Ishikawajima-Harima Heavy Industries Co.,Ltd.

13 September 2006

Renewable Energy/Energy Efficiency and the CDM Workshop

held in Jakarta Indonesia

EFB Carbonising and Its Utilisation

in Cement Manufacturing

for GHG Reduction

by Masato Tamura

Siapa IHI ? Who is IHI ?

Didirikan/Established : December, 1853Modal/Capital : 590,218 (Thousands of US dollars)Sales tahunan/Annual sales : 5,530,628 (Thousands of US dollars)Pegawai/Employees : 7,386Pabrik/Works : 13 in JapanPerusahan utama/Major affiliated companies : 99 in JapanKantor, subsidiari /Offices, Subsidiaries & JV : 58 in Overseas

(as of Mar. 2005)

Jet engines Shield tunneling machine Power station

Contoh produk utama/Examples of Major products

1USD = \110

2

Planned PROJECT

- EFB Carbonising and Its Utilisation in Cement Manufacturingfor GHG Reduction -

3

Palm Oil Mill ： Oil Production Process

FFB Steaming Fruit Press

EFB

Palm Crude Oil

Core oil

Fibre Shell

Power Boiler

Incinerator

Seed

Waste

4

Cement factory：Cement producing process

Limestone

Cement Kiln

Plaster

Clay

Silica

COAL

Cooler

Pulveriser Cement

130kg/ton-cement

6,000kcal/kg

Iron material

5

Carbonising plant

External Heating type Kiln

Raw Materials

Dust collector

Carbonising fuel

Heating gasHeating gas Pyrolysis gas

6

Carbonising process

Carbonising furnace

Combustion chamber

Boiler

Gas cooler

Bagfilter

Stack

iron・aluminum separatorDechlorineDechlorine

EquipmentEquipment

Pelletiser

Carbonised fuel

Iron・Aluminum

LimestoneActive carbon

Flying ash

Ash pot

Residence time1hr

Heating gas temp. 550℃ Flue gas

temp.160℃

Pyrolysis gas temp.430～470℃

Cl<0.5%

φ5～20mmpellet

WasteWaste

Flue gasFlue gas

CarbonisedCarbonised fuelfuel

PyrolysisPyrolysis gasgas

Iron, Iron, AluminumAluminum

Firing temp.>850℃

Air heater

Gas cooler

waste

Down sizing<□150mm

crusher

(option)

Char Char DischargerDischarger

7

Carbonising Process

Stack

ＥＦＢ

Dryer

Carbonised fuel

BagFiltre

Flues

CarboniserＥＦＢ Pyrolysis gas

BoilerCombustion

chambre

Inside of the combustion chambre

8

O perating trend data

0

200

400

600

800

1000

1200

0:00 3:00 6:00 9:00 12:00 15:00 18:00 21:00

T im e

Temperatu

re,℃

0

40

80

120

160

200

240

Oil consu

mption, l/h

G as tem perature at C om bustion cham ber outlet

O il consum ption

No external fuel

Possible Operation without external fuelsIt is possible to operate with only waste calorie It is possible to operate with only waste calorie withoutwithout any external fuels.any external fuels.

•• DryerDryer ：： Direct heating by hot flue gas from Combustion chamberDirect heating by hot flue gas from Combustion chamber

•• CarboniserCarboniser ：： InIn--direct heating by hot flue gas from Combustion chamberdirect heating by hot flue gas from Combustion chamber

•• Combustion chamber Combustion chamber ：： High temperature firing of High temperature firing of pyrolysispyrolysis gasgas

Operating without external fuels

Without external fuel

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Property of Carbonised fuel from waste

Fuel properties

2.2

40.9 wt%

18.3 wt%

35.1 wt%

5.7 wt%

16.95 MJ/kg(4,050 kcal/kg)

B

2.1

43.5 wt%

20.6 wt%

33.3 wt%

2.6 wt%

19.17 MJ/kg(4,579 kcal/kg)

C

1.5～2.51.9Fuel ratio

41.3～46.8 wt/%43.5 wt%Fixed carbon

29.8～33.4 wt%23.2 wt%Volatile matter

13.1～25.1 wt/%31.4 wt%Ash

0.2～0.3 wt%1.9 wt%Water

27.55 MJ/kg(6,580 kcal/kg)

20.16 MJ/kg(4,816 kcal/kg)

HHV

CoalAFuel

35.1 ％31.4 ％

15.8 ％

33.3 ％

43.5 ％43.5 ％

54.6 ％

40.9 ％

23.2 ％ 27.0 ％20.6 ％18.3 ％

2.02.2

1.92.1

0％

20％

40％

60％

80％

100％

炭化物A 炭化物B 炭化物C 石炭

含有

率

0.0

1.0

2.0

3.0

4.0

5.0

燃料

比

揮発分

固定炭素

灰分

水分

燃料比

Volatile matter

Fixed carbon

Ash

Water Fuel ratio

Fuel

rat

io

Coal Carbonised fuel

A B C

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Combustibility of waste Carbonised fuel

•• Fuel ratioFuel ratio•• Ignition and burnout propertiesIgnition and burnout properties•• Combustion speedCombustion speed

炭化物の燃焼時間と燃焼率の関係

0

20

40

60

80

100

120

0.0 0.5 1.0 1.5燃焼時間 [s]

燃焼

率 [

%]

炭化物D（400℃，1.1) 炭化物E（450℃，1.7）

炭化物F（450℃，2.4） 石炭　　( － ，2.0)

(Carbonised temp.，obtained Fuel ratio）

炭化温度と燃料比の関係

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

250 300 350 400 450炭化温度[℃]

炭化

物燃

料比

Similar combustion performance with CoalSimilar combustion performance with Coal

Residence time [s]

Coal

Carbonising temp. [OC]

DF

E

Fuel

rat

io

Bur

nout

[%]

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Combination of Palm Oil Mill and Cement Industry

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Palm Oil Mill

Compress

Cement Factory

Grinding

Steaming

Carboniser

Palm Oil

Powergeneration

Bio-Fuel

EFB

Shell/FibreCement Kiln

Coal

Transportation

Cement

Plaster

Pulverising

FFB

Palm Oil Mill

Compress

Cement Factory

GrindingGrinding

Steaming

CarboniserCarboniser

Palm OilPalm Oil

Bio-Fuel

Shell/FibreCement KilnCement Kiln

Coal

Transportation

CementCement

PlasterPlaster

Pulverising

FFB

CO2 from Bio-Fuel

CO2 from Coal

Example of Expected Results

CO2 Reduction： 32,350 ton-CO2/yearreplacement of Waste EFB 68,400 ton/year

8,840 ton-CO2e/yearreduction of CH4 from land-fill EFB 6,840 ton/year

68,400 ton/year EFB will be 13,680 ton/year carbonised fuel.It can be expected more than 20MJ/kg calorific value.

Case study of one Palm Oil Mill in sumatra

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Expected Future Planning

Farm Waste

Low rank coal

Forest Waste

Food Waste

Carboniser

High Grade

Export to foreign Country

Cement Industry

Power Generation

Steel manufacturingCarbonised Fuel

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