Prezentare Holcim Engleza

Co Processing of AFR in Holcim and its

Enhancement with CFD

Anne Dekeukelaere and Tom Lowes, CIE AFR BD

2

Holcim Group Support AD/TML Global Fuels Conference London 5th Feb

Scope of Paper

Holcim

Waste and co-processing

Rules of the game

Technical Issues

Computerized Fluid Dynamics

Conclusion

3


Who is Holcim?

With majority and minority interests in more

than 70 countries on all continents, Holcim is

one of the world's leading suppliers of

cement, as well as aggregates (gravel and

sand), concrete and construction-related

services.

Employees: 61,000+

Production capacity: > 160 Mio tons

Net sales 2005: 18.5 billion CHF

Member of World Business Council for

Sustainable Development (WBCSD)

Selected as an index component for the Dow

Jones Sustainability World Index and the

European Dow Jones STOXX Sustainability

Index

4


Holcim presence: balance between emerging and

mature markets

USA

Canada

Ecuador

Chile Brazil

Venezuela

Colombia

South Africa

Madagascar

Australia

New Zealand

Philippines

Vietnam

China

Lebanon

Austria

Germany

Switzerland

Belgium

France

Spain

Morocco

Guinea

Ivory Coast

Burkina Faso

Russia

Guayana

Peru

Czech Republic

Hungary Croatia Estonia

Italy

India

Argentina

Slovakia

Tanzania

La Reunion

Cambodia

Sri Lanka Egypt

Rumania Bulgaria

Uzbekistan

Malaysia

Thailand

Macedonia

Mexico

Honduras

El Salvador

Costa Rica

Nicaragua

Dominican Republic

Netherlands

Cyprus

Haiti

Singapore

Nigeria

Guatemala Caribbean

Azerbaijan

USA

Canada

Ecuador

Chile Brazil

Venezuela

Colombia

South Africa

Madagascar

Australia

New Zealand

Philippines

Vietnam

China

Lebanon

Austria

Germany

Switzerland

Belgium

France

Spain

Morocco

Guinea

Ivory Coast

Burkina Faso

Russia

Guayana

Peru

Czech Republic

Hungary Croatia Estonia

Italy

India

Argentina

Slovakia

Tanzania

La Reunion

Cambodia

Sri Lanka Egypt

Rumania Bulgaria

Uzbekistan

Malaysia

Thailand

Macedonia

Mexico

Honduras

El Salvador

Costa Rica

Nicaragua

Dominican Republic

Netherlands

Cyprus

Haiti

Singapore

Nigeria

Guatemala Caribbean

Azerbaijan

5


Cement industry characteristics

Cement Is an Energy and Capitally Intensive Industry and annually Holcim needs to acquire:-

@ 18 mtpa of coal or equivalent @ 12 Twh of Electricity

The high thermal Energy comes from the needs to sinter Limestone and Argillaceous Components (Al2O3, SiO2, Fe2O3) at @ 1450C to produce clinker, that is then ground to cement with gypsum and in some cases extenders

Energy costs run at @ 30 % of production costs and @ 65% of variable costs

At current UK Greenfield Site Costs 180 /tpa) to renew Holcim Global capacity would cost in excess of $ US 40 Billion

A typical New Plant is a calciner with 2.5 tpa capacity

6


Sustainable development and Holcims mission

Sustainable Development is a core

element of Holcims Mission:

Our mission is to be the worlds most respected and attractive company in our industry creating value for all our stakeholders.

Our goal is to continually demonstrate our

commitment to sustainable Environmental

Performance, and visibly play a leading

role in Social Responsibility within our

sphere of influence.

7


Holcim triple bottom SD

Because of its Energy Intensive nature and Size of

Installations, Holcim is very much aware and is

committed to the needs for Sustainable Development

Social progress

Economic growth

Environmental performance

Sustainable

Development

8


Our SD priorities

We have outlined strategies and set targets in

clearly defined priority areas including:

Occupational health and safety (OH&S)

