Alternative Fuels and refractories

Use of alternative fuels in the cement industry

Dipl. Ing. Stefan Thomas

How can you make Profit?

Total Profit = Tons x sales prices

–

(Cost/t production + costs for distribution and sales) x Tons

The Elements of Profit

Total Profit = Tons x sales prices – (Cost/t production + costs for distribution and sales) x Tons Cost/t production Fix costs

independent from plant output

Variable costs

depending on plant output

What to do to increase the profit

Total Profit = Tons x sales prices – (Cost/t production + costs for distribution and sales) x Tons

What to do to increase the profit

Total Profit = Tons x sales prices – (Cost/t production + costs for distribution and sales) x Tons Variable costs Fuel

Coal, Lignite, Petcoke, heavy oil, gas

Electric Power Raw Materials

Limestone, SiO2, Clay, iron ore, gypsum

Materials consumed

explosives, Diesel oil, bags, additives,…

How can you reduce the costs ?

Fuel Reduce fuel consumption by Optimized kiln output Increased cooler efficiency Controled kiln feed chemistry Increased heat exchange efficiency Reduced of kiln stops

How can you reduce the costs ?

Fuel Reduce fuel costs Reduce number of kiln stops Minimize the use of noble fuels Increase the use of alternative fuels

The use of alternative fuels (and raw materials) is mainly driven by • Economical aspects Return on invest Influence on system Influence on clinker quality • Environmental aspects Permission Public acceptance Customer acceptance

Why is it possible to burn alternative fuels in Cement Kilns

• Extreme high process/flame temperatures ～ 2000°C Waste Combustion: min 850°C • λ > 1, air excess • Long retention time in Kiln and Calciner > 6 sec Waste Combustion min. 2 sec • Free lime as a good absorbance for hazardous Elements • No solid waste, all ash is product

Usage of SRF in German cement kilns in 2006 Sum: 2.6 Mill tons/a

sewage sludge; 238 solvents; 93

SRF from MSW; 212

meat & bone meal; 317

others ; 45

Tires; 265 waste oil; 69 Tires waste oil SRF commercial waste meat & bone meal SRF from MSW solvents sewage sludge others

SRF commercial waste; 1361

SRF solid recovered fuel

Substitution Rate in German Cement Kilns 2006 >50% 70,0%

Fossil

SRF

60,0%

50,0%

40,0%

30,0%

20,0%

10,0%

0,0% 2001

2002

2003

2004

2005

2006

What are Alternative Fuels

Alternative Fuels Liquid

Solid

• Waste oil

• Petcoke

• Solvents

• Tyres chipped or complete

• Animal fat

• Animal meal + Bone meal

• Sewage sludge

• Dried Sewage sludge

• Etc.

• RDF – refuse derived fuel from: Pulp, paper and cardboard; plastics; Packaging; Textile industry; others • Scrap wood • Etc…

Liquid Alternative Fuel Solvents Availability is depending on the local market Calorific value changes from 15 -28 MJ/kg, may content water Used for main burner Composition: • Alcohol (Methanol, Ethanol, Isopropanol) • Ketone (Aceton) • Ester (Xylol, Benzol, Toluol)

Liquid Alternative Fuel, Equipment Solvents Control equipment Level, Temperature, Pressure, gas detector Stainless Steal Tanks 2x100m³ Health and safety Info Collecting tray Unloading device

Liquid Alternative Fuel, Equipment Solvents Mixing equipment out of quality reasons Pump Station with filters Leakproof Concrete Surface with collecting sump Fuel pipes to main burner

Solid Alternative Fuel : some examples Tires Availability is depending on the local market Calorific value 27 MJ/kg, Chipped 250mm or complete depending on kiln size or dosing system Used in Preheater, also without calciner May content water, depending on the environmental conditions Composition: • Carbon • steel

Solid Alternative Fuel Tires storage Plant A, all types of tyres

Solid Alternative Fuel Tires storage Plant B

Solid Alternative Fuel Tires storage Plant C, all types of tires

Storage area

Necessary Equipment for tire use in Cement Kilns Tire transport to kiln

Walking floor bunker for daily/shift consumption

singularize device Wheel rim detection Weighing station

Necessary Equipment for tire use in Cement Kilns Storage area Walking floor bunker for daily/shift consumption

singularize device Wheel rim detection Weighing station

Tire transport to kiln

Solid Alternative Fuel Tires Air lock before preheater

Solid alternative fuel, Equipment Precombustion Chamber, up to 7000 kg/h tires ～ 1000 pcs/h

Solid alternative fuel RDF - refuse derived fuel Availability is depending on the local market Calorific value depends on contracting High calorific value up to 23 MJ/kg Mid calorific value approx. 16 MJ/kg Low calorific value approx. 8 MJ/kg Water Content up to 15% Chlorine content depends on contracting 0,3% up to 2% Size:two dimensional 25 – 35 mm for optimized combustion for main burner up to 150mm for use in calciner Used in main burner or calciner

RDF before Preparation

RDF final Product

RDF Preparation

Primary Shredder

FE Separation

Heavy Fraction separation

Secondary Shredder

RDF final Product

RDF Homogenisation

RDF, constant Quality?

RDF, constant Quality?

RDF Storing and dosing

RDF Input area in a German cement plant

RDF Input area in a German cement plant

RDF Input area in a German cement plant

RDF automatic sampling

You still have Fuel Control? Coal

RDF Oil, Waist Oil & Solvents

Primary Air

Alternative Fuels, how main burner looks like

Alternative Fuels, how main burner looks like

Alternative Fuels, how main burner looks like Axial air channel Radial air channel Petcoke channel:

14.000 kg / h

Solid waste:

9.000 kg / h

Natural gas:

6.240 Nm³/ h

Heavy fuel oil: Waste oil:

11.300 kg / h 9.170 kg / h

The benefit of Alternative Fuels AF One easy calculation under the following assumption VARIABLE COSTS Kiln capacity Production days specific heat consumption Hu (coal) noble fuel Noble fuel cost at Burner tip Fuel cost

3.000 330 3.300 27.000 100

t/d d/a kJ/kg kJ/kg EUR/t

12.100.000 EUR/a

The benefit of Alternative Fuels AF

Fuel Cost with noble fuel

12.100.000 EUR/a

Hu AF Fuel Costs AF rate Yearly amount of AF AF costs Total yearly fuel costs

20.000 - 10 50 81.675 -816.750 5.233.250

kJ/kg EUR/t % t/a EUR/a EUR/a

Your save in variable costs

6.866.750 EUR/a

The benefit of Alternative Fuels AF

Total yearly fuel costs

5.233.250 EUR/a

Emission Trading CO2 from AF does not count! Price for CO2 at the European Stock Exchange (EEX) http://www.eex.com 04.09.2008 24,49 CO2 Emissions from Noble Fuels (100%) 443.666 You could save CO2 costs 5.432.690 Or increase Production by approx. (0,8tCO2/tklinker) 277.291

EUR/t CO2 t CO2/a EUR/a t/a