Practical Aspects of Alternative Fuels cpi · 2009-03-26 · Practical Aspect of Alternative Fuels...
Transcript of Practical Aspects of Alternative Fuels cpi · 2009-03-26 · Practical Aspect of Alternative Fuels...
Practical Aspect of Alternative Fuels Usage
Mark MutterCement Performance International
Practical Aspect of Alternative Fuels Usage
Aims of PresentationThe alternative views of alternative fuelsSuccess with alternative fuels – technical vs. human factorsAlternative fuels trialsOperating with multiple alternative fuelsThe public perspectiveSummary
The alternative views of alternative fuels
• The Corporate View• The Operational View• The Quality View• The Regulators View• The Public View
Success with Alternative Fuels
• What are the key factors in using alternative fuels?– Technical and Quality Aspects?– Public Relations Programme?– Regulatory aspects?– Supply and specification issues?– Financial Issues?
The key to Alternative Fuels Success
Solving the human aspects is at least as important as solving the technical aspectsEx: Relationships with the regulator
Relationships with the suppliersBuy-in from employeesBuy-in from engineering, quarry etc
Alternative Fuels Trials
• Relationship and communication with the regulator– Length of trial and optimisation period– Agreeing baseline periods– Procedures– Maintaining flexibility– Agreeing “special” trials– Interpretation of the results– The “what if” scenarios
Alternative Fuels Trials
• Relationships with fuels (and materials) suppliers – Does the supplier understand the cement manufacturing process?– What quality control procedures are in place?– Will the material suit the trial equipment?– Who is responsible for the trial equipment?– Is there sufficient supply of material for the trial?– What about other materials suppliers – coal, coke, bauxite etc.?
Alternative Fuels Trials
• Employees and in-house relationships – Employees could and should be the best form of PR– Quarry must be informed of the importance of consistent feed– Engineering need to understand the materials handling characteristics– Kiln burners need to understand the objectives of the trial
Alternative Fuels Trials
•Timing of trials – Good forecast of clinker stock to last through the trial– Anticipate drop in output/some off spec– How long to optimise the process?– All resources available – engineering and equipment– What are the other environmentally “sensitive” parts of the plant – what actions can be taken to reduce the impact?
Operating with multiple alternative fuels• The plants with negative or neutral fuels costs tend to be those operating with a number of alternative fuels• Fuels tend to start off at negative cost and then tend towards zero as other uses are found for them• Therefore need a long term programme to replace those with low revenue with newer, high revenue streams• Quantities do not have to be large as long as they have a CV and are contributing to revenue
Operating with multiple alternative fuels
• Upside
– reduced operating costs– carbon neutral fuels– reduction in landfill/incineration– gives flexibility– increases the learning within the organisation and the willingness to take on new fuels
Operating with multiple alternative fuels
• Downside– Management of the fuels requires resource– Impact upon laboratory testing and storage of samples– Impact upon emissions when one fuel is not available– Inter-works competition for fuels– Variable overall “fuel mix” quality– Loss of output/increased fuel consumption
Operating with multiple alternative fuels – an example
Resource required to ensure supply
Proven technology but fats in summer
Negative but decreasingCompetition
Variable phosphateGood NOx reduction
Animal meal
Good delivery schedule in place
Unsuitable feeding system from supplier
Very negativeCO creation good for NOxNot good for build-up
Tyres/car frag
In house supplierDependent upon chemical industry
Management of tank farm –safety and environment
Negative but stable
Good CVStabilized flameMultiple points of injection
RLF
ManagementHandlingCostProcessFuel
Operating with multiple alternative fuels – an example
Simple – take what available
Same as RLFSlightly negative
Good NOx reductionHigher fuel consumption
Waste water
Availability dependent upon refinery
Simple – as per petcoke
Highly negative but low volume
Caused high NOx
Refinery coke
ManagementHandlingCostProcessFuel
The public perspective
• Use of Alternative Fuels still not understood• Still seen as using cement kilns as incinerators• Other factors get dragged into the discussion• Generally the regulator gets stuck in the middle• Need to be open and honest with the public• Environmental improvements on the back of the fuels – should not be greedy!• Make sure the plant is in order before starting trial!
The public perspective - tools
• Employees and getting the message right• Plant visits and public exhibitions• ISO 14001/EMAS Schemes• Sponsorship of local events• General good communications with the community• Appreciation of history
Summary
• The human relationships are as important (if not more) than thetechnical issues.• Need a long term programme to ensure that there is a steady stream of materials to use• The plant needs to be in order before a trial is started• Ensure that the suppliers are on board• Make sure all of the plant personnel understand the objectives of the trials• Support the regulators and do not put them in a difficult position
Practical Aspect of Alternative Fuels Usage
Mark MutterCement Performance International