Industrial Training Report at Lafarge Malayan Cement Langkawi Plant
Beneficial Recovery of Materials in Cement Industry · •Lafarge Exshaw Cement Plant is actively...
Transcript of Beneficial Recovery of Materials in Cement Industry · •Lafarge Exshaw Cement Plant is actively...
For a zero-waste future
© 2015 Geocycle
Beneficial Recovery of Materials in
Cement Industry
Presentation title, Function, 2015-01-01 © 2015 Geocycle
© 2015 Geocycle
Geocycle – Facts and Figures
Subsidiary of LafargeHolcim since the 1970’s
2000 employees
50 countries on all continents
180 cement plants (co-processing) facilities
80 pre-treatment facilities
14M tonnes of waste treated by Geocycle every year leaving no
residues
North America – 3M tonnes
16M tonnes of C02 emissions prevented through recovery of energy
from processed waste
2
© 2015 Geocycle
Exshaw Cement Kiln
© 2015 Geocycle
Lafarge Exshaw – Future of Co-Processing
• Lafarge Exshaw Cement Plant is actively working on securing a
permit to co-process the following materials:
Construction, Renovation and Demolition Waste (CRD)
Non-Recyclable Plastics
Wood based materials
Asphalt Shingles
Carpet and Textiles
Treated Wood (pressure treated, creosote)
Rubber
Nylon Fibre (derived from tires)
© 2015 Geocycle
Co-Processing and Beneficial Resource Recovery
“Sometimes the best thing to leave our children
is nothing”
© 2015 Geocycle
What is Co-Processing?
Simultaneous recovery and recycling process
Combustible Waste = Energy
Mineral Waste = Raw Material
Developed in the late 1970’s
Co-processing is NOT incineration (WTE)
Higher on waste management hierarchy than incineration and
recognized as such in various jurisdictions worldwide
Unique waste management solution
Main objective is substitution of primary fossil fuels and raw
materials in one single industrial process. The production of clinker
and cement.
No ash residues generated through co-processing as mineral
components are recovered in the cement product
Regulated process
Higher on waste management hierarchy than incineration (WTE)
6
© 2015 Geocycle
Advantages of Co-Processing
LCA demonstrates co-processing offers superior environmental
performance to landfilling and incineration
Completely destroys waste material due to high temperature (1450C) and
long residence time
Avoids formation of dioxin and furan due to temperature profile
Leaves no ash that needs to be landfilled
Reduced GHG emissions as waste is used to replace fuel
Preserves non renewable materials (fossil fuels and minerals)
7
© 2015 Geocycle
Co-Processing Reduced GHG Emissions
Presentation title, Function, Name, 2015-01-01 8
© 2015 Geocycle
Typical Alternative Fuels
• Wood materials • Non-Recyclable
Plastics • Paper • Coated paper • Biomass such as seeds
and shells • Treated Wood • Used oils • Oil sludge
• Municipal Solid Waste
• Roofing tear-off
• Tires – whole or shred
• Carpet
• Textiles
• Waste oils and solvent
• Coffee chaff
• Haz wastes
• And many more….
© 2015 Geocycle
Presentation title
Cement Manufacturing Process
Presentation title, Function, Name, 2015-01-01 10
“Understanding the cement manufacturing process is of
prime importance to understanding the business of waste
derived alternative fuels and working with cement plants.”
© 2015 Geocycle
Cement vs Concrete – There is a difference!
Cement Concrete
Water + Rocks +Sand
© 2015 Geocycle
Cement Manufacturing Process
Step 1. Create a raw mix
Step 2. Burn the raw mix in a kiln to produce
“clinker”
Step 3. Pulverize the clinker to make the powder
known as cement
Knowledge of the cement manufacturing process is crucial
to understanding the alternative fuel (AF) business
© 2015 Geocycle
Step 1. Creating a raw mix
• Raw materials are combined in exact proportions to create
a chemically correct raw mix Silica (sand, clay, shale)
Alumina (clay, shale, low grade bauxite)
Iron (mill scale, smelter slag)
Lime (limestone)
• Raw mix is pulverized in a mill
© 2015 Geocycle
Creating a Raw Mix
Cement
Alumina: Ash
Silica: Sand Limestone: Quarry
1450oC
Chemical
Transformation
Iron: Steel slag
Burning the raw mix
Pulverizing Clinker to
Cement w/Gypsum
© 2015 Geocycle
Step 2. Burning the raw mix in a kiln
• Raw mix is burned in a kiln
• Material temperatures >1450 0 C
• End product is cooled to form pellet size material “Clinker”
• Alternate fuels are introduced here
© 2015 Geocycle
Step 3. Pulverizing the Clinker
• Clinker is combined with a small percentage of
gypsum and ground in a mill to produce the powder
know as cement
© 2015 Geocycle
Cement Manufacturing Process
© 2015 Geocycle
Cement Kiln – Heating and Burning Zones
AF burned here
AF burned here
© 2015 Geocycle
Cement Kiln – Heating and Burning Zones
• Exshaw kiln is newest technology (short dry kiln with 5 stage cyclones
and PRE-CALCINER)
• Precalciner burning zone
• “Forgiving” for AF. Can accept larger particle size (2” minus), some
contamination (i.e. oversize, metal that gets through), and higher
moisture than feeding into the main burner zone
• 7 seconds retention time
• Main Burner Firing
• Requires the highest quality fuels
• Requires very good heat values (20 gj/t +) in order to maintain
constant flame shape and temperature – otherwise cement
production is compromised
• Particle size of 3/8” minus (very high grinding costs)
• Very low moisture required and NO contamination
• Currently no fuel is fired in the pre-calciner
• Burner nozzle subject to plugging
© 2015 Geocycle
Cement Kiln – Heating and Burning Zones (2/2)
• Preheater Tower Kilns (Delta, Lafarge Kamloops, Lafarge Bath)
• Primary difference is these kilns have no pre-calciner (firing point) in
the tower.
