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Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Klaus-Martin Meier Edward Le Ted.

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Presentation on theme: "Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Klaus-Martin Meier Edward Le Ted."— Presentation transcript:

1 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Klaus-Martin Meier Edward Le Ted T Reese Cadence Environmental Energy Maximizing the Benefits of Staged Combustion

2 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Europe has 2 nd most plants in World EUROPEAN CEMENT KILNS ARE WORLD LEADERS Europe is 3 rd largest producer of cement in World World Leader in Alternative Fuel Use World Leader in Meeting Strict Environmental Compliance

3 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Kilns currently running at lower utilization rates Production Opportunity lies in improving efficiencies and reducing operating costs No current incentives for increasing production

4 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Alternative Fuels Europe operating at 28% fuel substitution rate Opportunity exists in optimizing current alternative fuel programs High percentage of kilns invested in alternative fuel programs

5 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Environmental Requirements Regulations will continue to tighten Optimized performance will help to meet new requirements NOx emission requirements will become more stringent Is it realistic to expect less environmental compliance?

6 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Lower Fuel Costs What Does Everyone Want? Operation Efficiencies Lower Emissions

7 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Lower Fuel Costs What Does Everyone Want? Improved Operation Lower Emissions HOW DO YOU GET ALL THREE?

8 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Transition from Staged Fuel Combustion to… Staged Combustion Benefits Staged Air Combustion

9 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Reduce Baseline NOx Improve SNCR Efficiencies Increase Alternative Fuel Use Staged Air Combustion Benefits

10 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Staged Air Combustion Staged Air Combustion (SAC) puts mixing energy and combustion air in a critical kiln area Addresses: gas stratification temperature imbalance

11 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Staged Air Combustion SAC reduces kiln gas stratification Effectively utilizes the excess oxygen for CO reduction SAC OFF Kiln Gas Stratification SAC ON NO Kiln Gas Stratification

12 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Staged Air Combustion BENEFITS CO reduction NOx reduction Higher AF rates Heat transfer Reduces excess air in burning zone

13 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Mixing Air Injection Whole tires or Alt. fuels at the feed shelf. Preheater or Precalciner Kiln Staged Air Combustion

14 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level National Cement - Ragland, Alabama USA Kiln information Clinker production = 108 tph Heat consumption = 3.1 MMBtu/t kk Type of fuels = Coal, TDF, Saw Dust, Glycerin

15 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Staged Air Combustion BaselineWith SAC O2O2 3.0 % PH CO1200 ppm410 ppm1150 ppm Stack NO x 475 ppm314 ppm %Alt. Fuel Substitution21% 26% Process Modification

16 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Staged Air Combustion Multiple Benefits Operational Flexibility Emission Reduction Cadence Mixing Air Improved Alternative Fuel Usage Heat Consumption Improvement

17 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln Uncontrolled NOx (mg/Nm3) Normal Ranges

18 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln Controlled NOx (mg/Nm3) BAT (Best Available Technology) for NOx Abatement Normal Ranges

19 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln (mg/Nm3) BAT (Best Available Technology) for NOx Abatement CURRENT – 500 mg/Nm3 Meeting Environmental Compliance BAT does not guarantee meeting NOx requirements

20 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln NOx (mg/Nm3) BAT (Best Available Technology) for NOx Abatement Meeting Environmental Compliance Current NOx requirement is 500 mg/Nm3 SNCR AGENT REQUIRED

21 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level PC Kiln PH Kiln Long Kiln White Kiln Lime Kiln NOx (mg/Nm3) BAT (Best Available Technology) for NOx Abatement MORE SNCR AGENT REQUIRED Meeting Environmental Compliance NOx regulations expected to further decrease permit levels AMMONIA SLIP HIGHER REAGENT COST DETACHED PLUME CONCERNS

22 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Alternative Fuel 5-8% Increase Staged Combustion Benefits Preheater Cement Kiln Improve SNCR Efficiencies 20-25% Molar Efficiency Improvement Reduce Baseline NOx mg/Nm3 (10%) mg/Nm3 (16%)

23 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Reduce Baseline NOx mg/Nm3 (37%) mg/Nm3 (31%) Staged Combustion Benefits Lime / White Cement Kiln Improve SNCR Efficiencies

24 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Ash Grove Cement Capitol Aggregates Buzzi Unicem California Portland Cement Essroc Cement Holcim Cement Lafarge Cement Lehigh Cement St. Lawrence Cement Over 21 line installations Proven Technology Over 37 years experience

25 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Aalborg Cement Denmark Akmenes Cementas Lithuania JSC Krasnos Belarus Kirchdorfer Cement Austria Lafarge Cement England* Holcim Spain* Holcim Belgium* Expanding…

26 Click to edit Master title style Click to edit Master text styles –Second level Third level –Fourth level »Fifth level Klaus-Martin Meier Edward Le Ted T Reese Cadence Environmental Energy Maximizing the Benefits of Staged Combustion Thank You! Come visit our team at Cadence Booth…


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