Effective Utilization of Fly-Ash

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1 24 th Jan, 2013 in Mongolia under the framework of NAMAs Effective Utilization of Fly-Ash from Power Plant for Cement Production YOSHIYUKI UENOYAMA General Manager Green-Innovation Business Promotion Department TAIHEIYO CEMENT CORPORATION

2 Taiheiyo Cement s activities span the world Dalian(China) Qinhuandao(China) Japan (11 plants) Nanjing(China) Korea USA Vietnam Philippines Papua New Guinea Locations of Taiheiyo Group s cement plants 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%) Domestic Sales: 14,829 kt + Export 5,009 kt 2

3 Contents Outline of dry process of cement production and energy efficiency Recycling - utilization of by-products and industrial waste including coal fly ash Taiheiyo's advanced technology for utilizing MSW incineration ash Conclusion 3

4 Typical cement production process Limestone Belt conveyer Iron slag 1. Mining Clay minerals Stack Dust collector Preheater Coal Coal mill 3. Burning process Stack Material flow Fuel flow Gas flow Dust collector Raw mill Homogenizing i silo 2. Raw material process 4. Shipping Cement silo Classifier Rotary kiln Gypsum Clinker cooler Clinker silo Cement vessels Freighters Bulk trailers Bags Finish mill 4. Finishing 4

5 Raw material for cement Cement is made from Limestone, Silica, Clay and Iron slag Clay (dried) d) Silica Limestone Iron slag Limestone: Occupying 70-80% of total raw materials and transported from a mine by a belt conveyer, for instance Iron slag: By-product of iron manufacturing Limestone mine Long distance belt conveyer The composition of raw material effects property of cement 5

6 Burning process Excellent cement can be manufactured by burning at very high temperature of 1450 o C 1. Raw material is heated gradually by hot gas in the preheater 2. Preheated raw material is burned in the rotary kiln at a temperature t of 1450 o C 3. Approximately 30 min of burning, the raw material turns red-hot lava like lumps Preheater (back) of 65m in height and Rotary kiln (fore) of 5.4m in diameter, 95m in length, 3200 ton/day production capacity, 250 kw powered Inside view of Rotary kiln operating at a very high temperature of 1450 o C 6

7 Finishing process Grinding clinker with gypsum into fine powder, that is cement Clinker Gypsum To control setting time of cement Finish mill Power required: 3875 kw Milling capacity: 120 ton/h Size: 4.6m dia. and 13.1m Classifier Cement 7

8 Difference of wet-process kiln in energy efficiency Providing slurred raw material directly into rotary kiln Schematic wet-process cement kiln r) (MJ/t-clinke Specific required heat 0 Wet-process kiln Specific production of kiln volume DB-type SP-type NSP-type kiln kiln kiln Specific required heat and production on various types of kiln (kg/m 3 /h) 8

9 Specific required energy and energy efficiency (MJ/t-cement) Including alterative waste fuel Excluding alterative waste fuel Typical technology on heat efficiency - NSP type burning system - Five-cyclone cascaded preheater - Air beam type clinker cooler - Pulverizing coal constant feeder - Automated quality monitoring Transition of unit heat energy Typical technology on power efficiency - Vertical type mill - Pre-grinding system - High efficiency classifier - High efficiency blower fan (kwh/t-cement) Including waste heat recovery power generation 80 Excluding waste heat recovery power generation Transition of unit power 9

10 The top runner on energy efficiency 180 consump ption inde ex Energy Japan Thailand Italy Mexico Germany India Spain Brazil Korea Canada USA China Weighted Av. Comparison of Energy consumption index on clinker and cement manufacturing Reference :The International Energy Agency (IEA),Worldwide Trends in Energy Use and Efficiency

11 Business scheme of material recycling Practically performed Waste to Resources business scheme on cement plants Conservation of natural resources Prevention of global warming Elongation of landfill service life Industrial clustering Natural resources Recycling of municipal waste Steel plants Coal fired power plants Others waste tires waste plastics Blast furnace slag Coal fly ash Desulfurazation gypsum Limestone & slaked lime Alterative fuel & raw materials Cement plants Incineration ash Raw materials Admixtures Incineration ash Separation and Incineration Mixing admixtures Incineration MSW ge sludge Sewa sehold General hou Cement and concrete products 11

12 Utilizing by-products and waste Why by-products and waste can be utilized at cement plants? Because: 1. Cement majorly contains CaO, SiO 2, Al 2 O 3 and dfe 2 O 3. 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. 4. Hazardous materials such as dioxin can be decomposed in the rotary kiln under the high h temperature t of 1450 o C. 12

