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The use of alternative fuels and materials in cement...
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The use of alternative fuels and materials in cement sector: state of the art in EU vs Italy” Ing. Daniele Gizzi Milano, November, 20 th
Transcript of The use of alternative fuels and materials in cement...
The use of alternative fuels and materials in cement
sector: state of the art in EU vs Italy”
Ing. Daniele Gizzi
Milano, November, 20 th
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Associazione Italiana Tecnico Economica del Cemento
Associates (2013)
• Buzzi Unicem spa
• Cementir Italia Srl
• Cementerie Barbetti Spa
• Industria Cementi Rossi Spa
• Cementizillo spa
• Cementi Moccia Srl
• Colacem Spa
• Holcim Italia Spa
• Italcementi Group Spa
Plants in Italy
• N°52 full-cycle plant (Kiln)
• N° 28 Grinding facilities
• In each region you’ll find 1 kiln in
operation at least …(except in Liguria
Valle d’Aosta)
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EU Environmental Strategies = Low CARBON ECONOMY 2050
• Resource Efficency
• Energy Efficency
• Product Efficency
for Cement Industry means …..
• Alternative fuels
• Raw materials substitution
• Carbon Capture Storage (CCS) ?!
• Low carbon cement and concrete
Waste = RESOURCE = Green Economy
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Waste production in Italy
Municipal Solid Waste
30 Milions of tons (2011)*
Other waste stream
(Hazardous and not Hazardous Waste )
128.5 Milions of tons (2009)**
* Rapporto Rifiuti Urbani 2013 (ISPRA)
** Rapporto rifiuti speciali 2011 (ISPRA)
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Municipal Waste Management in EU*
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
UE-2
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Germ
ania
Aust
ria
Pae
si B
assi
Sve
zia
Dan
imar
ca
Belg
io
Luss
em
burg
o
Fra
ncia
Ital
ia
Fin
landia
UK
Spag
na
Irla
nda
Port
oga
llo
Slo
venia
Est
onia
Ungh
eri
a
Polo
nia
Gre
cia
Slo
vacch
ia
Rep.C
eca
Cip
ro
Lett
onia
Lituan
ia
Mal
ta
Rom
ania
Bulg
aria
Compostaggio
Riciclaggio
Recupero energetico
Discarica
Gestione dei RU in Europa, 2009
Ita
lia
Italia
Landfill
Composting
Recyling
Energy
*“Potenzialità e benefici dall’impiego dei Combustibili Solidi Secondari (CSS) nell’industria”
Nomisma Energia, 2012 - download www.aitecweb.com
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Italy – Waste Export ( hazardous and not ….)
Waste EXPORT 2010= 3,8 Milions of tons
Source: Rapporto Rifiuti Speciali, ISPRA 2012
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Infractions Procedures on Waste Management
Update to october, 2013 infractions open to Italy
25 (Environment) / 105 total
http://eurinfra.politichecomunitarie.it/ElencoAreaLibera.aspx
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EU - Economic Sanctions for Italy
European Court of Justice ‘s proposal for Italy
(not compliant management of 218 Landfills of which 16 per Hazardous waste )
61 Mln € + 256.000 €/day*
*Indennità di mora
** ANSA 31 ottobre NAPOLI - Rifiuti: navi in Olanda, esposto Rivellini a Corte Conti
ANSA 31.10.13 about Waste Export
Napoli (IT) Moerdijk (NL)
Until Today
4.850 t x 138 €/t = 669.300 €
Tomorrow ?!
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Use of waste in Cement plants : Co-Processing
Dir 2008/98/CE – (WFD) :WASTE Hierarchy
http://eur-lex.europa.eu/LexUriServ/LexUriServ.do?uri=OJ:L:2013:100:FULL:IT:PDF
Matter
Energy
EU Official Bullettin 9° April 2013
CE Desicion 26. 03.2013
Best Available Technique
http://world-you-like.europa.eu/it/perche-e-importante/recupero-riciclaggio/
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Cement Industry
Product (cement) quality has to be always granted
(Standard UNI-EN 197/1)
• Traceability:
– strict controls in acceptance concerning the compatibility of
all materials used (natural resources and waste) )
• On Line / continuous monitoring of the process :
– emissions levels are the main parameters of process
efficency: they are checked 24 h/day in continuous
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Resource Efficency : Alterantive raw materials (Aitec)
2012
Not Hazardous waste 1.016.000 tons
Alterantive Raw Materials = 1.333.000 tons
6.8 % Natural resources substitution rate
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The Kiln system (Dry process with calciner)
Specific Thermal Consumption:
3.200 - 4.200 MJ/t clinker
Fuel Fuel / Raw Material= 1/15
Limestone + clay
Stack Emissions
CALCINER T = 900°C
CaCO3 =
CaO + CO2
Main Burner
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Stack Emissions and Use of alterantive fuels (Studies)
COMMITTEE ON THE MEDICAL EFFECTS
OF AIR (UK 2009): “ The data
provided were reassuring. ….., no
changes in stack emissions were
likely to occur that would be of
significance for human health.”
