how to make money using afr despite rising prices’
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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
March 2012 GFC Aachen IC&C 2
Mission IC&C: Make Money From Sustainability!
Sustainable Development
Strategy IC&C
Energy EmissionsAlternative fuels / mat.
Max
Min
Profit
Maintain Quality and production level
March 2012 GFC Aachen IC&C 3
PRICES OF CEMENT IN USA
90
100
110
120
130
140
150
160
1880 1900 1920 1940 1960 1980 2000 2020
$ of
201
1Prices Cement
Mature Markets: The cement price in the USA is the same as in 1900.
March 2012 GFC Aachen IC&C 4
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
March 2012 GFC Aachen IC&C 5
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
March 2012 GFC Aachen IC&C 6
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
March 2012 GFC Aachen IC&C 7
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)
March 2012 GFC Aachen IC&C 8
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
March 2012 GFC Aachen IC&C 10
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
March 2012 GFC Aachen IC&C 11
IC&C offers support
March 2012 GFC Aachen IC&C 12
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
March 2012 GFC Aachen IC&C 13
IC&C Mercury / smell abatement 2
March 2012 GFC Aachen IC&C 14
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
March 2012 GFC Aachen IC&C 15
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
March 2012 GFC Aachen IC&C 16
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
March 2012 GFC Aachen IC&C 17
IC&C: Who can we support
March 2012GFC Aachen IC&C 18
Thank you for your attention.
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