16. Peter Windmoller VECOPLAN paper FICEM APCAC 2010 v 100830

8/13/2019 16. Peter Windmoller VECOPLAN paper FICEM APCAC 2010 v 100830

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1

Warm up

2

Production and Storage of solid alternative fuels for

substitution rates of over 30% in the Cement industrypresented by Peter Windmoeller

Agenda

background of the company VECOPLAN and the speaker

example 15t/hr substitution, detail

example MSW, conceptual example wood, conceptual

questions

35 slides total, Test after slide 23, please keep pen and paper ready.


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3

Turnover

3

in Mio.

Export quota: ~ 70%

4

Employees

4

Stable growth

Focus on education: 37 apprentices in 2008(Germany)

32 8 Anges tellte28 Aus zubildende


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5

Markets

Vecoplan AG and its affiliated companies

develop, produce and market machinery and

plants for the processing of

_ wood and biomass

_ plastics,

_ paper,

_ municipal and industrial waste,

_ specialty materials.

Vecoplans products and solutions are able to

cover the whole recycling process of these and

other materials.

5

6

Products and services

6

Single shaft shredders Double shaft shredders Chippers

Conveying technology Screening technology Separation technology

Sorting technology (intelligent) Storage sytems Full in house engineering


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Constant R&D

7

HiTorc - Drive VAZ - Shredder

Film and fiber rotor Flipper

Patent Pa

tent

Paten

t

8

Clients (partial)

8


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background of the speaker

As independent representative:

VECOPLAN cement industry

UniGear, specialty gears and gear box repairs

As partner in LOGEQUIP:

AirStream, fan upgrades

Darimec, girth gears

unitherm, burners

Iteca, process control

other

10

example Ciment Quebec

processing on site

Customer: Cement plant, 1000000t/a, dry process

Status: in operation since August 2009

Capacity: over 20t/hr

dry insustrial waste

majority autofluff

Addition for

preparation and

storage of

alternative fuels


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11

Concept (not final layout)

12

Receiving and preshredding


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Preshredder

Waste 0 - >1500 mm

Waste 0 200 (250) mm

Reality check:

Walking

floorunloading

manual

feed

opening

Door to

rotor open

Discharge

withcleaning

cvoneyor

14

FE separation and screening


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FE separation and Screening

FE Parts

< 50 (60) mm 50 (60) 120 mm

120 -200 mm

Reality check:Coveredscreen

area

Discharge

small

fraction

Collecting

conveyor

to storage

system

Discharge

large

fraction

16

Density separation


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Density separation

Light fraction Heavy fraction

Reality check:

Discharge

to

vibrating

Vibrating

to belt

Heavy

discharge

18

Reshredding


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Reshredding

RDF fuel tostorrage

Reality check:

2 reshredders

Collecting

conveyor

to storage

system

20

Storage


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Not just storage but intelligent storage!

Input: sorting into different fuel qualities

Output: blending into a most possible consistent quality,

managed by kiln control operators.

low mediumhigh

Reality check:

2 infeed

conveyor

Fuel in

storage

system

Discharge

system

22

What does this mean from the viewpoint

of the control room? (assuming 35% substitution rate)

BTUPVC

Coal fraction (65%)

0

2

4

6

8

10

12

14

16

time 1 2 3 4 5 6 7 8 9 10 11 12 13

COAL high quality medium quality low quality BLENDED

low quality

0

1

2

3

4

5

6

7

8

9

10

time 1 2 3 4 5 6 7 8 9 10 11 12 13


medium quality

0

1

2

3

45

6

7

8

time 1 2 3 4 5 6 7 8 9 10 11 12 13


high qual i ty

0

1

2

3

4

56

7

8

9

10

time 1 2 3 4 5 6 7 8 9 10 11 12 13


Coal / RDF blend

0

2

4

6

8

10

12

14

16

time 1 2 3 4 5 6 7 8 9 10 11 12 13



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example MSW

green field layout

processed off site by separate entity

only receiving and storage at the cement plant

Customer: JV in North America

Status: quote on hold

Capacity: 60t/hr at MSW processing

expected yield (dry, light, high BTU): 20%

26

Material preparation, first location = landfill

60t/hr

20t/hr


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Receiving and storage, second location = cement plant

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example wood

integration in existing plant layout

receiving of preshredded green wood

screening and processing on site

drying by others

Customer: cement plant in North America

Status: project to be downsized due to EPA

Capacities: 15t/hr out of the dryer (24/7)

receiving 120t/hr

3 day on site storage of green chips


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Receiving, storage and processing(integrate into existing plant layout)

Vecobelt

Rail track

30

Vecobelt


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Vecobelt, 155 m (about 450)

eliminate obstacles

on the gound

Extend Veco belt

into tower,

eleiminate towerextensioins

32

It is realistic??? (2008 figures)

0,0%

10,0%

20,0%

30,0%

40,0%

50,0%

60,0%

Germ

any

Switz

erla

nd

Austria

Norw

ay

Fran

ce

Belgiu

m

Swed

en

Luxe

mbo

urg

CzechRep

ublic

Japa

nUS

A

Cana

da

Australia UK

Denm

ark

Hung

ary

Finlan

dIta

ly

Spain

Pola

nd

RecentpatterninuseofRDF


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Does it pay???

1t/hr coal replacement

* 7500hrs/year operation

= 7500t/year coal replacement

* 20USD/t cost advantage over fossil fuel

= 150000USD/year fuel cost reduction per ton replaced

Alternative fuel projects strongly benefit from economies of scale

Bigger is better regarding

1. Economics, payback

2. Project management, very limited technological risk

3. Process control / operations, constant part of fuel mix

That depends (please use your own numbers)

Other considerations:Gate fees for HazMat

Carbon tax

Sustainability

34

What do the neighbours say???

Lafarge, Woessingen, Germany: target 2009 : 100% subsittution rate =>

(85% more realistic)

Negative fuel costs

Germany has an

average population

density which is higher

than in most regions in

the US

The Green Party

is a constant part of

the federal and

regional parliaments

since over 20 years


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Thank you for your attention

please quietly wake your neighbour

Questions welcome!

Come and see us

At booth # 7

Peter Windmoeller

+1 514 887 7172

Documents

16. Peter Windmoller VECOPLAN paper FICEM APCAC 2010 v 100830