Transcript Dia 1 - IC&C Cement

'How to make money using
AFR despite rising prices’
• Wim M.G.M. Heldens
• Manager Sustainable Projects
• IC&C B.V.
•
March 2012
Independent Clinker & Cement Consultancy
GFC Aachen IC&C
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Mission IC&C: Make Money From Sustainability!
Sustainable Development
Max
Alternative
fuels / mat.
Energy
Emissions
Profit
Min
Strategy IC&C
Maintain Quality and production level
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Prices Cement
PRICES OF CEMENT IN USA
160
150
$ of 2011
140
130
120
110
100
90
1880
1900
1920
1940
1960
1980
2000
2020
Mature Markets: The cement price in the USA is the same as in 1900.
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Prices Oil and Coal
PRICES OF OIL AND COAL
18
16
14
€/GJ
12
10
olie
Coal
8
6
4
2
0
1985
1990
1995
2000
2005
2010
2015
The prices of primary fuels oil and coal are rising steadily.
As you see coal still is feasible and compatible as fuel
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Prices Fuels
PRICES OF FUELS
4,0
3,0
2,0
€/GJ
1,0
0,0
2004
-1,0
RDF
2005
2006
2007
2008
2009
2010
2011
2012
Animal Meal
Coal
-2,0
-3,0
-4,0
-5,0
The prices of all AFR are rising.
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Prices of (existing) AFR are rising
Conclusion:
 Prices of cement are not rising
 Production costs are getting higher
 Gap between sales and costs is getting smaller
 If you have the possibilities, look for other materials with
lower costs which increases profit!
 Use profitable alternative AFR’s!
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Key performance data 2008 Best Practice Plant:
Dutch Cement Maastricht (The roots of IC&C)
 95% alternative fuels
 50 % biomass
 Fuel price < 2 €, $ 2.80 / ton clinker
(normally 12 €, $17 / ton clinker!)
 700 kg CO2 / ton clinker
(normally 820 kg CO2 / ton)
 CO2 reduction 20% achieved by
biomass
 NOx reduction 50% by SNCR urea
 SO2 reduction 80%
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Use profitable alternative AFR’s, but only if..!!
 You
may do it:
 You have the right licenses for using AFR
 If not: make it possible
You can do it:
 You have the technical possibilities
 Right place to dose in the kiln
 Right installations to handle and dosing
 Right organization
 If not create the technical possibilities
 You want it:
 The profit should be high enough
 Alt. Fuels: give Heat and if good priced money: €/GJ
 Alt. Raw Materials: give money: €/ton (+ €/GJ)
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If going into AFR; Control:
 Transport
 EVOA procedures
 Licenses
 Bank guaranties
 Licenses for the usage
 Local government/authorities, licensensor
 Unions
 Information to own workers
 Safety aspects
 material handling and safety sheets
 instructions
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IC&C some recent examples
• 2011
 Sludge: € 3.2 million in 3 month in one shot
• 2011
 Industrial Oil: € 0,9 million per year
• 2012
 Industrial Fluid: € 0,4 million per year
• 2012 Under testing
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IC&C offers support
 AFR network:
– Searches and screens the right materials for your kiln
– IC&C is not a cement work, but IC&C knows how it works and what is possible
– IC&C operates fully independent
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Knowledge about the allowed chemistry
Knowledge about how and where to use the material
Checking where it can be put into the kiln
Make the economical plan / feasibility study
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Go new ways…. Make it possible… !?
Continuation of reliable operation
Restriction often are emissions
Emission limitations such as Mercury /Smell / NOx abatement
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IC&C Mercury / smell abatement 1
Modular adsorption system consisting of several containers
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Proven technology: e.g. Waste Incinerators: AVR/VAM, new in cement
Each container can be individually switched on
Easy change out of carbon due to top loading
By-pass can be (partially) operated in case of clean fuel (e.g. low Hg)
Used carbon will be recycled
Mercury / smell filter
5 Adsorptie
containers
filter
E
E filter
filter
kiln
IC&C
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IC&C Mercury / smell abatement 2
Size and costs
 At ~300.000 Nm3/hr T~130 oC
 Each container will be 12 x 2,5 x 3,5 meters
 Per container 25 % reduction
 Approximately installed cost per container: 200 kEUR
 Low operating costs: € 30.000 / container/year
 Total space requirement for 5 units is about 20 m x 20 m
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IC&C Uptake mercury, smell and dioxins abatement
Uptake (adsorbtion)
Components
Temperature
Mercury Hg
Acetaldehyde
Dioxins
oC
130
130
130
Nm3/hr
120.000
200.000
125.000
Inlet concentration
mg/Nm3
0,1234
2 0,812 ng/Nm3
Outlet concentration
mg/Nm3
< 0,001
< 1 < 0,05 ng/Nm3
Limit
mg/Nm3
< 0,05
< 0,05 ng/Nm3
Flow
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IC&C DeNOx
 Burner performance optimization; primary measure
 SNCR in long kilns by injection of urea granulate (3 mm)
IC&C DeNOx
urea
air
kiln inlet
 Result: 60% reduction of NOx
 DeNOx by Flame cooling, without increasing fuel consumption
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IC&C New dryer technology PAD
PAD Pulverised Air Dryer: Biovalor
Is a non thermal separator of liquid and solid
components

 No heat required: 100-140 kWh/ton water
 Pulverises material up to 50 mm to ~ 45 um
 Dries any material from 90% to < 10%
moisture content
 Waste water treatment is necessary
 Reduction of emissions comparing to
thermal drying
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IC&C: Who can we support
 AFR
– Plant managers who want to increase profitability
– Plants who want to increase sustainability whilst maintaining
good performance
 Process & Environmental issues
– Integrating New Technology and sustainability
– Decreasing Emissions
– Decreasing Smell
 Drying and grinding of Biomasses etc.
– Cement plants who want to use wet materials
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Thank you for your
attention.
Questions?
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