effective utilization of fly-ash from power plantpower ... · pdf filefrom power plantpower...

24th Jan, 2013 in Mongolia under the framework of NAMAs

Effective Utilization of Fly-Ash from Power Plant for Cement Productionfrom Power Plant for Cement Production

YOSHIYUKI UENOYAMAGeneral Manager g

Green-Innovation Business Promotion DepartmentTAIHEIYO CEMENT CORPORATION

[email protected]

Taiheiyo Cement’s activities span the world

Dalian(China)Qinhuandao(China)

(C )

USAJapan (11 plants)

KoreaNanjing(China)

VietnamPhilippines

p ( p )

Philippines

Oversea Sales: 22 649kt (2009)

Papua New Guinea

Oversea Sales: 22,649kt (2009)U.S.A. 2,035 kt (9.0%)China 4,766 kt (21.0%)Korea 12,815 kt (56.6%)Others 3,033 kt (13.4%)

D ti S lLocations of Taiheiyo Group’s cement plants

2013 © TAIHEIYO CEMENT2

Domestic Sales: 14,829 kt + Export 5,009 kt

Contents

Outline of dry process of cement production and energy efficiency

Recycling utilization of by products and industrial waste including coal fly ashRecycling - utilization of by-products and industrial waste including coal fly ash

Taiheiyo's advanced technology for utilizing MSW incineration ash

Conclusion


Typical cement production processMaterial flow

1. MiningCoal

Material flowFuel flowGas flow

Stack Dust collector

Stack

Preheater

LimestoneDust collector

Belt conveyer

Clay minerals

Ironslag

Coal mill

Preheater

H i iRaw mill

g3. Burning process

Rotary kiln

Clinker coolerHomogenizingsilo

Raw mill

2. Raw material processClinker

siloCementGypsum

p4. Shipping silo

silo Classifier


Finish mill 4. Finishing

Cement vessels Bulk trailers BagsFreighters

Raw material for cement Cement is made from Limestone, Silica, Clay and Iron slag

Cl (d i d) Li t I lSilica

Limestone: Occupying 70 80% of total raw

Clay (dried) Limestone Iron slagSilica

Occupying 70-80% of total raw materials and transported from a mine by a belt conveyer, for i tinstance

Iron slag: By-product of iron manufacturing

The composition of raw materialLimestone mine


The composition of raw material effects property of cement

Long distance belt conveyer

Burning process Excellent cement can be manufactured by burning at very high temperature of 1450 oC

1. Raw material is heated gradually by hot gas in the preheater2 P h t d t i l i b d i th t kil t t t f 1450 oC2. Preheated raw material is burned in the rotary kiln at a temperature of 1450 oC3. Approximately 30 min of burning, the raw material turns red-hot lava like lumps

Preheater (back) of 65m in height and Inside view of Rotary kiln operating at a very high temperature of 1450 oC


Rotary kiln (fore) of 5.4m in diameter, 95m in length, 3200 ton/day production capacity, 250 kW powered

a very high temperature of 1450 C

Finishing processGrinding clinker with gypsum into fine powder, that is cement

ClinkerClinker

GypsumClassifierFinish mill

Power required: 3875 kWMilli i 120 /h

To control setting time of cement

Gypsum Milling capacity: 120 ton/h Size: 4.6m dia. and 13.1m

2013 © TAIHEIYO CEMENT7Cement

Difference of wet-process kiln in energy efficiencyProviding slurred raw material directly into rotary kiln

Schematic wet-process cement kiln

5000

6000

7000

120

r)

Specific required heat Specific production of kiln volume

2000

3000

4000

5000

60

80

100

(MJ/

t-clin

ke

(kg/

m3 /h

)

0

1000

2000

Wet-process

20

40

DB-type SP-type NSP-type

(


et p ocesskiln

DB typekiln

SP typekiln

NSP typekiln

Specific required heat and production on various types of kiln

Specific required energy and energy efficiency

Typical technology on heat efficiency - NSP type burning system

4500

4000

(MJ/t-cement)

NSP type burning system - Five-cyclone cascaded preheater- Air beam type clinker cooler

Pulverizing coal constant feeder

3500

3000Including alterative waste fuel

- Pulverizing coal constant feeder - Automated quality monitoring 2500

200070 75 80 85 90 95 00 05 09

Excluding alterative waste fuel

Transition of unit heat energy

70 75 80 85 90 95 00 05 09

130

120

(kWh/t-cement)

Typical technology on power efficiency - Vertical type mill - Pre-grinding system

110

100

Including waste heat recovery power generation

Pre grinding system - High efficiency classifier - High efficiency blower fan

90

80

70

Excluding waste heat recovery power generation

2013 © TAIHEIYO CEMENT9Transition of unit power

70 75 80 85 90 95 00 05 09

The top runner on energy efficiency

180ex

160

140

ptio

n in

de

120

100cons

ump

80

60Ene

rgy

Japa

n

Thai

land

Italy

Mex

ico

Ger

man

y

Indi

a

Spa

in

Bra

zil

Kor

ea

Can

ada

US

A

Chi

na

Wei

ghte

d Av

.

