LIXHE PLANTLIXHE PLANTALF-CEMIND study tour 29 Augustus 2007g

B. GastoutPlant ManagerPlant Manager

Benelux 1

Lixhe Plant - Overview

Benelux 2

Clinker Historical

1950 First the plant in Loën (kiln A&B)1960 kiln C VH - stopped in 19921967 kiln D – 1800T/d WL – stopped in 20011976 kiln E – 3500T/d DL2001 Modernization Kiln E Design 4200T/dA t l li k itActual clinker capacity : – Average 4400T/d (achieved in 2005: 4394T/d)– BDP 4630T/dBDP 4630T/d

Benelux 3

Lixhe plant location

Romont Quarry

Underground

Con e or BeltQuarry Conveyor Belt

2.2Km

LIXHE Plant

Loen Quarry

Benelux 4

Lixhe Clinker Data

Clinker productionWet line Kiln D: 500 000 Tons/y (stop 2001)– Wet line Kiln D: 500,000 Tons/y (stop 2001)

– Dry line Kiln E: Build 1974 - 1,100,000 Tons/yModif 2000 – 1,400,400 Tons/y

Clinker storage2 Sil 45 95 kT– 2 Silos: 45 + 95 kT

– Halls: 40kT + 20kTQuality:Quality:– C3S: 66.6% C2S: 11.7% C3A: 6.9%– Sat: 96.75% M.Si: 2.58 M.Al: 1.38– Free CaO: 0.3% Eq Na: 0.67% SO3: 0.6%

Benelux 5

Mineral substitution in clinker

Substitution of Al, Fe, Si oxyde by secondary , , y y ymaterials :– Waste from steel industry (Fe, Si)– Fly Ash (Si, Al)– Shales (Al)

Blast furnace Slag (Si Ca Al)– Blast furnace Slag (Si, Ca, Al)– Sludge from water treatment (Al)– …

Benelux 6

Mineral substitution 2 750 000 tons2.750.000 tons

Secondary Gypsum2% Special clinkers2%

Water treatment sludge

Chalk and marl68%

2%

Bl t f l

Misc.2%Secondary

Materials

Fly ash7%

Blast furnace slag16%

Iron by-products1%

Natural gypsum

7%

Silt2%

Natural gypsum0%

Benelux 7

Secondary Fuels

Process Caracteristics :High Temperatureg pOxydizing conditions– Necessary for clinker production

High residence time

No waste, no ash !Ashes contribute to clinker formation– Ashes contribute to clinker formation

Benelux 8

Implementation of a calciner and full revamping of the preheater

Benelux 9

Calciner arrangement

LOOP DUCTLOOP DUCTCONNECTING CONNECTING ARRANGEMENTARRANGEMENT

MINOX DUCTMINOX DUCT

SWIRLSWIRL BURNERBURNER

MIXING MIXING CHAMBERCHAMBER

SWIRL CALCINERSWIRL CALCINER

TERTIARY AIR DUCTTERTIARY AIR DUCT

Benelux 10

KILN GASESKILN GASES

Lansink Scale

Preventing wastePreventing waste production

li h dRecycling the product

Recycling the materialy g

Incineration with heat recoveryrecovery

Incineration without In only one operation,heat recovery

Dump site

y p ,

Without any secondary waste !

Benelux 11

Dump site

The Kiln

Precalciner :Impregnated saw dustTextile pellets Main burner :

I d dp

Shredded oil filtersPolluted soilsMisc.

Impregnated saw dustAnimal mealLiquid wastesPolluted water

Kiln Inlet :Whole tires

Polluted water

Dewatered sludge

Benelux 12

Secondary FuelSubstitution ratio (energy %)

Substitution rate evolution

OP200660%

Substitution rate evolution

40%

50%

20%

30%

10%

20%

0%1993 1995 1997 1999 2001 2003 2005 F2006

Benelux 13

Mix fuel 2006 Total fuel substitution rate : 53.3%

Hazardous fuel substitution rate : 28.3%

Waste liquids0.7%

Mix Coal45.6%

Shredded oil filters2.4%

Gaz

Tires7.8%

Impregnated saw dust25.2%

1.1%

Dewatered sludge0 7%

Animal meals13.6%

Textile pellets2.7%

0.7%Dry Step

0.3%

Benelux 14

Secondary Fuels

Main burner 55% of the heat– Fine solid fuels (<2mm) or liquidFine solid fuels (<2mm) or liquid– High heat value

⇒Impregnated saw dust⇒Animal meal⇒Solvents - Oil⇒…⇒…

Benelux 15

Main Burner

Multi-channel burner designed for secondary fuels (PILLARD)

Benelux 16

Main burner : animal meals

Benelux 17

Main burner : liquids

Benelux 18

Main burner : resofuel

Benelux 19

Secondary Fuels

Précalcinateur 35% of the heatC f l OK ( 3 )– Coarser fuels OK (<3cm)

– Low heat value OK⇒Impregnated saw dust⇒Impregnated saw dust⇒Filtration earth⇒Plastic, RDF

P ll t d il (“ êté l”)⇒Polluted soil (“arrêté sol”)⇒Dry sewage sludge⇒Paper sludge⇒Meals, seeds,…⇒…

Benelux 20

Precalciner (TECHNIP)

Benelux 21

Precalciner : resofuel and plastics

Benelux 22

Secondary Fuels

Kiln Inlet 10% of the heat– Bulky FuelsBulky Fuels

⇒Whole tires – Dewatered Sludge : pumping of pasty sludge;

d i d i i ti i hdrying and incineration in one phase⇒Urban Sewage Sludge

– Limited flow (kiln unstability)Limited flow (kiln unstability)

Benelux 23

Kiln inlet : tyres

Benelux 24

Kiln inlet : dewatered sludge

Benelux 25

injection of injection of Dewatered sludgesDewatered sludgesDewatered sludgesDewatered sludges

in clinker kilnin clinker kiln

Benelux 26

Definition

Dewatered Sludge= Residuary sludge coming from water g y g gtreatment from urban and industrialForm:– humid (80% H2O)– semi dry (60% H2O)

dry (20% H2O)– dry (20% H2O)Don’t mix with dredging sludge !!!

