Post on 23-Apr-2017
Bath Plant
Biomass Use in the Cement Sector A Fuel Users Perspective
April 14, 2011
Outline
Cement 101 – Cement and Concrete Primer
Biomass Fuels – a cement industry perspective
Cement 2020 – what’s next in the development process
Photos: Front slide, hemp produced for trial; Above – Shredded mixed biomass for the trial: Below – Close up of shredded biomass mix
About Lafarge Canada
Lafarge Canada is part of the Lafarge Group, headquartered in Paris, France.
Lafarge is the world leader in building materials, with top- ranking positions in all of its businesses: Cement, Aggregates & Concrete, and Gypsum.
Lafarge is ranked 6th in the “Carbon Disclosure Project”, for the sixth year in a row is listed in the “Global 100 most Sustainable Corporations in the World”, and entered the global “Dow Jones Sustainability Index” in 2010 in recognition of its sustainable development actions.
With the world’s leading building materials research facility, Lafarge places innovation at the heart of its priorities, working for sustainable construction and architectural creativity.
With 78,000 employees in 78 countries, Lafarge posted sales of 15.8 billion Euros in 2009.
Lafarge Canada is the largest cement producer in Canada.
Cement 101
Our product
Cement is to concrete as yeast is to dough
Cement is the glue that holds concrete together
More concrete sold per year than all other building materials combined.
Excellent Environmental features
Long lasting
LEED building materials
Low embodied energy
LIMESTONE
CLAY
FLYASH
IRON
Lime
CaO
Silica
SiO2
Alumina
Al2O3
Iron
Fe2O3
Major Oxides
7
The Cement Manufacturing Process
Kiln Feed:• 79% Limestone (calcium source - CaO)• 16% Shale (silica and alumina source-SiO2 , Al2 O3 )• 3% Slag (iron source - Fe2 O3• 2% Sand / Silica Rock (silica source - SiO2 )
Minor elements present in kiln feed:– Sulphur, chloride, sodium, potassium
Calcination of limestoneCaCO3 CaO + CO2 (60% of GHG emissions)
Clinkering:CaO + SiO2 + Al2 O3 + Fe2 O3 Calcium Silicates + Calcium Aluminates
Calcium Alumino-ferriteCement:
Clinker + gypsum + limestone (+ flyash + slag) cement
Typical Cement Kiln
The burner heat source is at the discharge end of the kiln, so the feed gets hotter as it moves its way down the kiln
Flame temperature is 2300ºC
At 1450ºC clinker material pours out the end of the kiln into the cooler
Kiln
Important Cement 101 Implications for Ag Fuels
Ash components are partitioned (sequestered) into the product (see cobalt example below)
Unique combustion conditions (high temperatures, ultra-long residence times)
Systems are sized and designed for coal use
At 5% of the world’s CO2 emissions, the opportunity is huge. Ideas to emerge out of Cement 2020 could be adopted worldwide (e.g. 40% reduction in CO2 from cement industry is equivalent to removing Canada’s CO2 emissions.
Inputs Outputs
(Coal/Coke)/biomass(90:10)
Raw mix Stack Emissions Clinkerby difference
Partitioning Factors
Cobalt 26.0 506.8 0.126 533 99.976%
Biomass Fuel – Opportunities & Challenges
Photo of the injection of biomass into the kiln during the biomass demonstration test in October, 2010
Results will be made available at www.cement2020.com
What are the important questions for fuel use?
Chemistry
C-H ratio• “Lower Heating value”• Refractory compounds
Particle size
Ash & metals• Partitioning• Effects on product
quality
Free moisture
Practical Matters
Storage
Transportation
Reliability of Supply
Processing
Cx Hy + (x+0.5y)O2 =>
xCO2 + (0.5y) H2 O
Cobalt example – 99.98% sequestered in cement
A pile of coal will require 2.5-3 same size piles of biomass for the same energy value.
Coal is typically 60- 80% carbon while biomass is 40-50% carbon.
Wood can be 50% moisture
Note: We may end up consuming more energy when using biomass
Challenge 1: Producing biomass fuels
Supply
ForestSlash, Harvest
SolidPower, Steel,
Cement, Home, Greenhouse, other
thermal
Fuel ProductProcessing
LiquidTransportation, Thermal, Power
GasPower, Home,
Commercial, other thermal
Purpose Grown
Crops, Agriforest, stover
Waste / ByproductPulp & paper,
post consumer, biosolids, other
Pelletization
Baling / Shredding
Torrefaction
Liquefaction
Pyrolysis
Gasification
These technologies may be applicable to a variety of feedstock sources.
