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
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.
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.
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)
