-up and clogging in the Cooler can cause your Kiln to go off line. Removing hard to reach build-up in the Cooler can now be accomplished with ATD’s new Patented Straight Shot and 100% Locking Collar. ATD now offers a variety of specialized Discharge Tubes for the toughest hard to reach jobs.
Keep Your Silos Flowing with ATD Cardox Keep your bulk storage silos flowing. A targeted Pressure Gas Tube blast of gaseous CO₂ dislodges residual material build-up, plugs or bridges in nearly all types of material. LOAD IT UP LOCK IT IN BLOW IT AWAY!
 All Types of Bulk Storage:  -Cement  – Lime  – Coal  – Iron Ore  – Fly Ash  – Soda Ash  – Gypsum  – DDG  – Bone Meal  – Grain  - Wood Chips Keep Your Silos Flowing with ATD Cardox
Pressure Gas Tubes (Cardox) In Action
Removing Rings from a Rotary Kiln Removing a ring from a Rotary Kiln is another ATD specialty. We were the first to remove a Kiln Ring with Cardox technology all the back in 1961. ATD equipment, experience and site specific Safety Training truly sets us apart from the rest. Our ATD Technicians specialize in understanding your specific ring problem by gathering the applicable important information. This information and our experience insures a successful installation.
Removing Kiln Ring example The location of the Ring zone can be determined with the use of a Thermal Heat gun or Thermal Imaging. Once the zone is determined the Base Sockets are installed axially along the zone. The amount of rows installed and spacing of the Base Sockets is determined based on the Kiln Diameter as well as details and location of the ring
Basic Procedure The Kiln is stopped with the Base Socket location at a accommodating working position.
Basic Procedure Remove Locking Plate from Base Socket and insert the Drill Guide.
Basic Procedure A Bore is created in the material build-up with ATD specialized drilling equipment. Softer materials may not require any drilling.
Basic Procedure The loaded Cardox Tube is inserted into the Base Socket at a predetermined depth and locked in place with the Grip Case. The detonating wires are now connected.
Basic Procedure The tube is safely activated remotely.
Results Before After
How do we protect the refractory and Vessel Wall? Our ATD Pressure Gas system is specifically designed to insure there is no damage to the refractory or vessel wall while targeting the buildup. ATD also offers custom Discharge Tubes that insure the operator inserts the tube at the correct depth. Our specialized Discharge Tubes come in a variety of types for your specific application. Heat resistant Tubes and Straight Shot type are also now available!
Advantages using Cardox Technology Safety! Material Build-up is removed from the outside of the vessel. The operator is in a safe area when the Cardox Tube is activated. Cardox is safe to use in nearly every process and material as the discharge is inert gaseous CO₂. The system is specifically designed to insure there is no damage to the refractory or vessel wall while targeting the unwanted buildup. Down time is drastically reduced. Removal of deposits in most applications is achieved in just minutes. Ring removal in kilns averages between 2 – 6 hours with as little as 4 operators. Using Cardox Technology proactively can prevent the ring or Build-up from becoming problematic.
Removing Kiln Rings/Build-up WITHOUT Cardox • 24 Hour Cool Down Time • Confined Space Permits • Workers are Subjected to Dangerous Conditions • 24 Hours Heat Up Time • Loss of Production
Thank you for your time! Please contact us for any questions or additional information. We specialize in providing solutions for your specific application. John C Stulack john.stulack@atd-pgs.com (843-830-8488)