Comparison of Energy consumption index on clinker and cement manufacturing

( )

W


Reference :The International Energy Agency (IEA), Worldwide Trends in Energy Use and Efficiency 2008

Business scheme of material recyclingPractically performed “Waste to Resources” business scheme on cement plants

Elongation of landfill Prevention of global Conservation of service lifewarmingnatural resources

Natural resources

Industrial clustering Recycling of municipal wasteBl t fSteel plants

Coal fired

Blast furnace slag

Coal fly ash

Incineration ash

Separation andIncineration

seho

ldMS

W

Cement plants

Limestone & slaked lime Admixtures

Coal fired power plants Desulfurazation

gypsumRaw

materialsMixing

admixtures

Gen

eral

hou

ge s

ludg

e

Otherswaste tires

waste plastics

Alterative fuel & raw materials

Incineration ash Incineration

G

Sew

a

2013 © TAIHEIYO CEMENT11Cement and concrete products

Utilizing by-products and waste

Why by-products and waste can be utilized at cement plants?

Because:

1 C t j l t i C O SiO Al O d F O1. Cement majorly contains CaO, SiO2, Al2O3 and Fe2O3. Waste containing such components may be used as raw material.

2. Combustible waste may be used as fuel for burning process in the rotary kiln.

3. No secondary waste is generated because cinders of combustible waste will be consumed as raw material.combustible waste will be consumed as raw material.

4. Hazardous materials such as dioxin can be decomposed in the t kil d th hi h t t f 1450 C


rotary kiln under the high temperature of 1450 oC.

Chemical compositions of waste The reason why by-products and waste can be utilized at cement plants

Composition of major elements (%)

SiO2 Al2O3 Fe2O3 CaO Total Alkali SiO2 Al2O3 Fe2O3 CaO Na2O eq.

Ordinary Portland Cement 20~23 3.8~5.8 2.5~3.6 63~65 0.3~0.7

Limestone ~4 ~2 ~2 47~55 ~0.2Major natural resources

Limestone 4 2 2 47 55 0.2

Clay 45~80 10~30 3~10 ~5 2~6

Silica 70~95 2~10 ~5 ~2 0.5~3

By-products

Coal fly ash 40~65 10~30 3~10 5~20 0.5~20

Blast Furnace slag 20~45 10~20 ~5 30~60 0.1~0.5

S 20 0 20 0 1 30 1and waste Sewage sludge 20~50 20~50 5~15 5~30 1~5

Casting sand 50~80 5~15 5~15 ~5 1~5


Clark numbers: O=49.5 Si=25.8 Al=7.56 Fe=4.70 Ca=3.39 ....

Fly- and Bottom-ash recycling on cement production

FY2009Consumption of waste: Cement

Dust-collector

p26,290kt/y (451kg/t-cement)

Ref.: Japan Cement Association Milling Mixing

Dust-collector

ClinkerFly ash By-product g ps m

Gypsum

Limestone DryingOrganic Waste: Waste plastic Waste oil

gypsum

RaSilica ClayIron slag

y gGrindingBlending

Waste plastic Waste oil

Rotary KilnCoal

Coal

Raw material

Bottom ashOther waste

i l Massive waste:Clinker cooler

Coal

Fly ash


materials Massive waste: Sludge Sewage sludgeTires MSW

Cement industry as an MVP of recycling Approximate 26 million tons of industrial waste including 6 million tons of coal fly ash was recycled in cement industry in 2009

L dfill

Others16%

Landfill 3% Cement

13%

Export

Others15%

Cement

Construction material 17% Paper

32%Reuse

Export15%Total amount

of recycling8,924 kt

Total amount of recycling

1,056 ktCement 64%

32%

Steel 4%

Thermal recycle

10%

Reuse basement

15%

Usage of coal fly ash

4%10%

Usage of waste tires


References: Japan Fly Ash Association and Japan Automobile Tyre Manufacturers Association

Utilizing by-products and waste Organic waste is potentially used as fuel

Waste tires Waste plastics

2013 © TAIHEIYO CEMENT16Wood chips and other biomass Recycled oil

Key technology of bypass system Enables to utilize respectively inorganic waste as raw material and organic waste as fuel, and to recover minor elements

