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March 2012GFC Aachen IC&C1 'How to make money using AFR despite rising prices Wim M.G.M. Heldens Manager Sustainable Projects IC&C B.V. Independent Clinker.

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Presentation on theme: "March 2012GFC Aachen IC&C1 'How to make money using AFR despite rising prices Wim M.G.M. Heldens Manager Sustainable Projects IC&C B.V. Independent Clinker."— Presentation transcript:

1 March 2012GFC Aachen IC&C1 '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

2 March 2012GFC Aachen IC&C2 Mission IC&C: Make Money From Sustainability! Sustainable Development Strategy IC&C Energy EmissionsAlternative fuels / mat. Max Min Profit Maintain Quality and production level

3 March 2012GFC Aachen IC&C3 Prices Cement Mature Markets: The cement price in the USA is the same as in 1900.

4 March 2012GFC Aachen IC&C4 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

5 March 2012GFC Aachen IC&C5 Prices Fuels The prices of all AFR are rising.

6 March 2012GFC Aachen IC&C6 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 AFRs! Prices of (existing) AFR are rising

7 March 2012GFC Aachen IC&C7 95% alternative fuels 50 % biomass Fuel price < 2, $ 2.80 / ton clinker (normally 12, $17 / ton clinker!) 700 kg CO 2 / ton clinker (normally 820 kg CO 2 / ton) CO 2 reduction 20% achieved by biomass NOx reduction 50% by SNCR urea SO 2 reduction 80% Key performance data 2008 Best Practice Plant: Dutch Cement Maastricht (The roots of IC&C)

8 March 2012GFC Aachen IC&C8 Use profitable alternative AFRs, 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)

9 March 2012GFC Aachen IC&C9March 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:

10 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 2012GFC Aachen IC&C10 IC&C some recent examples

11 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 2012GFC Aachen IC&C11 IC&C offers support

12 March 2012GFC 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

13 Size and costs At ~ Nm3/hr T~130 o C 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: / container/year Total space requirement for 5 units is about 20 m x 20 m March 2012GFC Aachen IC&C13 IC&C Mercury / smell abatement 2

14 March 2012GFC Aachen IC&C14 IC&C Uptake mercury, smell and dioxins abatement Uptake (adsorbtion) Components Mercury HgAcetaldehydeDioxins TemperatureoC130 FlowNm3/hr Inlet concentrationmg/Nm30,123420,812 ng/Nm3 Outlet concentrationmg/Nm3< 0,001< 1< 0,05 ng/Nm3 Limitmg/Nm3< 0,05 < 0,05 ng/Nm3

15 March 2012GFC Aachen IC&C15 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

16 March 2012GFC Aachen IC&C16 IC&C New dryer technology PAD PAD Pulverised Air Dryer: Biovalor Is a non thermal separator of liquid and solid components No heat required: 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

17 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 2012GFC Aachen IC&C17 IC&C: Who can we support

18 March 2012 GFC Aachen IC&C18 Thank you for your attention. Questions?


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