March 2012GFC Aachen IC&C1 'How to make money using AFR despite rising prices Wim M.G.M. Heldens...

March 2012 GFC Aachen IC&C 1

'How to make money using AFR despite rising prices’

• Wim M.G.M. Heldens• Manager Sustainable Projects• IC&C B.V.• Independent Clinker & Cement Consultancy


Mission IC&C: Make Money From Sustainability!

Sustainable Development

Strategy IC&C

Energy EmissionsAlternative fuels / mat.

Max

Min

Profit

Maintain Quality and production level


PRICES OF CEMENT IN USA

90

100

110

120

130

140

150

160

1880 1900 1920 1940 1960 1980 2000 2020

$ o

f 2011

Prices Cement

Mature Markets: The cement price in the USA is the same as in 1900.


PRICES OF OIL AND COAL

0

2

4

6

8

10

12

14

16

18

1985 1990 1995 2000 2005 2010 2015

€/G

J olie

Coal

Prices Oil and Coal

The prices of primary fuels oil and coal are rising steadily.As you see coal still is feasible and compatible as fuel


Prices Fuels

The prices of all AFR are rising.

PRICES OF FUELS

-5,0

-4,0

-3,0

-2,0

-1,0

0,0

1,0

2,0

3,0

4,0

2004 2005 2006 2007 2008 2009 2010 2011 2012€/G

J RDF

Animal Meal

Coal


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!

Prices of (existing) AFR are rising


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%

Key performance data 2008 Best Practice Plant:Dutch Cement Maastricht (The roots of IC&C)


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)

March 2012 GFC Aachen IC&C 9March 2012 9

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

If going into AFR; Control:

• 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


IC&C some recent examples

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

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

Go new ways…. Make it possible… !? Continuation of reliable operation Restriction often are emissions Emission limitations such as Mercury /Smell / NOx abatement


IC&C offers support


IC&C Mercury / smell abatement 1

Modular adsorption system consisting of several containers

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

kiln

E filter

5 Adsorptie

containers

IC&C

E filter

containers

filter

containers

Mercury / smell filter

IC&C

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


IC&C Mercury / smell abatement 2


IC&C Uptake mercury, smell and dioxins abatement

Uptake (adsorbtion)

Components Mercury Hg Acetaldehyde Dioxins

Temperature oC 130 130 130

Flow 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


IC&C DeNOx

Burner performance optimization; primary measure SNCR in long kilns by injection of urea granulate (3 mm)

Result: 60% reduction of NOx DeNOx by Flame cooling, without increasing fuel consumption

urea

kiln inlet

air

IC&C DeNOx


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

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


IC&C: Who can we support

March 2012GFC Aachen IC&C 18

Thank you for your attention.

Questions?

March 2012GFC Aachen IC&C1 'How to make money using AFR despite rising prices Wim M.G.M. Heldens...

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