Climate and energy

Community involvement

Stakeholder relations

Sustainable construction

9


Field for

AFR-BD

BUILDING

infrastructure

Natural

Resources ENERGY

fuels

Emissions CO2

Conservation of non-renewable natural resources

QUARRY

limestone

QUARRY

aggregates

MILL

cement

KILN

clinker

READY MIX

concrete Operations

Substitutes Recycled

building

materials

By-products

from other

industries

Alternative

fuels / waste

materials

Holcim is

increasing the

use of

alternative

fuels & raw

materials

Recovery from energy and material from selected waste leads to

the conservation of non-renewable natural resources

10


Emissions from fossil fuel and waste as fuel

Waste incineration & cement

manufacturing

Waste as fuel in cement

manufacturing

GHG

GHG

GHG Emissions

Waste

Incinerator Cement plant + Cement plant

Waste Fossil Fuels Waste Fossil Fuels Resources

11


The GTZ-Holcim partnership

GTZ is a German-based organization promoting international cooperation on sustainable development. It operates on a worldwide basis.

The Holcim-GTZ partnership has produced guidelines on Co-Processing of Waste Materials in Cement Production.

The purpose of these guidelines is:

to reduce deficiencies in waste management;

to provide objective information about co-processing in the cement industry;

to propose realistic and achievable standards, suitable for and acceptable to all stakeholders involved;

to enable capacity building and to offer a joint platform for institutions and

companies active in the field of co-processing.

See www.coprocem.com

12


Scope of Paper

Holcim


Rules of the game

Technical Issues


Conclusion

13


What is co-processing?

Co-Processing refers to the use of waste materials in

industrial processes, such as cement, lime, or steel

production and power stations. It is a recovery of energy or

material from waste. The cement industry is the only industry which does both at the same time

Calciners all Shapes

and Sizes,

depending on

Manufacturer, need

CFD to otimise for

AFR and PC

14



What is AFR Co Processing in Holcim :- It is the preservation of natural raw materials by the use of

Industrial Waste or by products as a source of Energy and or Raw Materials for Cement Production, without:-

- Increase in Emissions

- Degradation of Cement Quality

This is no easy task plus as most of the Holcim World is a sold

out market and wastes are not coal or well prepared raw materials.

Considerable effort and expertise has needed to be developed and investments made to ensure Emissions and Cement Quality Standards are maintained as well minimal production loss occurring

15



What is AFR Co Processing in Holcim (Contd) :-

The minimisation of the impact on production is done via the

consideration of the details of the total process from the

service(TSS) to the Country/Community in helping with their

waste problem to the final cement product and its customers

Holcim has developed a series of AFR Co Processing Business

Units Globally to acquire and prepare AFR for the Cement

Process

Holcim has developed detailed understandings and capital

investment required to process waste into a fuel for all types of

cement plants, in order to ensure its Co Processing Goals are

achieved Globally

16


Holcim is increasing its thermal substitution rate

Acid tar deposit Landfilling Industrial wastes Hydrocarbon sludge's

Plastics mixtures

Used tires

Thermal Substitution Rate by Alternative Fuels

0

5

10

15

20

25

30

35

40

Africa Asia-Pac Europe LatAm NthAm Group

% t

he

rma

l e

ne

rgy

fro

m a

lt.

fue

l

1990 2005 2008 Forecast

22


Waste Management Hierarchy

Cement

Industry

25


Scope of Paper

Holcim


Rules of the game

Technical Issues


Conclusion

27


The 9 principles of our AFR policy

Elements of

sustainability

I. Act as a partner to society by offering waste

management solutions

II. Keep our environment safe

III. Add value to our core business

What we will do IV. Ensure occupational health & safety

V. Refuse the listed banned wastes

VI. Guarantee the quality of our products

How we will do it VII. Comply with the relevant regulations and

promote best practices

VIII. Monitor and control the inputs, process, products

and emissions

IX. Communicate transparently

When using AFR our goal is to:

No Increase

in Emissions

No volatile

organics in

ARM and

EMR

Consistent

with GTZ PPP

29


Scope of Paper

Holcim


Rules of the game

Technical Issues


Conclusion

30


Technical Issues

The Technical Issues associated with the use of AFR are significant but fascinating.

Investment in the appropriate Preparation and Handling systems ($$$s) application of Rigorous QA/QC and OH&S protocols are necessary precursors of a good Co processing operation.

Once these are taken care of then the main issues to be taken care of are:-

Combustion/Emissions

Cement Quality

Production

31


AFR Combustion /Emissions

Issues come from several areas:-

Ensuring that the AFR has sufficient TOM&T (Temperature,

Oxygen, Micro mixing and Time )for high DREs, hence avoiding increased organic emissions.

