- Associação Técnica da Indústria de Cimento FORO DE INSTITUTOS DE FICEM Energy efficiency Current situation and trends of the Portuguese Cement Industry 1
AGENDA ATIC s and Portuguese Cement Industry presentation Energy Efficiency Introduction Calorific consumption Electric energy consumption Alternative raw materials Non-CEM I Cements 2
ATIC s and Portuguese Cement Industry presentation ATIC - Associação Técnica da Indústria de Cimento Associated companies: CIMPOR o Business Activity in 13 countries at world level o 3 plants in Portugal (6 kilns) SECIL o Business activity in 5 countries at world level o 1 plant in Portugal (2 kilns) CMP o 2 plants in Portugal (4 kilns - 1 of white Ck) 3
C. P. Souselas Fábrica Cibra-Pataias Fábrica Maceira-Liz C. P. Alhandra Fábrica Outão MOSSINES C. P. Loulé CIMENTAÇOR 4
9, Clinker Production (Mton) 8, 7, 6, 5, 4, 3, 2, 1,, 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 5
11, Cement Production (Mton) 10, 9, 8, 7, 6, 5, 4, 3, 2, 1,, 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 Installed Global Capacity of 10,97 Mton Number of workers - 1352 (2008) 6
Introduction Technological transformations o Most important investments before 1990 Before and after EU ETS Aspects of energy efficiency o Calorific consumption o Electric energy consumption Process emissions - Alternative raw materials Importance of alternative fuels 7
Calorific consumption 845,0 kcal/kg clinker 840,0 835,0 830,0 825,0 820,0 815,0 810,0 805,0 95 96 97 98 99 00 01 02 03 04 05 06 07 08 8
Calorific consumption Most important investments o Transformation from wet to dry process o Pre-heater towers (today in all kilns, except 1 white clinker kiln) o and/or pre-calciners (in 4 of 11 kilns) o False pre-calciners o Sistems of automatic kiln control 9
Calorific consumption Alternative fuels 18,00 % Alternative fuels 16,00 14,00 12,00 10,00 8,00 6,00 4,00 2,00 0,00 95 96 97 98 99 00 01 02 03 04 05 06 07 08 10
Calorific consumption Alternative fuels o The use of alternative fuels is considered BAT (Best Available Techniques) according to the recently approved BREF (May 2010) o The use of RIPs (Hazardous Waste) Government option for CIRVERs (Integrated Centers of Recycling, Recovery and Elimination of Hazardous Waste) All RIPs go first to CIRVERs. Only the RIPs not recovered in CIRVERs are incinerated in cement kilns, according to contracts between cement companies and CIRVERs This means to incinerate less RIPs than other European countries, that can use RIPs with higher net calorific value 11
Calorific consumption Alternative fuels o Legal problems to use RIPs o Huge variation between installations as a result of RIBs (Non- Hazardous Waste) availability o Its use is expected to increase o At European level there are already installations with 100% of substitution of conventional fuels o Biomass: Importance (CO2) Availability 12
Calorific consumption Alternative fuels o Alternative fuels consummed: Used tyres and shredded tyres Vegetal (wood, wood fragments, cork waste) and animal (animal meal) biomass RDF (Refused Derived Fuels) Fluff (end of life vehicles) Industrial sludges Waste oils 13
Electric energy consumption 102,0 kwh/t cem 100,0 98,0 96,0 94,0 92,0 90,0 88,0 95 96 97 98 99 00 01 02 03 04 05 06 07 08 14
Electric energy consumption Investments o Transformation of pneumatic into mecanic transporters o 3th generation separators o speed converters (variable speed motor) o Installation of soft starters Key factor for consumption o Market structure as far as traded cement types are concerned (cements with more or less embeded energy) 15
Use of alternative raw materials The availability issue Alternative raw materials used o Used foundry sand o Industrial sludges o Waste concrete and concrete sludge o Waste limestone and wastes from stone cutting ofly ash and bottom ashes o Pyrite ash 16
Non-CEM I Cements Main issue - less % of clinker Less % of clinker means less energy consumption Promotion campaigns developed by companies Cembureau created a dedicated TF Possible use of wastes from other sectors (fly ashes and granulated blastfurnace slag) The result will be lower CO2 footprint in final product 17
Thank you very much for your attention 18