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Warm up

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Production and Storage of solid alternative fuels for substitution rates of over 30% in the Cement industry

presented 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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Turnover

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in Mio. €

Export quota: ~ 70%

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Employees

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Stable growth

Focus on education: 37 apprentices in 2008(Germany)

328  Anges tellte28  Aus zubildende

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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.

Vecoplan´s products and solutions are able to cover the whole recycling process of these and other materials.

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Products and services

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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

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HiTorc - Drive VAZ - Shredder

Film and fiber rotor „Flipper“

Patent Patent

Patent

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Clients (partial)

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9

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

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example Ciment Quebecprocessing on site

Customer: Cement plant, 1’000’000t/a, dry processStatus: in operation since August 2009

Capacity: over 20t/hr dry insustrial wastemajority autofluff

Addition for preparation and

storage of alternative fuels

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Concept (not final layout)

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Receiving and preshredding

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Preshredder

Waste 0 - >1500 mm

Waste 0 – 200 (250) mm

Reality check:

Walking floor

unloading

“manual feed”

opening

Door to rotor open

Discharge with

cleaning cvoneyor

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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:Covered screen area

Discharge small

fraction

Collecting conveyor to storage

system

Discharge large

fraction

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Density separation

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Density separation

Light fraction Heavy fraction

Reality check:

Discharge to

vibrating

Vibrating to belt

Heavy discharge

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Reshredding

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Reshredding

RDF fuel tostorrage

Reality check:

2 reshredders

Collecting conveyor to storage

system

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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

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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

0123456789

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

COAL high quality medium quality low quality BLENDED

medium quality

012

3456

78

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

COAL high quality medium quality low quality BLENDED

high quality

0123456789

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

COAL high quality medium quality low quality BLENDED

Coal / RDF blend

0

2

4

6

8

10

12

14

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

COAL high quality medium quality low quality BLENDED

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Intelligent storage is part of the production!

AFTER blending

NOT after grinding

Where is the final point of the fuel preparation line?(Rethorical) Test question:

Vecoplan philosophy:

Fuel production Fuel storage

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Final consideration: Future expansion, fill the gaps

End fluff example, you made it 2/3!

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example MSWgreen field layoutprocessed off site by separate entityonly receiving and storage at the cement plant

Customer: JV in North AmericaStatus: quote “on hold”

Capacity: 60t/hr at MSW processing expected “yield” (dry, light, high BTU): 20%

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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 woodintegration in existing plant layoutreceiving of preshredded green woodscreening and processing on sitedrying by others

Customer: cement plant in North AmericaStatus: project to be downsized due to EPA

Capacities: 15t/hr out of the dryer (24/7)receiving 120t/hr3 day on site storage of green chips

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

Vecobelt

Rail track

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Vecobelt

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Vecobelt, 155 m (about 450’)

“eliminate” obstacles on the gound

Extend Veco belt into tower,

eleiminate tower extensioins

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It is realistic??? (2008 figures)

0,0%

10,0%

20,0%

30,0%

40,0%

50,0%

60,0%

Germany

Switzerland

Austria

Norway

France

Belgium

Sweden

Luxembourg

Czech Republic

Japan US

A

Canada

Australia UK

Denmark

Hungary

Finland

Italy

Spain

Poland

Recent pattern in use of RDF

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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

= 150’000USD/year fuel cost reduction per ton replaced

Alternative fuel projects strongly benefit from economies of scale

Bigger is better regarding

1. Economics, payback2. Project management, very limited technological risk3. Process control / operations, constant part of fuel mix

“That depends…” (please use your own numbers)

Other considerations:•Gate fees for HazMat

•Carbon tax•Sustainability

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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