Benelux 27

Technical Data

%H2O % 65-75Vol %/dry 60-65Ash %/dry 35-30PCS GJ/d 15 16PCS GJ/dry 15-16Ash composition (on dry basis)SiO2 % 5-10 Pb ppm 1000SiO2 % 5-10 Pb ppm 1000Al2O3 % 1-6 Sb ppm 200-2000Fe2O3 % 1-6 Ti ppm 5-10.000ppCaO % 2-10 Zn ppm <10.000P2O5 % 1-5 Hg ppm <1

PCI: ~2 GJ/TbrutNB: ppm = 1 gr for 1000 kg

Benelux 28

NB: ppm = 1 gr for 1000 kg

Minor elementsLimite

sur MB Permis agricultureH2O Humidité % 80 sur sec sur sec

Boue STEP

Cl Chlore % < 2 0,2 1,0S Souffre % < 3 0,4 2,0

F+Br+I autres allogènes ppm < 2000 0g pp

Sb Étain ppm < 200 0As Arsenic ppm < 200 0Cd Cadmium ppm < 70 0 < 10Cr Chrome ppm < 1000 0 < 500Co Cobalt ppm < 200 10 50Cu Cuivre ppm < 1000 6 30 < 600Sn Étain ppm < 1000 28 140Mn Manganèse ppm < 2000 200 1.000Hg Mercure ppm < 3 0,2 1 < 10g ,Ni Nickel ppm < 1000 4,0 20 < 100Pb Plomb ppm < 1000 14,0 70 < 500Tl Thallium ppm < 10 0,0

Benelux 29

V Valadium ppm < 1000 12,2 61Zn Zinc ppm < 5000 230 1.150 < 2000

Installation Lixhe

ompe àPompe à ���� � S �����

Benelux 30

Pilot InstallationP S h iPompe Schwing KPS12

Trémie 10m3

Stockage 100m3

Benelux 31

New installation

Unloading cover hoper 30m³Storage silo 500m³Storage silo 500m³Handling by screwSludge pomp: 1 – 7 T/hSludge pomp: 1 – 7 T/h Investment:

– For CBR: 150.000 € (Civil Work)S 800 000 € ( 1 €/ C– For SoTraEx: 800.000 € (contract phi 15€/T charged to CBR cover the

utilization incl. maintenance – exploitation, breakdown service by CBR)– Savings: 1M€/year (35kT/y at 45-15€/T)

Planning:Planning: – Erection: October à December 04– Electrical erection and programming : January 05

C i i i F b 05– Commissioning: February 05

Benelux 32

Flow sheet

Benelux 33

Flow sheet

Benelux 34

Installation industrielle

Silo stockage 500m³

Trémie de réception 30m²réception 30m²

avec vis d’évacuation

Pompe à boue Schwing

Benelux 35

Fosse de déchargement

Vis d’extraction sous silo Vis de gavage

Layout

Pompe Fosse

déchargement pSchwing

Trémie exterieur vers pompe

déc a ge e t1 + 1 réserve

Cit

Silo stockage

vers pompeCiterne eau

stockage boue

Boxe stockage ext – alim par

Benelux 36

chargeur

Constraints and Limitations

Technical

EnvironmentalEconomical

EnvironmentalValorization

SafetyLegal S e yLegal

Benelux 37

Environnement 2006

56 81

High 8 Nbr 9Avg 7

32 3011 9530 (50 4) 2T l d

Permit limitEmissionWID limit 1Pollutant, mg/Nm3

dioxin&furan ng/Nm3

56 81

High 8 Nbr 9Avg 7

32 3011 9530 (50 4) 2T l d

Permit limitEmissionWID limit 1Pollutant, mg/Nm3

dioxin&furan ng/Nm3

0.17

1.65

56.81

0

0

32

20.031 2HF

150.0810 2HCl

3011.9530 (50 4) 2Total dust

0.17

1.65

56.81

0

0

32

20.031 2HF

150.0810 2HCl

3011.9530 (50 4) 2Total dust

1120.1060.0440,05 3Hg (our analyser): MES

1125 8

0.050,05 3Cd+Tl

800560800 (1200 5) 2NOX

1120.1060.0440,05 3Hg (our analyser): MES

1125 8

0.050,05 3Cd+Tl

800560800 (1200 5) 2NOX

,

10,5 3Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V

0.050,05 3Hg

,

10,5 3Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V

0.050,05 3Hg

3078 627 7TOC recalculate

45.2 0 2504.250 2 6SO2

0.10,1 3Dioxins & furans

3078 627 7TOC recalculate

45.2 0 2504.250 2 6SO2

0.10,1 3Dioxins & furans

3078.627.7TOC recalculate

1221 2 1000346By authority 2CO

3078.627.7TOC recalculate

1221 2 1000346By authority 2CO

Benelux 38

Kiln and preheater tower

Benelux 39