- Need 2 secs > 800C and 1% O2 micro mixed with the fuel to

ensure all organic bonds and broken and combusted

Controlling the total metals inputs to ensure that emissions limits

are met.

Ensuring that the impact traditional raw materials and their

impact on SO2, CO, VOC Dioxins, plus other micro pollutants

are fully understood and tracked

- Need to ensure that these impacts are separated from AFR, as

this has led to erroneous conclusions on the impact of AFR on

emissions being reported

32



For AFR via the Flame, the TOM&T is far in excess of what is needed for complete combustion, even with the most strong

organic bond.

The US EPA require a demonstration of a DRE of 99.99% for

Haz waste in both the flame and calciners to get a permit

A recent test burn carried out by SINTEF for pesticides on the

Holcim Plant in Vietnam resulted in > 99.9999, with numbers < 9

coming from LODs

33



The next slides

Shows how emissions of D&Fs, VOC and HCl with Haz waste firing into the burning at 20% TSR with 1.5% Cl

has no influence on these emissions.

How the 40% TSR with tyre chips in a calciner has no

impact on D&Fs, but give indications how insufficient test points could give erroneous conclusions due to the

impact of organic in the raw materials

How in the trials above the tyre chips drop the overall

NOx emissions

Dioxins, HCl and VOC vs Baseline and RLF

0

5

10

15

20

25

RLF RLF B RLF B B RLF RLF RLF B RLF RLF

Baseline or RLF

HC

l, V

OC

pp

m

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

Dio

xin

s n

g/N

m3

te

q

HCl VOC's Dioxins & Furans Linear (VOC's) Linear (HCl)

40% TSR from tyre Chips in Calciner with RT @

2secs

The variation is due to the

variation of organic C in the raw

materials

Drop in NOx by 27% with Tyres Chips at an 24%

Overall TSR

38



The WHO safe limit for Daily Dioxin intake is 1 pg/kg.bwt.day

At 0.1 ng TEQ/Nm3 at 10% O2 and dioxin trail with a stack dilution factor to the MEI of 100,000 results in 100 times lower than the WHO.

The emission from the Cement Industry stacks that comes closest to WHO Air Quality standards is NOx, with between 5 and 20% of the limit for the MEI resulting from plume dispersion modelling.

AFR normally drop the NOx emission, a typical drop of 20% with 20% TSR, as demonstrated means no emission of NOx from the AFR hence more than compliant with the Incinerator limit of 200 mg/Nm3 from the AFR

This indicates that there can often be an overall reduction in emissions with AFR and a positive impact on the Integrated Environmental Index, as is in fact needed in the UK to get and AFR Permit

39



Metals emissions are normally not a problem as the Cement Industry can normally readily meet the 2000/76/E directive for :-

Class 1 0.05 mg/Nm3 at 10% O2 Class 2 0.05 mg/Nm3 at 10% O2 Class 3 0.5 mg/Nm3 at 10% O2

This is because of the high retention factors for metals within the clinker generally > 99%, that means little goes up the stack.

For the more volatile metals (Hg, Cd and Tl) with lower retention factors the specification of AFR is controlled to ensure that these emissions limits are readily met

Holcim's average Hg emission throughout the group is < 0.02 mg/Nm3 at 10% O2, coming primarily from coal and raw materials

The WHO annual AQS limit for the MEI is 1ug/Nm3 , the above emission by stack dispersion modelling is < 1% of the AQS

41


Cement Quality

There is little impact of AFR on Cement Quality providing the

guidelines are followed:-

There are two main potential problem areas for the cement plant

and its customers are:-

Variable burning

- Taken care of via QA/QC and CAPEX

Change in clinker chemistry that impact on key properties

- Taken care of via specification of AFR, ensure no metal in clinker is >

0.2% from fuel,and raw materials, plus adjustment of raw materials as

needed e.g

- Limiting MBM or sewage sludge so that P2O5 does not go > 0.3% in

the clinker

- Increase in raw material LSF by 4% to incorporate 20% TSR with rice

hulls

42


Cement Quality

The impact of metals contained in the clinker can cause concern

and phrases such as pollutants not transferred to the product appear in EU missives.

