Enhanced usage of Alternative Fuels in Cement Industry

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ALTERNATE FUEL --- MSW RDF

BY

V. P. TONDAPURKAR

ROCHEM GREEN ENERGY PVT LTD

MUMBAI 51

UNDERSTANDING OF CEMENT INDUSTRY - Cement Production India

Year Capacity Mn T2010 228.3

2014 255.6

2024 666

Plant above 1 MnTonne/Yr contributes 88% of Total Prod.

Cement Production Growth – 8.5 - 10% /Annum .

Investment – Rs-500 Crore/Million tonne.

Per Capita Consumption - 178 Kgs

Capacity Utilisation > 90%

Enhanced usage of Alternative Fuels in Cement Industry

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Enhanced usage of Alternative Fuels in Cement Industry

UNDERSTANDING OF CEMENT INDUSTRYCement Production is Energy Intensive & Carbon Intensive Process

Thermal Energy Consumption is 650 –to - 750Kcal/kg

Electricity Consumption 70 – to-90Kwh/Ton

Thermal & Electric Energy accounts for 40% of Operation Cost

Cement Production accounts for 5% of Global MM CO2 Emissions

Let us understand the challenges of Cement industry. ---

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SOURCEhttp://ibm.gov.in/IMYB%202011_Cement.pdfhttps://www.pwc.in/assets/pdfs/industries/power-mining/icc-coal-report.pdfhttp://dipp.nic.in/English/Performance_Cement_Industry.pdfhttps://law.resource.org/pub/in/bis/S11/is.12770.1989.pdf

CHALLENGES OF THE CEMENT INDUSTRY

Substitution of Traditional Fossil Fuel with Alternative fuel

Reduce energy Cost using RDF as energy source

Co-process RDF using Cement Kiln – Dual Effect

o Energy Gain

o Solves problem of Space & Environ Impact

Elemental Composition Of RDF.

MSW –RDF Composition is region based

we will Look at Requirements of the Cement Industry ----

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Enhanced usage of Alternative Fuels in Cement Industry

SOURCEhttp://dipp.nic.in/English/Performance_Cement_Industry.pdf

Requirements of Cement Industry for Co-Processing RDF

RDF must supply GCV/Material Value to cement KILN

Important parameters of alternate fuel –RDF- Be in proximity of the Values mentioned.

Let’s look at EU countries Who started using alternate fuels. 5

Enhanced usage of Alternative Fuels in Cement Industry

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Substitution rates for alternative fuels

EU 30% to 83%, USA 25%,

Japan 10%

INDIA 01%

TRIALS CONDUCTED

Canada Cement Lafarge Ltd.

1.A full year of trials

RDF used 10 to 50 % of the energy input a wet process cement

Refuse is shredded to 150 mm particle size

Air classified. RDF re-shredded 76 mm size

- Pneumatic feeding – No data released

(a phenomenon also reported by the Blue Circle Group)

Enhanced usage of Alternative Fuels in Cement Industry --- TRIALS USING RDF IN CEMENT KILNS

Enhanced usage of Alternative Fuels in Cement Industry --- TRIALS USING RDF

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The Gulf Coast/ BFI. I. Trials conducted At the substitution levels 20, 30, 40 %(of fuel feed), II. Results were reported to be satisfactory. III. X- ray diffractions & petrographic examination ResultsIV. No significant differences between cement Strength . RDF cement was superior in compressive strength

The BLUE CIRCLE –WESTBURY PLANT

Trial runs of up to five days. Fluff RDF particle size less than 2 in. (51 mm) It could be pneumatically fired into a kiln, with RDF supplying up to 30 percent of the energy to the kiln,

There were no observed changes either in chemical or physical properties of the clinker or in operating Performance of the kilns.

The only major problem expressed by Blue Circle has been “The need for more

reliable shredders -

Enhanced usage of Alternative Fuels in Cement Industry TRIALS USING RDF

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The only major problem expressed by Blue Circle has been the need for more reliable

shredders -. This is Where Rochem has proven record of producing Reliable Shredding. Let’s understand

Waste picked up by front loaders/overhead grab cranes

Primary Shredder waste conveyed to a drier for initial moisture removal

Then size based separation takes place – Air classification

Oversized fraction from Tromel Screen is sent to Magnetic Separation

Ferrous & non Ferrous is separated

Undersized heavies removed in screen separators – Compost

Inerts comprising of grit, sand, stones, C&D goes for Road

Coarse MSW goes to fine Shredder

PRECONDITIONING OF SOLID WASTE

Waste picked up

by front

loaders/overhead

grab cranes

Conveyed to

Primary Shredder

to improve

flowability

Primary Shredded waste conveyed to a drier for initial moisture

removal (Drier to utilize waste heat from energy producing device

to ensure no fossil fuel is burnt for providing heat of evaporation)