A brief aside – what is a Gigajoule???
A unit of energy, 1 million joules = GJ
It is accepted practice to compare prices of fuels, apples to apples, using $/GJ
1 GJ = 278 kW.h. *
1 GJ = 947,817 BTU
* As energy released which, with electricity efficiency etc would not equal the electricity delivered to an end user.
Some mathematics (for illustration)
Start with 1 Acre
4 tonnes per Acre = 4 Tonnes
18 GJ/Tonne [dry] = 72 GJ/acre
Revenue of $150/ac = $2.08/GJ
Price to produce bales on the farm?
Pelletization = $50/tne = $2.8/GJ
Transportation of pellets
30 tonnes = 540 GJ/truck [minus water]
Cost at $5/loaded km = $0.93/GJ/100km
Price FOB to fuel user 200 km away is $6.74/GJ
Excludes additional costs at fuel user’s site
These are all assumptions and can be adjusted in the privacy of your own home.
Clearing the air on pellets
Doing the math assuming loose biomass at 20 tonnes per truck load results in a transportation cost of $1.4/GJ/100 km (also and importantly avoids on site cost to re-grind pellets, if necessary)
Breakeven is over 400 km – assuming 1% of land within a 400 km radius…1.24 million tonnes of biomass available
Advantages of pellets
Recognized product
Good for systems designed to use pellets
Economical at long transportation distances
Some benefit in heating value (GJ/tonne) [Drier]
Improved conveyability
Disadvantages
Cost & must be stored in covered storage
Cement kilns prefer smaller particle size fuel
Dusting and off-gassing
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Challenge 2: Cost of Biomass Fuels
Fuel Type Cost per Gigajoule
Gasoline $24
Natural Gas $5-$12
Grown Biomass $6-$10 (OMAFRA est)
Coal $3-$5
Coke $2-$4
Note: Coal releases about 90 kg CO2 /GJ; a “Cap & Trade” cost of $50/tne CO2 will add about $4.5/GJ to the cost of coal.
Challenge 3: the Quality of Biomass as a Fuel [Or…“know thy enemy”]
Characteristic Coal Biomass
$/GJ $3-$5 $6-$10
Energy Density 32 GJ/m3 13 GJ/m3
Shipping Boat Truck
% Ash 5-20% 3-10%
Ash Chemistry Useful Neutral
Availability High Low-Moderate
CO2 Emissions 100% <10%
Other Emissions Present Lower (caution)
Water Use 0.16 m3/GJ Variable, TBD
Storage Outdoor Covered?
Problems to be solved (and how Cement 2020 is working on them)
How to improve biomass fuel quality
Use waste heat
Carbonization? Torrefaction?
How to create biomass ready fuel infrastructure
Start with biomass byproducts, co-products
Continue crop development research (yield improvement)
Water use
Include water in LCAs
Cost
What is the case for government subsidies?
Food vs Fuel
Policy development
Emissions from combustion
Less of an issue when replacing fossil fuels, especially coal – biomass demonstration
For unsophisticated cases, standards around biomass use and associated emission controls
Gasification for home use?
Other social aspects
Local fuel is a big positive
Trucks vs boats
Land use and biodiversity
Community involvement
Cement 2020
Life Cycle Assessment of ag biomass and other sources
Carbon
Water
Greener Fuel Screening Protocol
Landscape issues with land conversion to biomass production
How best to use waste heat
Electricity?
Carbonization?
Both?
Road map
Implementation in 2012
• Partners
– Lafarge, SVI, WWF Canada, NRCan, MOE, Env. Canada, Queen’s, RMC, Portland Cement Association
• Steering Committee
– Rob Cumming, Brian Gasiorowski, Warren Mabee, Sebnem Madrali, Andrew Pollard, Glynn Robinson, Steven Price
• Researcher and Contributors
– Darko Matovic, Ted Grandmaison, Tom Carpenter, John Chandler, Sam Fujimoto, Sharon Regan, Goni Boulama, Mike Lepage, International Review Team, Lafarge Engineer Team
• Project Management
– Ron Quick, Alison Obenauf, David Hyndman, Anjali Varma, Sarah Harrison
Thank you to NRCan and Environment Canada for their financial support
Follow us on Twitter! Cement 2020 business cards are available at the front desk