• Thus AF’s are primarly fed through the main burner and possibly the
kiln inlet (back end)
• Requires 3/8” minus sizing (expensive to grind)
• Recommend this particle size is screened (always better to screen
than grind) out for customers requiring this particle size, when
making fuel for Lafarge specs
© 2015 Geocycle
Presentation title
Co-Processing and Beneficial
Resource Recovery
Presentation title, Function, Name, 2015-01-01 21
© 2015 Geocycle
Alternative Fuel Opportunities: C&D
• Construction and
demolition debris,
industrial solid waste,
and other waste are
ground for use as an
alternative fuel/ coal
replacement.
• Richmond, BC Plant
© 2015 Geocycle
Alternative Fuel Opportunities: Wood residues
• Cedar shavings
• Mill planings
• Mill wastes
• Secondary
manufacturing Wood working
(cabinetry etc)
• Green wood (hog)
typically not suitable
due to high moisture
© 2015 Geocycle
Alternative Fuel Criteria - Expected Exshaw Specs
Description Minimal Nominal Maximum
Moisture As low as possible 15% 20-30% (TBD)
Particle Size (2D) 90% passing at 3.0” Max 4” any dimension
Particle Size (3D) 90% passing at 2.0” Max 3” any dimension
Thickness < 10mm
Chlorine (Cl) As low as possible 0.3% TBD
Ash < 20% TBD
Low Heat Value 12 Gj/tonne 16 Gj/tonne
Sulfur 1.0%
Lab Analysis Required to Qualify ASF:
• Proximate Analysis and Ultimate Analysis
• Net Calorific Values
• Moisture %
• Chlorine %
• Total Metals – SALM (EPA 6020A)
• Mercury total by CVAA (BCMOE/EPA)
Contamination:
When sourcing materials for the
production of ASF, the material
should be as free of contamination
as possible (i.e. rocks, dirt, metals,
other non-combustible materials)..
© 2015 Geocycle
Lafarge Exshaw – Future of Co-Processing
• New kiln commissioned June 2016 – 2M tonne total plant
capacity (two kiln lines)
• Estimated co-processing capacity at 150,000-180,000
tonnes of waste byproducts annually based on 50%
thermal substitution rate by alternative fuels
• Permit process underway Partner with Pembina Institute, University of Calgary
Project Advisory Council set up with stakeholders (local
gov’t, community members, NGO’s, plant staff)
• If permit approved next stage is construction of a
storage, handling and feeding system ($30M+) Capital approval process
© 2015 Geocycle
Low Carbon Fuel System
Richmond
Pneumatic
Transport &
injection
Kiln Building
Reception
& Storage
Hall
Screening Blending
Main burner
Reception
© 2015 Geocycle
Risk Management
Risks professionally managed
© 2015 Geocycle
The H&S “rules”
28
H&S policy H&S rules
H&S management system
AFR policy
Commercial directive
Design & engineering
directive Operations directive
ACert
© 2015 Geocycle 29
What is ACert*?
Overview of the ACert Risk Management System
ACert Program is a comprehensive assurance
methodology for LafargeHolcim Group Companies
involved in the waste management for co-processing
value chain to gauge compliance in order to evaluate,
understand and control their H&S, environmental and
specific business risk exposure.
© 2015 Geocycle 30
The AFR policy defines the principles which are mandatory to be followed including H&S
This policy should be implemented in all pre-processing and co-processing facilities
The AFR directives defines the requirements which are mandatory to comply with, in order to fulfill
the AFR Policy principles
They cover dedicated points to waste management business and complete LH «rules »
AFR Policy and Directives
Commercial Design and
engineering
Operations
• Qualification of the waste
• Risk assessments for all new AFR
• Logistics and transport
• General Health and Safety Aspects
(human contact, ventilation,
escape routes, alarms, AFR lab,
etc)
• Explosion risks
• Fire risks
• Industrial hygiene and medical
monitoring
• Risk assessments for all new AFR
or ways to process AFR
• Emergency plan
• Qualification of the waste
• Acceptance, quality and H&S
control
• Acceptance, emergency equipment
• Acceptance, unloading
• Non compliance management
• Logistics and transport
© 2015 Geocycle
Cement Kiln Use Summary
© 2015 Geocycle
Cement Kiln Beneficial Recovery
• Cement kilns can provide complete and safe
destruction for a variety of byproducts while
recovering their inherent value.
• Beneficial recovery is aligned with the concept of
sustainable development through the replacement of
fossil fuels and conventional materials with
byproducts.
• Proven safe use of byproducts at many cement
plants worldwide.