Gas flow Material/Fuel flow

Raw material

400oC

Dust collector Preheater

Heat recovery

boiler

Heat recovery

boilerCoal

1000oC

Coal mill

Coal

Rotary kiln

1000 C

1450oC 250oC

2013 © TAIHEIYO CEMENT17Clinker cooler

y

ClinkerChloride bypass and minor elements recovery system

Waste to Resources on MSW management

Development of CommunityCommunity

AK (Applied Kiln)MSW

AK (Applied Kiln)

IncineratorsAsh

processing

Incinerators

Incineration ash

Cement & Concrete

Existing Cement Plants

Eco-cement

Incineration ash

Cement & Concrete


Eco-cement PlantsLandfill sites (extension of service life)

AK（Applied Kiln） System

Hidaka City: P l ti 50 000Population 50,000MSW 15,000 ton/y

Crushing and separatingseparating

Aerobic bio-Incinerators

Aerobic biodigester

Cement production line making use of

digested MSW


g

Saitama Plant, TCC

Ash processing systems

Fly Ash Washing System (15,000 t/y)

B tt A h P iBottom Ash ProcessingSystem (50,000 t/y)


Kumagaya Plant, TCC

Eco-cement plant

Futatsuduka Landfill, Tokyo

One third of MSW in Tokyo has been recycled as Eco-cement since 2006.Tokyo Metropolitan Government has constructed the plant in their landfill site and

ti h b i i d t TCC b idi

Futatsuduka Landfill, Tokyo


operation has been commissioned to TCCs subsidiary. - Input MSW (as incineration ash) 300t/d- Output Eco-cement 430t/d

Conclusion 1. Coal fly ash generated at thermal power plants can be recycled as

alternative clay raw material in large quantities and continuously.

2. The cement manufacturing process with advanced quality and process controls enables to recycle by-products and waste generated p y y p gby other industries as alterative raw material and fuel.

3 By means of installing Chloride bypass technology the cement plant3. By means of installing Chloride bypass technology, the cement plant can recycle municipal solid waste (MSW) and its incinerated ash as raw material.

4. Taiheiyo Cement has accumulated advanced technologies and experiences related environment as mentioned above and energy ffi i ll d i d l i h ibl defficiency as well, and intends to consult with possible customers and

to provide such technologies.

2013 © TAIHEIYO CEMENT22Thank you for your attention.

Th k f tt tiБаярлалаа！

Thank you for your attention


Locations of Domestic Plants

Direct operation plantSubsidiary and Affiliate

Kamiiso3,829

yTotal production capacity: 21,067 kt/y

Myojo1,763

Ofunato2,032Eco-cement

Tsuruga677

S it

Kumagaya2,027

F ji

D C

Saitama1,470

Fujiwara2,326

D.C. 1,199

Oita


5,744

Recycling systems clustered on cement industry


Reducing CO2 Emission by utilizing waste as fuel

Energy from

wasteWaste

I i C b i

Fossil energy Fossil energy

Cement plantsIncine-rators

Co-combustion at cement plants

Reference: CEMBUREAU, Alternative Fuels in Cement Manufacture, 1997http://www cembureau be/Documents/Publications/


http://www.cembureau.be/Documents/Publications/Alternative_Fuels_in_Cement_Manufacture_CEMBUREAU_Brochure_EN.pdf

Utilizing by-products and waste Transition of ratio of waste derived fuel

Reference: Japan Cement Association

Waste derived fuel

gy

Fossil Energy

sil e

nerg

o of

foss

Rat

io

Fiscal Year


Technical configuration of AK System

Crushing and separatingGarbage

trucksBio-digester

Feed to rotary kiln

g

MSW

1 t d 2 d d 3 d d Digested MSW1st dayGarbage bags

tear and fragment

2nd day Aerobic

digestion quickly

3rd day MSW turns cement raw material and

Digested MSW


fragment quickly develops

material and fuel

Fly ash processing system

Fly AshLi id

WaterLiquidGas

Dissolution tank

From incinerators

Belt filter

FiltrateFilter CakeRotary kilnFiltrate

Decanter Settling

SewageKiln exhaust

CO2 reactorSand filter Hg remover

Filter cake


Filter press

Filter cake

Advantages of Eco-cement

More ash can be recycled Approximately 50% or more of incineration ash and less natural limestone can be used as raw material.

Standards provide easy use of Eco-cementEco cement is regulated in JIS (Japanese Industrial Standards)Eco-cement is regulated in JIS (Japanese Industrial Standards), and can be used easily for practical purposes.

H t l b d Heavy metals can be recovered Some of heavy metals, such as Cu, Pb and Zn can be recovered from collected dust.
