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 2000C

Waste Combustion: min 850C
> 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
2x100m
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 Nm/ 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