12_M.E. Erguclu_TCMA_Bastas Baskent Cimento_Turkish cement industry recognizes alternative fuels as a key lever for its sustainability

MVW LECHTENBERG&PARTNER 2ND ALTERNATIVE FUELS SYMPOSIUM

Mete Emre ERGÜÇLÜ

Turkish Cement Manufacturers Association Baştaş Başkent Çimento Sanayi ve Ticaret AŞ

15.10.2015

«Turkish Cement Industry recognizes Alternative Fuels As A Key Lever for

its Sustainability»

PART I: GENERAL REVIEW

1. Framework

2

• Turkish Cement Industry and TCMA

• Use of Alternative Resources

o Alternative Fuels

o Alternative Raw Materials

Turkish Cement Industry

3

Turkish Cement Industry

• Cement Industry

o 1911 20.000 ton/year

o 2014 74,400 Mton/year

o 2014 69 Cement Plant

(50 integrated)

o In Europe 1.,

o In the World 5.

• Fınancially,

o % 77 local capital

o Share of foreigners % 23 (France,

Italy, Germany, Brazil ve Greece)

o 15.000 employee

o Financial Turnover 4 Billion US-$

o Export 600 million US-$

4

Turkish Cement Manufacturers’ Association

5

TCMA

Establishment 1957 – Official Representative of Industry

Place Ankara

Number of Employee

69

Supported Articles

Production Quality Trainning Environment Technology

Contacts (Local and abroad)

Private Sector Government Public Non-Governmental Organizations


6

TCMA

Memberships and

Cooperations

1972- CEMBUREAU (European Cement Association) Member

2009- EUPAVE (European Concrete Paving Association) Associated Member 2009- AUCBM (Arab Union for Cement and Building Materials) – Cooperation Protocol

2010- CMA (Indian Cement Association) – Cooperation Protocol

2011- CCA (China Cement Association) – Cooperation Protocol


http://www.tcma.org.tr/ 7

http://www.tcma.org.tr/
















TCMA

COMMITIES

Natural Sources and Process

Natural Sources

RD, Quality and Commercial Enterprises

Process

Products-Economical

Analysis

Concrete Roads, Innovation

Lobby, Publicity

Relationship between

Members and Non-

Governmental Organizations

Sustainable Production

8

Climate Change and Energy

Environmental Legislation

GHG Climate Change

AF/ARM

Energy

Use of Waste in Cement Industry

Main Purpose Cement Production

Additionally Use of Waste

Use of Wastes Instead of Conventional Fuels and Raw Materials

10

• In Turkey, Cement Plants are making efforts to become a solution partner in the Turkish Waste Management Policies.

Use of Waste in Turkish Cement Industry

• Started at 2004 (AF and ARM) Beginning

• Licensed Plants; 35/49 • Thermal Substitution Rate

• Permitted Capacity: % 40 (with co-incineration license)

• Average Thermal Substitution: % 3,71 (2014)

Existing State

• 2004-2010 : General Regulation on Use of Alternative Fuels (Abrogated)

• 2010 : Waste Incineration Regulation

• 2011 : Non-Hazardous Waste Regulation

• 2014 : RDF, AF and AFR Regulation

Legislations

10


• Waste Oil

• Tyres

• Refuse Derived Fuels

- Non-Hazardous

- Hazardous

• Mineral Based

Wastes

- Iron

- Aluminate

- Calcium

- Silica

Non-Hazardous Waste

By-products

Clinker

Production

Cement Production

11

Alternative Fuels Alternative Raw Materials Additives

Hazardous Non-Hazardous Non-Hazardous Hazardous

Turkish Cement Industry was a solution partner for waste

management activities with 1,6 mton AF and AFR.


Numbers of Out of Scope codes: 435

Numbers of waste codes for cement

industry: 404 Determined by Ministry

AF and AFR

12

RDF 275/404

AFR 137/404

AF 247/404

Numbers of Codes: 839

World Data for AF - 2012

Total: ~%15 (waste+biomass)

Kaynak: http://www.wbcsdcement.org/GNR-2012/index.html

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http://www.wbcsdcement.org/GNR-2012/index.html




























EU Data for AF (28 Countries) - 2012

Kaynak: http://www.wbcsdcement.org/GNR-2012/index.html

Total: ~%37 (waste+biomass)

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Use of Alternative Fuels in Turkish Cement Industry