Dried Waste for

Inert and Metal

Removal

Rotary trommel for size based

separation

Undersized heavies removed in

screen separators – Inerts comprising

of grit, sand, stones, C&D

on

Oversized fraction from

Trommel Screen

Recyclables

Recovery

FerrousNon

Ferrous

Pre-conditioned

waste for energy

generation

Secondary

Shredder

Enhanced usage of Alternative Fuels in Cement Industry

Briquett

Briquetting m/c

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WHERE ROCHEM DIFFERS FROM OTHERS

1) RDF GENERATION PROCESS IS COMPLETELY AUTOMATED.

2) PROPER UTILIZATION OF SEGREGATION AND SORTING EQUIPMENT

TO PRODUCE PRODUCT OF CONSISTENT QUALITY.

3) BETTER QUALITY CONTROLS.

4) LONG TERM RDF SUPPLY CONTRACT CAN BE OFFERED.

5) ENRICHED EXPERENCE OF MSW – RDF MANAGEMENT

6) LOW COST TECHNOLOGY – LOW COST PROCESS

Enhanced usage of Alternative Fuels in Cement Industry

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WHERE ROCHEM DIFFERS FROM OTHERS - SELECTIONE MECHANISM OF TECHNOLOGY

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TO PRODUCE BEST QUALITY PRODUCT – RDF ’ FOR YOU

THREE SEPARATION SYSTEMS FOR HETROGENOUS ‘MSW “

DENSITY SEPARATION - SELECTION CRITERIA ❖Factors considered

Characteristics of material produced by the device:

Materials specifications for light fraction:

Air classifier design parameters:

Operational characteristics: Energy requirements, maintenance requirement, simplicity

of operation, noise, air emission

Site considerations: floor space & height, access

Magnetic and Electric field separation – FACTORS CONSIDERED

Magnetic separation -- Magnetic permeability >Separate ferrous from nonferrous metals

Electrostatic separation - Differing surface charge characteristics

Eddy current separation - Varying magnetic fields to induce eddy currents in nonferrous metals

Ash 10-13%

Chlorides 0.21

Sulphur 0.27

Volatile matter 53%

Gross Calorific Value 3000-3500 Kcal

Total moisture 15-20%

Av. Concentration of PM (mg/NM3) 49.5 (PCB limits: 150)

SO2 concentration (ppm) 21.80 (PCB limits:100)

NOX concentration 3.10 (PCB limits: 50)

RDF Size 100mm

RDF ANALYSIS

Parameters BEFORE TREATMENT AFTER TREATMENT

MSW RDFCalorific value (kcal/kg) 1500 3000-3500

Moisture content (%) 20-40 (max) 15-20

Bulk density (t/m3) 0.5 0.2

Feed size (mm) 1000 (max) 0-50

Ash (%) 10– 13 Dust (%) < 0.3 `Plastic (%) 4 – 6

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COAL VS RDF

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Enhanced usage of Alternative Fuels in Cement Industry

Price : Performance

WHERE ROCHEM DIFFERS FROM OTHERS - SELECTIONE MECHANISM OF OUR TECHNOLOGY

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performance characteristics OF Density, Eddy Current, Magnetic separation

Magnetic and Electric field separation-Selection of equipment- Factors ConsideredCharacteristics of material to be separatedMaterials specifications for separated materialsDevice design parameters.Operational characteristics: energy & maintenance requirement, simplicity

of operation, noise, air emissionSite considerations: floor space and height, access

Rochem is working across Four states to establish this Facility

Rochem is Supplying RDF as a substitute for Coal for last three Years to

i. Textile Mill Process house

ii. Paper Mills

iii. Power Palnts

Enhanced usage of Alternative Fuels in Cement Industry

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Rochem will be a Effective partner of Cement Industry in making RDF as successful Alternate Fuel saving Energy cost For Cement Industry

Let’s together understand the Issues involved

MAJOR ISSUES

When considering the use of RDF in cement plants, issues to be Addressed.

a) Handling properties of the fuel.

b) Ability to control temperature in the kiln

c) Effect of RDF combustion products on kiln coatings.

d) Effect of RDF combustion products on Clinker chemistry.

e) Changes in physical properties of clinker and cement.

f) Effect of using RDF on air emissions.