Metals may be pollutants once they go up the stack and hazardous

in their powder form, but in capsulated in the clinker mineral

structure they are primarily inert and do not leach.

As part of the Applications of the AFR Policy, Holcim will be

taking regular clinker sample and carrying out leaching tests

Holcim in its survey of 64 kilns has not found a trend between AFR

and metals in clinker, indicating that the clinker metals are coming

primarily from the raw materials, the data from this survey is shown

on the next slide, where although the % TSR has gone from 10 to

20% over 6 years the metals in the clinker remain essentially the

same

43


Cement Quality

44


Production

The biggest concern of the Cement Plant Manager with using AFR is its impact on Production rate.

QA/QC, Preparation and Handling resolves a lot of basic potential problems, however natural laws come into force that need innovative solutions to mitigate production loss.

Generally AFR is wetter than coal/petcoke and cannot be readily dried

1tph of extra H2O in the system generally equates to 2 tph production loss, if the process is fan limited

Hence flow bottlenecks have to be found and eliminated or exhaust fan capacity increased, etc

Water decreases flame temperature and hence reducing heat transfer and potentially reduces kiln output rate as a function of TSR burner configuration

Generally AFR is coarser than coal/petcoke and hence combusts more slowly and again potentially reduces production rate as a function of TSR and calciner configuration

45


Production

Burner and Calciner Configurations and Design need to be considered to maximise % AFR as a function of its type, properties and quality

The Cement Plant is not a ideal experimental tool, due to:-

Needs to Produce Lead time Cost of the modifications

Holcim over the last 2 years have found that working with CINAR on the use of Computerised Fluid Dynamics (CFD) to optimise the Combustion and Heat Transfer process in both the Burner , Kiln and Calciner a low cost shortcut to increasing the use of AFR

46


Scope of Paper

Holcim


Rules of the game

Technical Issues


Conclusion

47


Computerized Fluid Dynamics (CFD)

Over the last 2 years Holcim with CINAR have used CFD to:-

Optimise AFR injection points into calciners and increase the % AFR

Assess the impact of AFR and burner modification on emissions as a prerequisite to applying and getting permit for trial

Assess the impact of AFR into mid kiln on emissions Assess how micro mixing of O2 with the AFR can be optimised to

get better combustion using Swirling Air and Mixing Fan system Develop the optimum burner and calciner configurations for an

8000 tpd plant for 65% TSR from Rice husks and Palm Kernel Shells in Indonesia

- This is Holcim biggest Biomass projects involving @ 400,000 tpa of Biomass

Assess how the impact on Kiln hood geometry and flow misalignment around the burner resulting in high CO and kiln build ups can be best overcome.

- Typical prediction are shown on the next slides

49


51


Computerized Fluid Dynamics (CFD)

The Tertiary Air take off from the side of the kiln hood is producing

more flow around the burner on one side than the other

Apart from giving poor combustion on one side of the burner, it also

induces a swirling flow that moves the coal into a low O2 region

which produces more CO and build up.

The cheapest potential solution is a wedge in the cooler throat to

direct more flow to side the has the lowest air flow.

This has to be done before AFR via the burner can be considered.

Without CFD the cause or the solution would not have been

obvious

CFD to a powerful tool ,do not just play with it USE IT, as Holcim

has/is doing in North America, Spain, Mexico, Switzerland and the

Philippines, with planned activities in other GCs.

52


Scope of Paper

Holcim


Rules of the game

Technical Issues


Conclusion

53


Compared to other cement producers:

Holcim realized that AFR is a complete business line and not just a

procurement activity - Communication / lobbying - Marketing and channel management / customers - Production - HR

Holcim is driving the AFR market development

A comprehensive know how of all aspects of co-processing is available

Main competitive advantages of Holcim AFR business

compared to other players in the value chain

Compared to other waste management solutions than co-processing in cement kilns:

Kilns are available (with potential global coverage)

Know How in co-processing is available

Co-processing is an increasingly accepted sustainable waste

management solution

Strong public private partnerships of Holcim

54


Benefits of co-processing

Provides a permanent solution to waste management

problems

Lessens reliance on fossil fuels

Preserves natural resources

Reduces emissions and greenhouse gases

Saves on fuel costs

In short . . .

Co-processing is the environmentally-friendly

alternative for responsible industries.

Documents

Prezentare Holcim Engleza