15

Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study


Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study 18


19

Total AF 566.800 ton for 2014


Use of Alternative Raw Materials in Turkish Cement Industry

2010 2011 2012 2013

21


Use of Alternative Raw Materials in Turkish Cement Industry

22


Turkish Cement Industry – AF/AFR Papers

Documents:

• Position Paper

• AF/AFR Users' Manual (Technical Advice Document)

http://www.tcma.org.tr/index.php?page=habergoster&hbrID=305

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MVW LECHTENBERG&PARTNER 2ND ALTERNATIVE FUELS SYMPOSIUM

PART II: TECHNICAL APPLICATIONS AND OPPORTUNITIES

Scope

22

• Recovered Waste: Examples

• Costs and Controls

• Acceptance and Analysis opportunities

• Alternative Fuels

• Preparation

• Feedingg

• Fire & Explosion Precautions

• Alternative Raw Materials

• Suggestions

RECOVERED WASTES: EXAMPLES

23

Use of AF and ARM

5

Co-Incineration GRINDING Clinker Cement

Conventional Fuels Coal, petcoke, fuel- oil,

natural gas

Alternative Fuels

RDF Waste Tyres Waste Oils Sewage Sludges Impregnated w. Plastics Solvents Waste Paint

Conventional RM Limestone, clay, marn

AlternativeRM

Mineral Mud (Ca) Foundry Sand (Si) Waste Bricks Pirit (Fe), Grit

Grinding Additives

Conventional: Gypsum,

Anhydride ARM

Artificial Gypsum

Active Grinding Additives:

Conventional: Pozzolan

ARM

Slag (by-product) Fly Ash (by-product)

Use of AF

Cement Plant Co-Incineration

REFUSE DERIVED FUEL

RDF Production in Cement Plants

Purchased RDF

ALTERNATIVE FUEL

25

Waste to AF/ARM

Wastes

Non-Hazardous Industrial Waste

Impregnated

Waste

AF/ARM

Waste Tyres

Sewage Sludge

RDF

TDF

Dried Sludge

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COSTS AND CONTROLS

10

Additional Costs of AF/ARM

Investment Costs

• Storage

• Preparation

• Feeding

• Laboratory

• Precautions for Fire & Explosion

• HS Measurements • Process Control

Additional Costs

• Production Loss

• Increasing Specific Heat

• Maintenance

• Additional labor

• Emission Measurements

COSTS

İlgili taraflar, çimento sektörünün alternatif yakıt ve Alternatif Hammadde kullanımından kaynaklanan ilave maliyetler hakkında yeterince bilgi sahibi değildir!

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Emission Measurements

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• Instant Measurements o In all stacks

o By Authorized Measurement Companies

• Continuous Measurements: o Flue Gases

o Dust

o TOC

• Periodical Measurements o Flue Gas, Dust, TOC and;

o Heavy Metals

o PCDD, PCDF and PAHs

• Online Monitoring o From 31.12.2014

ALTERNATIVE FUELS ACCEPTANCE CRITERIA AND

ANALYSIS

30

Acceptance Criteria and Analysis

• First Control - Physical Control

- Sampling

- Accordance of Acceptance Criteria

•Analysis

- Calorific Value

- Chlorine

- Water Content

- Heavy Metals

- Other Parameters

• Acceptance

- Physical Control

- Analysis of Output Material 31

Properties of RDF

• Chemical and Physical Criteria of RDF/SRF (RDF, AF and ARM Regulation)

32

ALTERNATIVE FUELS

PREPARATION

20

RDF Plants

34

5 Cement Plants have own RDF Plants. 2 Cement Plants have TDF Preparation Plant.

RDF – Refuse Derived Fuel

35

Sludge Dryers

36

Acceptance

Transfer Systems

Sludge Dryers

37

Dryer Belts

Dried Sludge Silo

38

ALTERNATIVE FUELS FEEDING

SYSTEMS

Dried Sludge Feedig System

Granulated Dried Sludge

Pneumatic System

39

SRF Feeding

Bale Opener Machine

31

Covered Belt (to the Calciner)

41

First Automatical Feeding System in Turkey- 2009

• Capacity: 15 ton/hr

Automatical Weighing

and Dosing System Regular and Constant

Feeding Rate Automatical

Manupulation

42

Feeding System -Storage

• Crane System Crane System determines storage and feeding manupulations with its automation system.

43

Dosing system

• Automatical Weighing System

System determines all movements according to setted feeding rate.