“RDF” & process issues – parameter

1) study that analyzed “RDF” composition, in particular nitrogen, sulphur, and chlorine content affirmed that the formation of nitrogen oxides is related to

i. The temperature of the kiln,

ii. The residence times,

iii. the types of burners, and the amount of nitrogen in the fuel.

2) in general, air pollutants are reduced when MSW is used as a fuel in cement kilns instead of fossil fuels & reductions in nox and so2 emissions are also cited in many studies.

Nitrogen content is linked to the formation of nox

The study showed that the content of nitrogen in rdf is lower than in fossil fuels (0.3-0.5% versus 1.5-2%),

It Means that nox emissions from RDF are lower than for fossil fuels, all other things being equal .

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Enhanced usage of Alternative Fuels in Cement Industry

Enhanced usage of Alternative Fuels in Cement Industry --- MAJOR ISSUES

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1. FEEDINGCement kiln fuels are fed pneumatically, need to design the RDF feeding system For pneumatic firing.The pneumatic firing of RDF is not unique to the use of RDF in kilns

2. ABILITY TO CONTROL TEMPERATURE ---

i. Variation in the amount & composition of fuels can affect temperature- +55deg Cii. Variations in Clinkering reaction makes temp control imp

3. EFFECT OF RDF ON CLINKER CHEMISTRY

Interaction among fuels & raw materials may affect the chemical properties of the cement clinker due to chemical composition of the fuel, especially ASH.

4. CHANGES IN PHYSICAL PROPERTIES OF CLINKER OR CEMENT

Two physical properties of research interest . 1. The grind ability of the clinker.2. Strength of the Cement

5. EFFECT ON AIR EMISSIONS -- No Effect on Air Pollution

Environmental and human health impact of using msw rdf

the use of msw implies a reduction of the use of fossil fuels in cement kilns

(heidelberg,2007; heidelberg, 2007; hashimoto etal, 2010).

many studies verify a net reduction in co2 emissions in comparison to fossil fuel

combustion

(UK ENVIRONMENT AGENCY, 2008; HEIDELBERG, 2007B; HEIDELBERG, 2007D; HASHIMOTO ET AL., 2010; HEIDELBERG, 2007A; U.S.

ENVIRONMENTAL PROTECTION AGENCY, 2008; GENON AND BRIZIO, 2008).

one study (u.s. environmental protection agency, 2008) also found that the

use of msw in cement kilns reduces methane emissions, the rationale being

that using msw as an alternative fuel avoids landfilling waste, a source of

methane emissions (METHANE IS APPROXIMATELY 25 TIMES MORE EFFECTIVE AT TRAPPING HEAT IN THE ATMOSPHERE THAN CARBON

DIOXIDE).

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Enhanced usage of Alternative Fuels in Cement Industry

Enhanced usage of Alternative Fuels in Cement Industry NO MAJOR ISSUES

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1. There were no changes observed in chemical or physical properties of the clinker

2. There were no changes observed in operating performance of the kilns

3. No specific reason that RDF affects the physical properties of clinker or cement

4. No significant build-up of alkali(or chemical constituent) has been observed.

5. No Effect on Air Pollution. No incremental Effect on Air Pollution was observed .

Favourable conditions for rdf – process

No modifications required in kiln .

Achieves greater efficiencies - blends of Rdf and coal are co-fired

i. These conditions are favourable for the burning of refuse waste.

ii. Pollutant emission implications of using rdf as a supplementary source of heat

in a cement kiln. - there is no increase in the emission levels of air pollutants

iii. no special firing technology has to be installed only the rdf handling system,

there is an upper limit for firing RDF (no more than 30 %)

The Technical advantages of co processing of alternate fuel in cement plant

co processing ranks higher in the waste processing hierarchy .

high flame temperature (2000°c) – ensures complete destruction of harmful pollutants

Residence time of combustion gases above 1000°c in excess of 3-4 seconds – ensures complete destruction of pollutants.

Complete destruction of organic compounds.

Total neutralization of acid gases, sulphur oxides & hydrogen, Chloride, by the activelime in the kiln load,in large excess to the stoichiometry.

Embedding of the traces of heavy metals in the clinker structure with very stable links (metallic silicates formation).

No production of by-products such as ash or liquid residue from gas cleaning.