CEMA, URS Corporation (2010):” … the
kind of fuel does not present a
significant influence in the calculated
risks indices.
it can conclude that no potential health
risk has been identified to any of
the receptors in the assessed
scenarios.”
ARPA CUNEO (2009) : “I dati del
Dipartimento Provinciale dell’ARPA di
Cuneo mettono in relazione una
diminuzione degli NOx nelle emissioni
con l’utilizzo di combustibile da rifiuto in
alternativa al combustibile fossile”
“…The risk was also calculated using
the emission data ……..using
hazardous waste as fuel for Secil-
Outão would not lead to a prediction of
risk levels of significant concern..”.
Intertox, (2007)
ARPA CUNEO (2009) : “I dati del
Dipartimento Provinciale dell’ARPA di
Cuneo mettono in relazione una
diminuzione degli NOx nelle emissioni
con l’utilizzo di combustibile da rifiuto in
alternativa al combustibile fossile”
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AITEC: First Sustainability Report (2009-2012)
Stack Specific Emissions (kg /t clinker)
• -7% NOx
• -15% SO2
• -10% DUST (PM10)
Resource efficency and Energy Efficency
• +20% Natural Resources Substitution rate (6,8% in 2012)
• +1% Fossil Fuels Saved Using SRF = 240.000 t (2012)
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Emissioni in atmosfera e utilizzo di CSS
Politecnico di Torino (2008) “L’utilizzo di
combustibili alternativi nei forni da
cemento consente di ridurre le emissioni
di NOx rispetto alla marcia a combustibili
fossili. Il beneficio quantificato dalla
commissione EUROPEA (2003) è stimato
pari a 0,36 kgNOx /t CDR utilizzato”
(Prof. Genon, Brizio, 2008)
PROVINCIA DI CUNEO (2009) “I
dati del Dipartimento Provinciale
dell’ARPA di Cuneo mettono in
relazione una diminuzione degli
NOx nelle emissioni con l’utilizzo di
combustibile da rifiuto in
alternativa al combustibile fossile”
(Dott. Fantino Atti FORUM PA
2009) CNR (2006) “DIOSSINE, la formazione
di tali microinquinanti è scoraggiata
dalla presenza del calcare (materia
prima) che blocca nel reticolo il cloro
presente, evitando i processi di
clorurazione” (Dott.Rotatori – CNR –
I.I.A., 2006)
CeSiSp “Le emissioni di polvere dei forni
di cottura del clinker dipendono
esclusivamente dalla tipologia del
sistema di abbattimento utilizzato, sia
filtro elettrostatico che a maniche di
tessuto, e dalla gestione operativa dello
stesso.” (Prof. Del Borghi, 2009)
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Use of Alterantive Fuels in raw materials
2012
305.000 tons - Total Alterantives
240 000 t - Fossil Fuel SAVED
450.000 t di CO2 Evmissions SAVED
10 % Thermal Substituion Rate (TSR)
AITEC - Alternative Fuels in Italian Cement industry (t/year)
0
20.000
40.000
60.000
80.000
100.000
120.000
140.000
160.000
180.000
200.000
RDF fromMSW Plastics and
Rubbers
Used Tyres Sewage
Sludge
Car Fluff Waste Oils Solvents Other liquid Animal Meat
SRF - Solid Recovered Fuels Liquid Alternative fuels
(Hazardous waste)
Other
t/year
2009 2010 2011 2012
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What Happens in Europe ? … Not In My Back Yard Sindrome ?
Thermal Substitution Rate in cement plants (%) 2011
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Cement Production
-
5.000
10.000
15.000
20.000
25.000
30.000
35.000
40.000
I talia Spagna Germania Francia Regno Unito Paesi Bass i Austr ia
x 1
.0
00
to
nn
ell
ate
/a
nn
o
2011
2010
2010
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Emission Trading Scheme: Allowances CO2 2013 -2020
Cement sector = carbon leakage
Free Allocations according benchamrk
60 % process
In italy biomass content of the fuel mix = 6 % !!!!
