Alternative Fuels and refractories
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Transcript of Alternative Fuels and refractories
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Dipl. Ing. Stefan Thomas
Use of alternative fuels in the cement industry
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How can you make Profit?
Total Profit = Tons x sales prices –
(Cost/t production + costs for distribution and sales) x Tons
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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
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What to do to increase the profit
Total Profit = Tons x sales prices
–
(Cost/t production + costs for distribution and sales) x Tons
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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,…
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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
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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
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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
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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
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Tires; 265
waste oil; 69
SRF commercial waste; 1361
meat & bone meal; 317
SRF from MSW; 212
solvents; 93
sewage sludge; 238others ; 45
Tireswaste oilSRF commercial wastemeat & bone mealSRF from MSWsolventssewage sludgeothers
Usage of SRF in German cement kilns in 2006 Sum: 2.6 Mill tons/a
SRF solid recovered fuel
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Substitution Rate in German Cement Kilns 2006 >50%
0,0%
10,0%
20,0%
30,0%
40,0%
50,0%
60,0%
70,0%
2001 2002 2003 2004 2005 2006
Fossil SRF
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What are Alternative Fuels
Alternative Fuels
Liquid
• Waste oil
• Solvents
• Animal fat
• Sewage sludge
• Etc.
Solid
• Petcoke
• Tyres chipped or complete
• Animal meal + Bone meal
• Dried Sewage sludge
• RDF – refuse derived fuel from:
Pulp, paper and cardboard; plastics; Packaging;
Textile industry; others
• Scrap wood
• Etc…
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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)
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Liquid Alternative Fuel, Equipment
Solvents
Collecting tray
Unloading device
Health and safety Info
Control equipmentLevel, Temperature, Pressure, gas detector
Stainless Steal Tanks2x100m³
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Liquid Alternative Fuel, Equipment
Solvents
Fuel pipes to main burner
Leakproof ConcreteSurface with collectingsump
Pump Station with filters
Mixing equipment out ofquality reasons
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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
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Solid Alternative Fuel
Tires storage
Plant A, all types of tyres
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Solid Alternative Fuel
Tires storage
Plant B
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Solid Alternative Fuel
Tires storage
Plant C, all types of tires
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Storage area
Walking floor bunker for daily/shift consumption
singularize deviceWheel rim detection
Weighing station
Tire transport to kiln
Necessary Equipment for tire use in Cement Kilns
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Storage area
Walking floor bunker for daily/shift consumption
singularize deviceWheel rim detection
Weighing station
Tire transport to kiln
Necessary Equipment for tire use in Cement Kilns
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Solid Alternative Fuel
TiresAir lock beforepreheater
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Solid alternative fuel, Equipment
Precombustion Chamber, up to 7000 kg/h tires ~ 1000 pcs/h
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Solid alternative fuel
RDF - refuse derived fuel
Availability is depending on the local market
Calorific value depends on contractingHigh calorific value up to 23 MJ/kgMid calorific value approx. 16 MJ/kgLow 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 burnerup to 150mm for use in calciner
Used in main burner or calciner
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RDF before Preparation
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RDF final Product
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RDF Preparation
Primary Shredder Secondary ShredderFE Separation Heavy Fractionseparation
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RDF final Product
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RDF Homogenisation
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RDF, constant Quality?
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RDF, constant Quality?
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RDF Storing and dosing
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RDF Input area in a German cement plant
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RDF Input area in a German cement plant
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RDF Input area in a German cement plant
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RDF automatic sampling
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You still have Fuel Control?
Primary Air
Coal
RDF
Oil, Waist Oil & Solvents
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Alternative Fuels, how main burner looks like
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Alternative Fuels, how main burner looks like
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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: 11.300 kg / h
Waste oil: 9.170 kg / h
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The benefit of Alternative Fuels AF
One easy calculation under the following assumptionVARIABLE COSTS
Kiln capacity 3.000 t/dProduction days 330 d/aspecific heat consumption 3.300 kJ/kgHu (coal) noble fuel 27.000 kJ/kgNoble fuel cost at Burner tip 100 EUR/t
Fuel cost 12.100.000 EUR/a
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The benefit of Alternative Fuels AF
Fuel Cost with noble fuel 12.100.000 EUR/a
Hu AF 20.000 kJ/kgFuel Costs - 10 EUR/tAF rate 50 %Yearly amount of AF 81.675 t/aAF costs -816.750 EUR/aTotal yearly fuel costs 5.233.250 EUR/a
Your save in variable costs 6.866.750 EUR/a
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The benefit of Alternative Fuels AF
Total yearly fuel costs 5.233.250 EUR/a
Emission TradingCO2 from AF does not count!
Price for CO2 at the European Stock Exchange (EEX)http://www.eex.com04.09.2008 24,49 EUR/t CO2
CO2 Emissions from Noble Fuels (100%) 443.666 t CO2/aYou could save CO2 costs 5.432.690 EUR/aOr increase Production by approx. (0,8tCO2/tklinker) 277.291 t/a