More Related Content

Cardox Technology for the Lime Industry

  • 1. ATD Pressure Gas System Presents: Cardox Technology for the Lime Industry. Safe, Fast and Effective Material Build-up Removal Presented by John Stulack
  • 2. ATD Pressure Gas System has been safely removing material build–up and blockages in industrial processes and bulk storage for over 60 years.
  • 3. ATD Provides Cardox Technology to over 300 customers in 50 Countries  Lime Industry  Pulp and Paper Industry  Cement Industry  Steel Manufacturing  Waste Industry  Power Industry  All Types of Bulk Storage  Chemical Industry
  • 4. Applications Examples:  Pyroprocessing/Calcining – Rotary Kilns – Riser Duct -Preheater – Chimney/Cassette - Ceiling/Roof - Cyclones – Feed Pipes – Feed shelf - Transfer Chute – Riser Duct - Downcomer – Cooler.  Incinerators – Combustion Chamber – Duct Work – Grate Cooler.  Power Industry – Super Heater Tubes – Economizer – Electrostatic Precipitator – Boiler Ash Hoppers – Lime silos –Flyash silos.  Steel Industry - Slag Pot Ladles – Coke Battery – Coal Feeders – Preheater Box.  Bulk storage/ Silos, Feeders and Rail Cars – Lime – Coal – Gypsum - Finished Cement - Iron Ore - Fly-ash - Raw Meal - Soda Ash – DDG - Bone Meal - Grain etc.
  • 5. How does a Cardox Tube Work? The Cardox Tube is loaded with a chemical Pressure Gas Generator and is then sealed with the Tube Head. The Discharge side of the tube is loaded with a Copper Washer and Shear Disc, followed by the operator’s choice of Discharge Head. After the tube is loaded it is then filled with liquid CO2.
  • 6. Loading the Tube with Generator, Copper Washer and Shear disc. This takes about two minutes with our Loading Table. Filling The Tube with liquid CO₂. This takes about 30 seconds with our Wall-mount Filling Station. Loading & Filling Equipment
  • 7. Three Main Components Cardox Tube Base Socket Gripcase The Base Socket is installed on the outside of the vessel wall in the location where the internal material build-up is to be removed. The Gripcase safely holds the tube in place while it is activated. The Cardox Tube removes the unwanted build-up with a high pressure blast of inert gaseous C0₂.
  • 8. When the Tube is Activated The operator detonates the Tube from a safe predetermined location. When detonated, the Chemical Generator creates heat, converting the liquid CO2 to Gaseous CO2 in 20 milliseconds. It expands at over 500 times its original volume and the gas ruptures the shear disc at 37,000 psi, producing traverse forces up to 15 tons. The CO2 discharge is deflected by the Discharge Head (type depending on application) removing the build-up from the refractory/vessel wall.
  • 9. Remove Material Build-up while on line Preheater Rotary Kiln Cooler Bulk Material Storage Cassette/Chimney Transfer ChuteCeiling Feed Shelf Hoppers/Silos
  • 10. “We were experiencing funnel flow (vs. mass flow) which leads to rat-holes putting the site at operational risk. We originally brought in a firm, that will remain nameless to clear the rat- hole in an alternate way than yours. This was costly, ineffective, and frankly I believe that firm was milking the job. When we contacted John Stulack he responded to our needs quickly and professionally with his mind on safety. His use of the Cardox System has kept the coal flowing in our silos and has relieved a great deal of stress for the people working in this power plant, not the least of which is mine. John is experienced, courteous and direct which is refreshing. He has helped us numerous times and without his dedication I have no doubt we would have process interruptions.” – Utilities Manager from Pennsylvania Pulp and Paper Industry ATD-Pressure Gas System – Because experience matters. We are your Cardox experts!
  • 11. Lime Preheater Build-up Examples Keep your Preheater clean and your Kiln running by using ATD Cardox. Our equipment and training is specifically designed for use in high heat applications. Material Build-up is safely removed from the outside of the vessel wall in minutes while keeping your work staff safe. Base Sockets can be installed with the assistance of our Technical Advisors in key areas from the Preheater to the Cooler allowing safe access to clear the unwanted build-up. Using Cardox proactively can prevent build-up from becoming problematic.
  • 12. Remove Build-up from Feed Inlet to Cooler Build-up and clogging in the Cooler can cause your Kiln to go off line. Removing hard to reach build-up in the Cooler can now be accomplished with ATD’s new Patented Straight Shot and 100% Locking Collar. ATD now offers a variety of specialized Discharge Tubes for the toughest hard to reach jobs.
  • 13. Keep Your Silos Flowing with ATD Cardox Keep your bulk storage silos flowing. A targeted Pressure Gas Tube blast of gaseous CO₂ dislodges residual material build-up, plugs or bridges in nearly all types of material. LOAD IT UP LOCK IT IN BLOW IT AWAY!
  • 14.  All Types of Bulk Storage:  -Cement  – Lime  – Coal  – Iron Ore  – Fly Ash  – Soda Ash  – Gypsum  – DDG  – Bone Meal  – Grain  - Wood Chips Keep Your Silos Flowing with ATD Cardox
  • 15. Pressure Gas Tubes (Cardox) In Action
  • 16. Removing Rings from a Rotary Kiln Removing a ring from a Rotary Kiln is another ATD specialty. We were the first to remove a Kiln Ring with Cardox technology all the back in 1961. ATD equipment, experience and site specific Safety Training truly sets us apart from the rest. Our ATD Technicians specialize in understanding your specific ring problem by gathering the applicable important information. This information and our experience insures a successful installation.
  • 17. Removing Kiln Ring example The location of the Ring zone can be determined with the use of a Thermal Heat gun or Thermal Imaging. Once the zone is determined the Base Sockets are installed axially along the zone. The amount of rows installed and spacing of the Base Sockets is determined based on the Kiln Diameter as well as details and location of the ring
  • 18. Basic Procedure The Kiln is stopped with the Base Socket location at a accommodating working position.
  • 19. Basic Procedure Remove Locking Plate from Base Socket and insert the Drill Guide.
  • 20. Basic Procedure A Bore is created in the material build-up with ATD specialized drilling equipment. Softer materials may not require any drilling.
  • 21. Basic Procedure The loaded Cardox Tube is inserted into the Base Socket at a predetermined depth and locked in place with the Grip Case. The detonating wires are now connected.
  • 22. Basic Procedure The tube is safely activated remotely.
  • 24. How do we protect the refractory and Vessel Wall? Our ATD Pressure Gas system is specifically designed to insure there is no damage to the refractory or vessel wall while targeting the buildup. ATD also offers custom Discharge Tubes that insure the operator inserts the tube at the correct depth. Our specialized Discharge Tubes come in a variety of types for your specific application. Heat resistant Tubes and Straight Shot type are also now available!
  • 25. Advantages using Cardox Technology Safety! Material Build-up is removed from the outside of the vessel. The operator is in a safe area when the Cardox Tube is activated. Cardox is safe to use in nearly every process and material as the discharge is inert gaseous CO₂. The system is specifically designed to insure there is no damage to the refractory or vessel wall while targeting the unwanted buildup. Down time is drastically reduced. Removal of deposits in most applications is achieved in just minutes. Ring removal in kilns averages between 2 – 6 hours with as little as 4 operators. Using Cardox Technology proactively can prevent the ring or Build-up from becoming problematic.
  • 26. Removing Kiln Rings/Build-up WITHOUT Cardox • 24 Hour Cool Down Time • Confined Space Permits • Workers are Subjected to Dangerous Conditions • 24 Hours Heat Up Time • Loss of Production
  • 27. Thank you for your time! Please contact us for any questions or additional information. We specialize in providing solutions for your specific application. John C Stulack john.stulack@atd-pgs.com (843-830-8488)