From 0 % to 80 % - Alternative fuel From 0 % to 80 % - Alternative fuel usage in the Broceni cement plant

Dr. Uwe Lubjuhn, October 2015

Investment decision

Capital expenditure 275 mill. €

� Start of construction 2007

� Start of kiln in May 2009

� Nominal clinker capacity 3500 t/d

� Cement capacity 1,2 mill. t/a (new plant)

Decision from the start to use alternative fuels (AF):

� AF storage

� AF handling & transport

� Combustion chamber

� Main burner for use of AF

Plant layout

Kiln Kiln lineline withwith

preheaterpreheater towertower

CCoaloal millmillRawRaw millmill areaareaCementCement millmill

RawRaw materialsmaterialsClinkerClinker silosilo

RawRaw millmill areaareaCementCement millmill

Alternative Alternative fuelsfuels

AAA of AF usage

Availability

Suitable waste in terms of amount, price/gate fee and quality

AcceptanceAcceptance

Authorities, neighbours and public stakeholders interested in environmental, H&S and firefighting aspects

Application

Reception and storage, feeding and burning, process and quality control

Availability

Suitable waste in terms of amount, price/gate fee and quality

Conventional:

� Municipal / household waste� Commercial waste� Industrial waste� Used tyres� Used tyres

Biomass:

� Agricultural residues� Wood chips, wood waste� Meat and bone one meal,� Sewage sludge

Acceptance

Authorities, neighbours and public stakeholders interested in environmental, H&S and firefighting aspects

� Emission prognosis� Emission monitoring� Dust� NOx� SO2� SO2� Heavy metals incl. Hg� HCl, HF, CO, TOC� Organics � NH3� CO2-emissions

� Type of wastes used� Air quality in storages� Fire alarm and protection systems� Inflammability / explosiveness of AF

Application

Reception and storage, feeding and burning, process and quality control

� Storage for bulk material� Storage for bales including debaler

� Mechanical transport� Pneumatic transport� Pneumatic transport� Main burner for different types of fuel� Kiln inlet, calciner, combustion chamber

� Chlorine-bypass� Bypass-dust handling� Use of bypass dust in cement� Use of bypass dust for binders� NOx abatement� SO2 abatement� Avoiding de-novosynthesis of dioxins

Alternative fuels in Latvia

Local Imported

Kiln and preheater (KHD / Germany)

Kiln line

PreheaterPreheaterPreheaterPreheaterPreheater tower with precalcinerand combustion chamber

CombustionCombustionCombustionCombustion ChamberChamberChamberChamberCombustionCombustionCombustionCombustion ChamberChamberChamberChamberNew KHD development for the use ofalternative fuels up to 70 mm particlesize

CoolerCoolerCoolerCoolerHigh

efficiency IKN cooler

KilnKilnKilnKilnShort kiln with twosupport stations andtertiary air duct

Combustion

chamber:

Alternative fuels

up to 70 mm

Combustion chamber

Picture: Picture: Inside Inside viewview combustioncombustion chamberchamber

Debaling

Bulk feeding

Feeding

Conveying

Alternative fuel feeding for combustion chamber

AF feeding system

Bulk feedingScreening

SulphuricSulphuric Acid Tar Waste is transformed into bulk ma terialAcid Tar Waste is transformed into bulk material

Processing of SATW

Extraction Neutralization Transportation

SATW

Cement plant

Contaminated lake

SATW processing and usage

StorageRecovery

Kiln Feed

Clinker

Primary Fuels

Alternative Fuels

Cement plant

Ventilation system for storage

Smelling air introduced into clinker cooler and used as combustion air.

BagBag filtersfilters::

DustDust emmissionemmission

< < 20 mg/m³20 mg/m³

Best available technology

Picture: Main Picture: Main bagbag filter filter

househouse / BK5/ BK5

SNCR:SNCR:

NONOxx emissionsemissions

< 500 mg/m³< 500 mg/m³

Best available technology

Picture: Picture: SNCR SNCR pumpspumps

Permanent Permanent displaydisplay ofof emissionemission

in in centralcentral controlcontrol roomroom

Continuous emission monitoring

Picture: Screen Picture: Screen shotshot Siemens Siemens controlcontrol systemsystem

From 0 % to 80 %

80

100

Hea

t Sub

stitu

tion

[%]

Alternative Fuels

0

20

40

60

Hea

t Sub

stitu

tion

[%]

2010 2011 2012 2013 2014 20152009

900

1000

1100

1200

kg C

O2/

t clin

ker

Jun 08 3rd period Apr 12

Reduced CO 2-footprint

Specific CO 2 emissions according EU allocation rules for trading perio d 2013–2020 compared to real emissions Broceni

600

700

800

900

Broceni BK4 EU Benchmark Broceni BK5

kg C

O2/

t clin

ker

- 36 %

Modern Modern clinkerclinker kilnkiln technologytechnology: : UseUse ofof alternative alternative fuelsfuels

COCO22--savings = 400.000 t/asavings = 400.000 t/a

CO2-improvements

EqualEqual toto emissionsemissions ofof moremore thanthan 200.000 modern 200.000 modern carscars drivingdriving

20.000 km per 20.000 km per yearyear

But everything starts with the people

Thank You!