40 % Fuel
Clinker ‘s Benchmark
766 kg CO2/t clinker biomass content in
FUEL Mix = 20 %
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LOW CARBON ECONOMY 2050 ROADMAP
Reduction fo 80 % CO2 Emission (2050)
Suggested by EU for CEMENT INDUSTRY
( -32 % on the acutal basis)
81 Millions CO2 Still need to be eliminated It has been assumed that …
85% of total clinker production (59 % of cement plants in EU)
will need to be equipped with breakthrough technologies
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(A.I.A e V.I.A)
6 years – average Time to get permits (IT)
6 -18 months Average Time in EU (DE e
FR)
Permits Procedures in Italy vs in EU and public opinion
D.M EoW
End of Waste (Dm 22/2013)
Public opinion and
Public Authorities
NIMBY – people ….
NIMTO - Authorities
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DM 22/2013 IT EoW Regulation for Solid Recovered Fuels
The Minister for the Environment and Land and Sea Protection
Necessary to promote the production and use of SRF, under certain conditions, with the aim of:
reducing polluting emissions, including climate-altering gasses
increasing the sustainable use of the biomass contained in waste
reducing the environmental and economic burden of waste disposal in landfills
reducing dependence on traditional fuels and saving natural resources
Increasing traceability for some waste streams
contributing to solve waste emergencies
Necessary to encourage production of high quality SRF
to increase confidence in the use
to provide legal clarity and uniform behavior nationwide
Reducing waste management costs
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SRF – IT EoW Decree : the multi-stakeholders process
Working Group for the elaboration of the draft
UNI – CTI : Technical Committee of Italian Standardization Body
LEGAMBIENTE: The most important National Environmental NGO
National Associations of Waste Management (collection, recycling, treatment, incineration, landfill) – public companies
(FEDERAMBIENTE) and Private (FISE ASSOAMBIENTE)
ASSOELETTRICA: National Electricity Producers’ Association
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National Supervisory and Monitoring Committee
Tasks
• Promoting a communication campaign
• monitoring the environmental impacts of the production and use of SRF
• verifying application of the criteria of efficiency, effectiveness and economics
• promoting cooperation between the parties
• examining quantities and quality of production and use of SRF
• monitoring the implementation and guaranteeing uniform and coordinated application of
the regulation
• yearly report to the Government
Members (tot 9)
• 2 by the Minister of the Environment
• 1 by the Minister for Economics
• 4 by associations of producers and users plants
• 1 by NGOs;
• 1 by Italian Thermo -technical Committee (CTI)
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FAQ – Frequently Asked Question
“Does the Italian Regulation go against Waste Framework Directive ? ”
No: it’s fully in line with WFD and with European strategy of “Zero discharge”.
“Is it dangerous for public health and environment ?”
SRF production and utilization will be operated under stringent and controlled
conditions, regulated by permits released by the Authorities. For some parameters,
limits in chemical composition are more stringent than EU limits (es. Metals…).The
stack emissions deriving from SRF combustion, for some pollutants are lower than
fossil fuels (NOx, CO2) and, in any case, shall be under co-incineration limits (Dir IED).
“Are illegal and criminal waste management encouraged by this regulation ?”
No, it’s the opposite: the increased traceability (comparing to landfills) and the
continuous control activities on industrial plants, guarantees against infiltration of
criminal activities.
“Does the regulation go against a virtuous “waste management”, not
considering prevention, re-use and recycling ?”
No, it doesn’t: the most part of SRF are produced starting from MSW fractions no more
recyclable and industrial waste with no chance of re-use at the end of their life cycle.
The regulation is a progress for National Authorities who intend avoiding landfills.
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Utilization of IT SRF EoW (Cement and Power Plants only)
Industrial plants admitted
1. CEMENT PLANTS with capacity > 500 t/d of clinker
2. THERMAL POWER PLANTS with heat rating > 50 MWt Obligatory for both categories: Authorization (according to Dir IED) and UNI EN ISO 14001 or EMAS
Stack Emissions Limits for
• Co - incineration limits (Dir IED): for cement plants: 500 mg/Nm3 NOx , etc …
derogations for CO and SO2
Yearly communication to the Authorities
• Quantities (t) and type (Classes) of SRF used
• Thermal Substitution Rate (TSR) [%] of fossil fuels
• Reduction of CO2 emissions (saving by the use of SRF Biomass' content)
• Reference of the producers
• Laboratory’s analyses by the producers and other eventual analyses carried out
by the users
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More Info …
www.aitec-ambiente.org
Ing. Daniele Gizzi
AITEC Environmental Manager