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Enhanced usage of Alternative Fuels in Cement Industry - ADVANTAGES

Enhanced usage of Alternative Fuels in Cement Industry

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THe advantages of co processing of alternate fuel in cement plant produces overall environmental benefits by reducing releases to air, water and land.

maximizes the recovery of energy while ensuring their safe disposal

saving of non renewable fossil fuels by substitution of coal with waste.

savings are made through resource conservation and associated co2 Emissions.

reduced burden on TSDF

Immobilization of toxic and heavy material

Reduced nox emissions when using certain types of waste

USAGE OF RDF – CONCERNS

•It became apparent that even though there is an interest, there also is a concern

Discrepancies between controls applied

Dearth of technology & devices to monitor different emission parameters

parameters online.currently, devices available to monitor sox, nox & dust.

Ability to supply and feed rdf continuously,

Firing characteristics and ability to burn rdf in suspension,

Effect on rdf chemical composition & variations in composition on cement

quality & chemistry,

Long-term effects of RDF on kiln operation & cement production

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Enhanced usage of Alternative Fuels in Cement Industry

rdf – v/s – fossil fuel

1) The Genon and brizio study found a similar situation in terms of

sulphur content( 0.1- 0.2% for rdf versus 3-5% for fossil fuels),

and the authors concluded that problems

2) Regarding precipitation and clogging could be excluded. the

opposite, however, was found for chlorine (0.3-0.5% for rdf

versus 0.1% in coke)

3) Though this implies that the use of rdf can create problems, such

as the volatilization of chlorides. therefore, the composition of the

fuel used in kilns, can influence the pollutant emissions23

Enhanced usage of Alternative Fuels in Cement Industry

Data availabilityo Waste statistics not updated o documentation systems for tracing waste not known.o important to know the origin of waste & its composition ensure easy and safe co-

processing. –Rochem does its best to provide same for its customer

Segregation of wasteo All types of Waste are currently mixed & sent to cement plants for co-processing.

Waste segregation would help cement -Rochem provides for it’s Customer

Pricing for waste disposal

o The price for the disposal of waste depends on its specific characteristics, o Infrastructure required to handle & manage it ---

Rochem Has a very Flexible Pricing Policy Long term RDF supply contract can be offered

o Facilities and efforts required to pre-process it to make it suitable for co-processing in the kiln, --Rochem rids Cement Industry of pre processing issues

Enhanced usage of Alternative Fuels in Cement Industry

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NEXT STEPS

vital for the government to create a waste bank. That helps cement plants in determining the type, quantity of waste available, to implement the polluter pays principle and allow the market forces to decide the price of disposal

Till Waste Bank is created - Rochem will do its best in providing said information to the Customer.

Mission on Co- ProcessingNext Steps

The government should establish a national level mission on co-processing that will focus on establishing a legal and institutional framework to facilitate increased usage of alternative fuels and raw materials.

This will provide the legal framework required for increasing and promoting co-processing. The mission will set minimum prequalification criteria to be met by cement plants that intend to implement co-processing.

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Enhanced usage of Alternative Fuels in Cement Industry

• CONCLUSIONS

i. WE STRONGLY RECOMMEND USAGE OF ROCHEM MSW – RDF AS AN ALTERNATIVE FUEL IN CEMENT INDUSTRY.

ii. NO SPECIAL FIRING TECHNOLOGY HAS TO BE INSTALLED ONLY THE RDF HANDLING SYSTEM

iii. THE PROCESS OF CLINKER BURNING IN A ROTARY KILN CREATES FAVOURABLE CONDITIONS FOR THE USE OF ALTERNATIVE FUELS --- MSW - RDF

iv. CLINKER BURNING PROCESS COMPLIES WITH ALL REQUIREMENTS OF THE EU DIRECTIVE 92/C130/01 CONCERNING HAZARDOUS WASTE INCINERATION. [5]

v. THERE IS NO INCREASE IN DISCHARGES TO THE ATMOSPHERE,

vi. REDUCE ENERGY COST USING RDF AS ENERGY SOURCE

vii. PRODUCES BENEFICIAL EFFECTS ON AIR EMISSION & ASH RESIDUE WHEN USED AS A FUEL

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Enhanced usage of Alternative Fuels in Cement Industry

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I AM THANKFUL TO OUR DIRECTOR

1. MR. PRAYAS GOEL

2. MR. PRERAK GOEL

FOR PERMITING ME TO PRESENT THIS PAPER

THANKS TO ALL OF YOU, FOR PATIENT LISTENING