12_m.e. erguclu_tcma_bastas baskent cimento_turkish cement industry recognizes alternative fuels as...
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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
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1. Framework
2
• Turkish Cement Industry and TCMA
• Use of Alternative Resources
o Alternative Fuels
o Alternative Raw Materials
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Turkish Cement Industry
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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
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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
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Turkish Cement Manufacturers’ Association
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
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Turkish Cement Manufacturers’ Association
http://www.tcma.org.tr/ 7
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Turkish Cement Manufacturers’ Association
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
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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.
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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
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Use of Waste in Turkish Cement Industry
• 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
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Turkish Cement Industry was a solution partner for waste
management activities with 1,6 mton AF and AFR.
Use of Waste in Turkish Cement Industry
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
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World Data for AF - 2012
Total: ~%15 (waste+biomass)
Kaynak: http://www.wbcsdcement.org/GNR-2012/index.html
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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
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Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study
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Use of Alternative Fuels in Turkish Cement Industry
Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study 18
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Use of Alternative Fuels in Turkish Cement Industry
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Total AF 566.800 ton for 2014
Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study
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Use of Alternative Raw Materials in Turkish Cement Industry
2010 2011 2012 2013
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Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study
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Use of Alternative Raw Materials in Turkish Cement Industry
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Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study
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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
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Scope
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• Recovered Waste: Examples
• Costs and Controls
• Acceptance and Analysis opportunities
• Alternative Fuels
• Preparation
• Feedingg
• Fire & Explosion Precautions
• Alternative Raw Materials
• Suggestions
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RECOVERED WASTES: EXAMPLES
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Use of AF and ARM
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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)
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Use of AF
Cement Plant Co-Incineration
REFUSE DERIVED FUEL
RDF Production in Cement Plants
Purchased RDF
ALTERNATIVE FUEL
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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
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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
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ALTERNATIVE FUELS ACCEPTANCE CRITERIA AND
ANALYSIS
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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
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Properties of RDF
• Chemical and Physical Criteria of RDF/SRF (RDF, AF and ARM Regulation)
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ALTERNATIVE FUELS
PREPARATION
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RDF Plants
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5 Cement Plants have own RDF Plants. 2 Cement Plants have TDF Preparation Plant.
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RDF – Refuse Derived Fuel
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Sludge Dryers
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Acceptance
Transfer Systems
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Sludge Dryers
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Dryer Belts
Dried Sludge Silo
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ALTERNATIVE FUELS FEEDING
SYSTEMS
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Dried Sludge Feedig System
Granulated Dried Sludge
Pneumatic System
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SRF Feeding
Bale Opener Machine
31
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Covered Belt (to the Calciner)
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First Automatical Feeding System in Turkey- 2009
• Capacity: 15 ton/hr
Automatical Weighing
and Dosing System Regular and Constant
Feeding Rate Automatical
Manupulation
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Feeding System -Storage
• Crane System Crane System determines storage and feeding manupulations with its automation system.
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Dosing system
• Automatical Weighing System
System determines all movements according to setted feeding rate.
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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
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Belts
• Width: 1,6 m
• Length: 150 m
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Waste Tyres
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Shredded Tyres Automatical Feeding Systems
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Burning Technologies
• HOTDISC Technology
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Burning Technologies
Rotary Weightfeeders
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ALTERNATIVE FUELS FIRE PRECAUTIONS
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Fire Precautions
• Sprinkler System
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Fire Precautions
• Thermo elements (Adjusted 60-65 °C)
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• Belt Sprinkler System
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Fire Precautions
• Automation System
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Fire Precautions
• CO2 Systems
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USE OF ALTERNATIVE RAW
MATERIALS
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Criteria for ARM
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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),
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Frequently used ARM
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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)
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The Target of Cement Industry:
Increasing use of AF and ARM
Suggestions
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Suggestions
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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
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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
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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
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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
• Use of Alternative Fuels
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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
• Use of Alternative Fuels
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Metropolitan Municipalities - Business Models
Technical Support and Bussiness
Models
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• Giving technical support to Municipalities about Pretreatment and Sewage Sludge Drying Units
• Giving support for establishment of business models (as in Europe).
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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
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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
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Thanks…
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