19_u. lubjuhn_cemex sia_from 0% to 80% - alternative fuel usage in the broceni cement plant
TRANSCRIPT
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From 0 % to 80 % - Alternative fuel From 0 % to 80 % - Alternative fuel usage in the Broceni cement plant
Dr. Uwe Lubjuhn, October 2015
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Investment decision
Capital expenditure 275 mill. €
� Start of construction 2007
� Start of kiln in May 2009
� Nominal clinker capacity 3500 t/d
� Cement capacity 1,2 mill. t/a (new plant)
Decision from the start to use alternative fuels (AF):
� AF storage
� AF handling & transport
� Combustion chamber
� Main burner for use of AF
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Plant layout
Kiln Kiln lineline withwith
preheaterpreheater towertower
CCoaloal millmillRawRaw millmill areaareaCementCement millmill
RawRaw materialsmaterialsClinkerClinker silosilo
RawRaw millmill areaareaCementCement millmill
Alternative Alternative fuelsfuels
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AAA of AF usage
Availability
Suitable waste in terms of amount, price/gate fee and quality
AcceptanceAcceptance
Authorities, neighbours and public stakeholders interested in environmental, H&S and firefighting aspects
Application
Reception and storage, feeding and burning, process and quality control
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Availability
Suitable waste in terms of amount, price/gate fee and quality
Conventional:
� Municipal / household waste� Commercial waste� Industrial waste� Used tyres� Used tyres
Biomass:
� Agricultural residues� Wood chips, wood waste� Meat and bone one meal,� Sewage sludge
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Acceptance
Authorities, neighbours and public stakeholders interested in environmental, H&S and firefighting aspects
� Emission prognosis� Emission monitoring� Dust� NOx� SO2� SO2� Heavy metals incl. Hg� HCl, HF, CO, TOC� Organics � NH3� CO2-emissions
� Type of wastes used� Air quality in storages� Fire alarm and protection systems� Inflammability / explosiveness of AF
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Application
Reception and storage, feeding and burning, process and quality control
� Storage for bulk material� Storage for bales including debaler
� Mechanical transport� Pneumatic transport� Pneumatic transport� Main burner for different types of fuel� Kiln inlet, calciner, combustion chamber
� Chlorine-bypass� Bypass-dust handling� Use of bypass dust in cement� Use of bypass dust for binders� NOx abatement� SO2 abatement� Avoiding de-novosynthesis of dioxins
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Alternative fuels in Latvia
Local Imported
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Kiln and preheater (KHD / Germany)
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Kiln line
PreheaterPreheaterPreheaterPreheaterPreheater tower with precalcinerand combustion chamber
CombustionCombustionCombustionCombustion ChamberChamberChamberChamberCombustionCombustionCombustionCombustion ChamberChamberChamberChamberNew KHD development for the use ofalternative fuels up to 70 mm particlesize
CoolerCoolerCoolerCoolerHigh
efficiency IKN cooler
KilnKilnKilnKilnShort kiln with twosupport stations andtertiary air duct
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Combustion
chamber:
Alternative fuels
up to 70 mm
Combustion chamber
Picture: Picture: Inside Inside viewview combustioncombustion chamberchamber
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Debaling
Bulk feeding
Feeding
Conveying
Alternative fuel feeding for combustion chamber
AF feeding system
Bulk feedingScreening
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SulphuricSulphuric Acid Tar Waste is transformed into bulk ma terialAcid Tar Waste is transformed into bulk material
Processing of SATW
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Extraction Neutralization Transportation
SATW
Cement plant
Contaminated lake
SATW processing and usage
StorageRecovery
Kiln Feed
Clinker
Primary Fuels
Alternative Fuels
Cement plant
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Ventilation system for storage
Smelling air introduced into clinker cooler and used as combustion air.
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BagBag filtersfilters::
DustDust emmissionemmission
< < 20 mg/m³20 mg/m³
Best available technology
Picture: Main Picture: Main bagbag filter filter
househouse / BK5/ BK5
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SNCR:SNCR:
NONOxx emissionsemissions
< 500 mg/m³< 500 mg/m³
Best available technology
Picture: Picture: SNCR SNCR pumpspumps
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Permanent Permanent displaydisplay ofof emissionemission
in in centralcentral controlcontrol roomroom
Continuous emission monitoring
Picture: Screen Picture: Screen shotshot Siemens Siemens controlcontrol systemsystem
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From 0 % to 80 %
80
100
Hea
t Sub
stitu
tion
[%]
Alternative Fuels
0
20
40
60
Hea
t Sub
stitu
tion
[%]
2010 2011 2012 2013 2014 20152009
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900
1000
1100
1200
kg C
O2/
t clin
ker
Jun 08 3rd period Apr 12
Reduced CO 2-footprint
Specific CO 2 emissions according EU allocation rules for trading perio d 2013–2020 compared to real emissions Broceni
600
700
800
900
Broceni BK4 EU Benchmark Broceni BK5
kg C
O2/
t clin
ker
- 36 %
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Modern Modern clinkerclinker kilnkiln technologytechnology: : UseUse ofof alternative alternative fuelsfuels
COCO22--savings = 400.000 t/asavings = 400.000 t/a
CO2-improvements
EqualEqual toto emissionsemissions ofof moremore thanthan 200.000 modern 200.000 modern carscars drivingdriving
20.000 km per 20.000 km per yearyear
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But everything starts with the people
Thank You!