7holcim PDF

Co Processing of AFR in Holcim and its Enhancement with CFD
Anne Dekeukelaere and Tom Lowes, CIE AFR BD
Scope of Paper
Holcim Waste and co-processing Rules of the game Technical Issues Computerized Fluid Dynamics
Conclusion
Holcim Group Support
AD/TML Global Fuels Conference London 5th Feb
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:
Production capacity: Net sales 2005:
61,000+
> 160 Mio tons 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
3
Holcim presence: balance between emerging and mature markets

Austria Canada Germany Switzerland Estonia Croatia Hungary Rumania Bulgaria Macedonia Czech Republic Slovakia
Russia
USA
Mexico Guatemala Honduras El Salvador Nicaragua Costa Rica Colombia Ecuador Peru
Netherlands Belgium France Italy Spain Dominican Republic Morocco Caribbean Haiti Venezuela Guinea
Ivory Coast Nigeria Burkina Faso Guayana
Azerbaijan Uzbekistan China Vietnam Thailand Cambodia Philippines Malaysia Singapore
Lebanon India Cyprus Sri Lanka Egypt La Reunion Madagascar Tanzania
Chile
Brazil Argentina
South Africa
Australia New Zealand 4
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
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.
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 Economic growth
Sustainable Development
Environmental performance
Social progress
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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
Conservation of non-renewable natural resources

Emissions
Field for AFR-BD
CO2 KILN clinker MILL cement READY MIX concrete BUILDING infrastructure
Operations
Natural Resources
QUARRY limestone
ENERGY fuels
QUARRY aggregates Recycled building materials
Substitutes
Alternative fuels / waste materials
By-products from other industries
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
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Emissions from fossil fuel and waste as fuel

Waste incineration & cement manufacturing Waste as fuel in cement manufacturing
GHG
GHG
Emissions
GHG
Waste Waste Incinerator
Fossil Fuels
Resources
Waste
Fossil Fuels
Cement plant
Cement plant
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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
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Scope of Paper
Conclusion
12
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
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Waste and co-processing

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
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Waste and co-processing

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
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Holcim is increasing its thermal substitution rate

Thermal Substitution Rate by Alternative Fuels
% thermal energy from alt. fuel
40 35 30 25 20 15 10 5 0 Africa Asia-Pac Europe LatAm NthAm Group
Used tires
1990
2005
2008 Forecast
Plastics mixtures
Acid tar deposit
Landfilling
Industrial wastes
Hydrocarbon sludge's
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Waste Management Hierarchy

Cement Industry
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Scope of Paper
Conclusion
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The 9 principles of our AFR policy

When using AFR our goal is to:
Elements of sustainability
I.
Act as a partner to society by offering waste management solutions
No Increase in Emissions
What we will do
II.
III.
Keep our environment safe

Add value to our core business Refuse the listed banned wastes
IV. Ensure occupational health & safety V.
Consistent with GTZ PPP No organics in ARM and EMR
VI. Guarantee the quality of our products
How we will do it VII. Comply with the relevant regulations and promote best practices volatile
VIII. Monitor and control the inputs, process, products
and emissions
IX.
Communicate transparently
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Scope of Paper
Conclusion
29
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
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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
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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
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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
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Dioxins, HCl and VOC vs Baseline and RLF

25 0.08 0.07 20 0.06
15
0.05 0.04
10
0.03 0.02
5 0.01 0 RLF RLF B RLF B B RLF RLF RLF B RLF RLF 0
Baseline or RLF
HCl VOC's Dioxins & Furans Linear (VOC's) Linear (HCl)
Dioxins ng/Nm3 teq
HCl, VOC ppm
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

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
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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
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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
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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
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Cement Quality
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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
44
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
45
Scope of Paper
Conclusion
46
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
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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.
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Scope of Paper
Conclusion
52
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

is an increasingly accepted sustainable waste management solution public private partnerships of Holcim
Co-processing
Strong
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

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

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.

54

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Co Processing of AFR in Holcim and its Enhancement with CFD

Anne Dekeukelaere and Tom Lowes, CIE AFR BD

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Member of World Business Council for

Sustainable Development (WBCSD)

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Holcim presence: balance between emerging and mature markets

Azerbaijan Uzbekistan China Vietnam Thailand Cambodia Philippines Malaysia Singapore

Lebanon India Cyprus Sri Lanka Egypt La Reunion Madagascar Tanzania

Australia New Zealand 4

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Cement industry characteristics

Global capacity would cost in excess of $ US 40 Billion

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Sustainable development and Holcims mission

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Holcim triple bottom SD

AD/TML Global Fuels Conference London 5th Feb

clearly defined priority areas including:

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Conservation of non-renewable natural resources

QUARRY aggregates Recycled building materials

Alternative fuels / waste materials

By-products from other industries

Holcim is increasing the use of alternative fuels & raw materials

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Emissions from fossil fuel and waste as fuel

Waste Waste Incinerator

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

The GTZ-Holcim partnership

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Waste and co-processing

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Waste and co-processing

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Holcim is increasing its thermal substitution rate

Acid tar deposit

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Waste Management Hierarchy

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

Holcim Group Support

AD/TML Global Fuels Conference London 5th Feb

The 9 principles of our AFR policy

Act as a partner to society by offering waste management solutions

Keep our environment safe