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YOSHIYUKI UENOYAMA
General Manager
g
Green-Innovation Business Promotion Department
TAIHEIYO CEMENT CORPORATION
yosiyuki_uenoyama@taiheiyo-cement.co.jp
Taiheiyo Cements activities span the world
Dalian(China)
USA
Qinhuandao(China) Japan
p ((11 p
plants))
Nanjing(China)
(C ) Korea
Vietnam
Philippines
Domestic
D ti Sales:
S l
14,829 kt + Export 5,009 kt 2
2013 TAIHEIYO CEMENT
Contents
Recycling - utilization of by
by-products
products and industrial waste including coal fly ash
Conclusion
3
2013 TAIHEIYO CEMENT
Typical cement production process
Material flow
Fuel flow
1. Mining Gas flow
Coal
Stack
Dust
Stack
collector
Preheater
Belt conveyer
Iron Dust Coal mill
Clay
Limestone collector
slag
g minerals
3. Burning process
Rotary kiln
Raw mill
Homogenizing
H i i Clinker cooler
silo
Gypsum
Clinker
2. Raw material p
process Cement silo
4. Shipping silo Classifier
Cl (d
Clay (dried)
i d) Silica Li
Limestone
t I
Iron slag
l
Limestone:
Occupying 70
70-80%
80% of total raw
materials and transported from a
mine by a belt conveyer, for
i t
instance
Iron slag:
By-product of iron manufacturing
Limestone mine
The composition of raw material
effects property of cement
5
Long distance belt conveyer 2013 TAIHEIYO CEMENT
Burning process
Excellent cement can be manufactured by burning at very high temperature of 1450 oC
1. Raw material is heated gradually by hot gas in the preheater
2 Preheated
2. P h t d raw material
t i l iis b
burned
d iin th
the rotary
t kiln
kil att a temperature
t t off 1450 oC
3. Approximately 30 min of burning, the raw material turns red-hot lava like lumps
Clinker
Cement 7
2013 TAIHEIYO CEMENT
Difference of wet-process kiln in energy efficiency
Providing slurred raw material directly into rotary kiln
7000
Specific required heat Specific production
6000 of kiln volume 120
r)
5000
(MJ/t-clinke
100
(kg/m3/h)
4000 80
3000 60
(
2000 40
1000 20
0
Wet-process
et p ocess DB-type
DB type SP type
SP-type NSP type
NSP-type
kiln kiln kiln kiln
120
Typical technology on power efficiency 110
Including waste heat
recovery power generation
- Vertical type mill 100
- Pre
Pre-grinding
grinding system 90
- High efficiency classifier
80 Excluding waste heat
- High efficiency blower fan recovery power generation
70
70 75 80 85 90 95 00 05 09
140
Energy consump
120
100
80
60
Mexico
Japan
Italy
India
Spain
Korea
Thailand
Canada
China
Germany
Brazil
Weighted Av.
USA
W
Comparison of Energy consumption index on clinker and cement manufacturing
( ) WorldwideTrendsin
Reference:TheInternationalEnergyAgency(IEA),
EnergyUseandEfficiency2008
10
2013 TAIHEIYO CEMENT
Business scheme of material recycling
Practically performed Waste to Resources business scheme on cement plants
Natural
resources
Industrial clustering Recycling of municipal waste
Blastt furnace
Bl f
Steel plants
MSW
slag Incineration Separation and
ash Incineration
household
Coal fly ash
Coal fired
power plants Cement plants
Sewage sludge
Desulfurazation Raw Mixing
admixtures
General
gypsum materials
Limestone & slaked lime Admixtures
G
Others Incineration
Alterative fuel &
waste tires Incineration
raw materials ash
waste plastics
Because:
1 C
1. Cementt majorly
j l contains
t i CaO,
C O SiO2, Al2O3 and
dFFe2O3.
Waste containing such components may be used as raw material.
Total Alkali
SiO2 Al2O3 Fe2O3 CaO Na2O eq.
Dust-collector
Organic Waste:
Limestone Drying
y g
Raw
Ra Waste plastic Waste oil
Silica Clay Grinding
Blending material Coal
Iron slag
Rotary Kiln
Coal
L dfill
Landfill
3% Others Cement
Others 15% 13%
16%
Export
15%
Total amount Total amount
Construction of recycling of recycling
material 17% 8,924 kt 1,056 kt Paper
Cement Reuse 32%
64% basement
15% Thermal
recycle Steel
10% 4%
Heat Dust
recovery collector
Preheater
boiler
Heat
recovery
boiler
Coal
Coal mill
1000oC
1450oC 250oC
Rotary
y kiln
Chloride bypass and minor
elements recovery system Clinker cooler Clinker 17
2013 TAIHEIYO CEMENT
Waste to Resources on MSW management
Development of
Community
MSW
AK (Applied Kiln)
Incinerators
Ash
processing
Incineration ash
Existing Cement Plants
Eco-cement Plants
Landfill sites (extension of service life)
18
2013 TAIHEIYO CEMENT
AKApplied Kiln System
Hidaka City:
P
Population
l ti 50
50,000
000
MSW 15,000 ton/y
Crushing and
separating
Incinerators
Aerobic bio
bio-
digester
Cement production
line making use of
digested
g MSW
19
Saitama Plant, TCC 2013 TAIHEIYO CEMENT
Ash processing systems
Fly Ash Washing System
(15,000 t/y)
Bottom
B tt Ash
A h Processing
P i
System (50,000 t/y)
23
2013 TAIHEIYO CEMENT
Locations of Domestic Plants
Direct operation plant
Subsidiaryy and Affiliate
Total production capacity: 21,067 kt/y
Kamiiso
3,829
Myojo Ofunato
Eco-cement
1,763 2,032
Tsuruga Kumagaya
677 2,027
Fujiwara
F ji Saitama
S it
2,326 1,470
D.C.
D C
1,199
Oita
5,744
24
2013 TAIHEIYO CEMENT
Recycling systems clustered on cement industry
25
2013 TAIHEIYO CEMENT
Reducing CO2 Emission by utilizing waste as fuel
Energy
Fossil
Waste Fossil energy from
energy
waste
IIncine-
i Co-combustion
C b i
rators Cement plants
at cement plants
Fossil Energy
o of foss
Ratio
Fiscal Year
27
2013 TAIHEIYO CEMENT
Technical configuration of AK System
Crushing and
Garbage separating
trucks
g
Bio-digester
Feed to
rotary kiln
MSW
1stt day
1 d 2nd
2 ddday 3rd
3 ddday Digested MSW
Garbage bags Aerobic MSW turns
tear and digestion cement raw
fragment quickly material and
develops fuel
28
2013 TAIHEIYO CEMENT
Fly ash processing system
Belt filter
From incinerators
Filter Cake
Filtrate Rotary kiln
Decanter
Settling
Kiln Sewage
exhaust
Sand filter Hg remover
CO2 reactor Filter cake
Filter press
29
2013 TAIHEIYO CEMENT
Advantages of Eco-cement
Heavy
H metals
t l can b
be recovered
d
Some of heavy metals, such as Cu, Pb and Zn can be recovered
from collected dust.
30
2013 TAIHEIYO CEMENT