13 Chemical compositions of waste The reason why by-products and waste can be utilized at cement plants Composition of major elements (%) SiO 2 Al 2 O 3 Fe 2 O 3 CaO Total Alkali Na 2 O eq. Ordinary Portland Cement 20~23 3.8~ ~3.6 63~65 0.3~0.7 Major 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 Byproducts 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 and waste Sewage sludge 20~500 20~500 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=

14 Fly- and Bottom-ash recycling on cement production FY2009 Consumption of waste: 26,290kt/y (451kg/t-cement) Ref.: Japan Cement Association Cement Milling Mixing Dust-collector Fly ash By-product gypsum Clinker Gypsum Limestone Silica Clay Iron slag Drying Grinding Blending Raw material Organic Waste: Waste plastic Waste oil Coal Rotary Kiln Coal Bottom ash Other waste materials Fly ash Massive waste: Sludge Sewage sludge Tires MSW Clinker cooler 14

15 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 Construction material 17% Others 16% Landfill 3% Others Cement 15% 13% Total amount of recycling 8,924 kt Cement 64% Export 15% Total amount of recycling 1,056 kt Reuse basement 15% Thermal recycle Steel 10% 4% Paper 32% Usage of coal fly ash Usage of waste tires References: Japan Fly Ash Association and Japan Automobile Tyre Manufacturers Association 15

16 Utilizing by-products and waste Organic waste is potentially used as fuel Waste tires Waste plastics Wood chips and other biomass Recycled oil 16

17 Key technology of bypass system Enables to utilize respectively inorganic waste as raw material and organic waste as fuel, and to recover minor elements Raw material 400 o C Gas flow Material/Fuel flow Preheater Heat recovery boiler Dust collector Heat recovery boiler Coal mill Coal 1000 o C 1450 o C 250 o C Chloride bypass and minor elements recovery system Rotary kiln Clinker cooler Clinker 17

18 Waste to Resources on MSW management MSW AK (Applied Kiln) Development of Community Incinerators Incineration ash Ash processing Existing Cement Plants Eco-cement Cement & Concrete Landfill sites (extension of service life) Eco-cement Plants 18

19 AK(Applied Kiln) System Hidaka City: Population 50, MSW 15,000 ton/y Crushing and separating Aerobic bio- digester Incinerators Cement production line making use of digested MSW Saitama Plant, TCC 19

20 Ash processing systems Bottom Ash Processing System (50,000 t/y) Fly Ash Washing System (15,000 t/y) Kumagaya Plant, TCC 20

21 Eco-cement plant Futatsuduka Landfill, Tokyo One third of MSW in Tokyo has been recycled as Eco-cement since Tokyo Metropolitan Government has constructed the plant in their landfill site and operation has been commissioned i to TCCs subsidiary. - Input MSW (as incineration ash) 300t/d - Output Eco-cement 430t/d 21

22 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 by other industries as alterative raw material and fuel. 3. 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 efficiency i as well, and intends to consult with possible customers and to provide such technologies. Thank you for your attention. 22

23 Баярлалаа! Thank you for your attention ti 23

24 Locations of Domestic Plants Direct operation plant Subsidiary y and Affiliate Total production capacity: 21,067 kt/y Myojo 1,763 Eco-cement Kamiiso 3,829 Ofunato 2,032 Tsuruga 677 Kumagaya 2,027 Fujiwara F ji 2,326 Saitama S it 1,470 D.C. D C 1,199 Oita 5,744 24

25 Recycling systems clustered on cement industry 25

26 Reducing CO 2 Emission by utilizing waste as fuel Waste Fossil energy Energy from waste Fossil energy Incine- Co-combustion rators Cement plants at cement plants Reference: CEMBUREAU, Alternative Fuels in Cement Manufacture, be/documents/publications/ Alternative_Fuels_in_Cement_Manufacture_CEMBUREAU_Brochure_EN.pdf 26

27 Utilizing by-products and waste Transition of ratio of waste derived fuel Reference: Japan Cement Association Ratio of foss sil energ gy Waste derived fuel Fossil Energy Fiscal Year 27

28 Technical configuration of AK System Garbage trucks Bio-digester Crushing and separating Feed to rotary kiln MSW 1st day 2nd day 3dd 3rd day Digested MSW Garbage bags tear and fragment Aerobic digestion quickly MSW turns cement raw material and develops fuel 28

29 Fly ash processing system Water Dissolution tank Fly Ash Liquidid Gas From incinerators Belt filter Decanter Filtrate Settling Filter Cake Rotary kiln Kiln exhaust CO 2 reactor Filter press Sand filter Hg remover Filter cake Sewage 29

30 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-cement Eco-cement cement is regulated in JIS (Japanese Industrial Standards), and can be used easily for practical purposes. Heavy metals can be recovered Some of heavy metals, such as Cu, Pb and Zn can be recovered from collected dust. 30

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