44

Belts

• Tube Belt

It reaches to 52 m height with 300 m length

Not affected geographical conditions (wind, rain etc.)

Carries 0,1-0,4 ton/m3 density

45

Belts

• Width: 1,6 m

• Length: 150 m

46

Waste Tyres

47

Shredded Tyres Automatical Feeding Systems

48

Burning Technologies

• HOTDISC Technology

49

Burning Technologies

Rotary Weightfeeders

50

47

ALTERNATIVE FUELS FIRE PRECAUTIONS

Fire Precautions

• Sprinkler System

52

Fire Precautions

• Thermo elements (Adjusted 60-65 °C)

53

• Belt Sprinkler System

Fire Precautions

• Automation System

54

Fire Precautions

• CO2 Systems

55

USE OF ALTERNATIVE RAW

MATERIALS

56

Criteria for ARM

57

Basic Principles; • Must content main elements (calcium, silica, alumina and iron)

• Calorific value recommended under 2500 kcal/kg (fire precautions)

• Must be non-hazardous (legal),

Frequently used ARM

58

1. Waste Roof Tiles (Clay – Al, Si) 2. Waste Marbles (Limestone – CaCO3) 3. Foundry Sans (Silica – Si) 4. Calcite Fines (Limestone – CaCO3) 5. Waste Gypsum (Natural Gypsum - CaSO4) 6. Grit (Iron – Fe2O3) 7. Waste Ceramic Tiles (Clay – Al, Si) 8. Waste Vitrification (Clay) 9. Non-Calorific Value Treatment Sludge (depends on type of wwtp

and process)

The Target of Cement Industry:

Increasing use of AF and ARM

Suggestions

59

Suggestions

60

Pretreatment of waste by waste producers

Establishing of pretreatment plants

Increasıng RDF Production by Industrial Zones

RDF Production with domestic solid waste

Increasıng use of dried sewage sludge by Municipalities

Metropolitan Municipalities - Business Models

Expectations from Metropolitan Municipalities

Expectations from Ministry of Environment

Pretreatment of Wastes

Increasing

use of AF

• Wastes from RDF Regulation • Example:

- Animal Wastes - Sewage Sludge

Pretreatment Plants

• Establishment of Pretreatment Plants - Mechanical Processes (shredding, pelleting etc.) - Drying

Cement Plants

• Use of processed wastes as Alternative Fuels

61

Increasıng RDF Production by Industrial Zones

Increasing

use of AF

• Wastes of Industrial Zones - Non-Hazardous Wastes - Hazardous Wastes

RDF

• RDF Production - RDF send to Cement Plants

Cement Plants

• Use of Alternative Fuels

62

RDF Production with domestic solid waste

Solid Waste by

Municipalities

• Extremely not recommended establishment of incineration plants by municipalities which have high investment and operation costs.

RDF Production with MBT

Plants

• Establishment of MBT Plants nearby Municipality Landfills. • SRF production by domestic solid wastes • Low investment and operational cost

Cement Plants


63

Increasıng use of dried sewage sludge by Municipalities

Wet Sewage Sludge

• Extremely not recommended establishment of incineration plants by municipalities which have high investment and operation costs.

Dried Sewage Sludge

Production

• Establishment of sewage sludge drying units in WWTP by Municipalities

Cement Plants


64

Metropolitan Municipalities - Business Models

Technical Support and Bussiness

Models

65

• Giving technical support to Municipalities about Pretreatment and Sewage Sludge Drying Units

• Giving support for establishment of business models (as in Europe).

Expectations from Municipalities

• Instead of incineration plants which have high investment and operational costs.

Using potential of Cement Industry

• hazardous and non-hazardous wastes which have calorific value and non-hazardous wastes which have mineral content, should not be accepted to the landfills.

Rearrangement of Acceptance Criteria

of Landfills

• Rearrangement of landfill fees according to investment and operational costs.

Taking Precautions in

Economical Issues

69

Expectations from Ministry

•Establishment a system and/or economical model for polluter pays principle because of investment/operational costs of cement industry.

Applying Polluter Pays

Principle

• Abolition of 40 % thermal substitution rate in Waste Incineration Regulation (for non-hazardous wastes)

The abolition of 40 % Limit

• Reviewing project approvals of incineration plants Reviewing Project Approvals

• Determination of a national policy

• Adding co-incineration option to Integrated Waste Management Plans

• Being solution partner in National Waste Management Plan

Being Solution Partner 79

Thanks…

[email protected]

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