www.GlobalCement.com Global Cement Magazine March 2017 35
4: All smiles on the Thorwesten
Vent / robecco / Yara Industrial stand. Left to right: Christian Fink (robecco), Ralf Schestak (Thorwesten Vent) and Carsten Pries (Yara Industrial).
is increasing quality control on imported waste and may eventually lead to the end of waste imports. There is a global oversupply of waste at the moment, so a Chinese ban would strongly impact on prices and profitability elsewhere in the industry. On the other hand, Europe currently ‘loses’ around 600Mt of waste each year to landfill that could be used as fuels and for other uses. Around 30% of municipal waste still ends up in landfill, although
there is a 2030 target of only 10%, EU-wide. An extension of ‘Ex- tended producer responsibility’ legislation should lead to more inherently recyclable products, and a reduction in supply for RDF. At the same time, competi- tion from the waste-to-energy (WtE) sector is likely to increase. CO2 prices are likely to increase,
possibly to Euro40/t, by 2030, although the Euro- pean cement industry may cease to be competitive at a rate of around Euro20/t. Plastics production will continue to grow worldwide, while paper recycling is at a high level already. The bulk of recycled paper is shipped to China, but again, higher quality barriers may decrease the amount admitted to China in the future. RDF has a CV value up to 15MJ/kg, while SRF has a calorific value (CV) of above 15MJ/kg and is
generally a highly processed ‘engineered’ fuel. Andy said that the market for SRF worldwide is around 60Mt. SRF is increasingly being pelletised, mean- ing that it can then be more easily co-processed and incinerated with coal. Freight rates are starting to rise again from historic lows, with price increases also being seen in container rates. Andy sug- gested that oil prices are now unlikely to rise above
US$75/barrel due to the impact of American drillers.
Vagner Maringolo of
Cembureau next spoke about opportunities for increased waste take-up for the European ce- ment industry. Vagner points out that the EU is moving towards a ban on landfilling for municipal waste, which will give a strong boost to the supply of alterna- tive fuels. A Cembureau/Ecofys study on the market potential of AF brought up a number of interesting conclusions. Around 10Mt of waste was co-processed in cement kilns in the EU28 in 2015, representing around 2% of total combustible waste each year, but representing 10% of all of the energy recovery from waste in the EU.
Jaime Ruiz de Haro, president of Cemex Spain
and president of Oficemen, the Spanish Cement Pro-
8: Christophe Garcia (left)
and Eric Plantie (right) on the Precimeca stand.
4
5
6
7
8
9
10
11
12
13
5: The stand of US-based
tyre derived fuel equipment manufacturer EcoGreen Equipment.
7: Staff from Molinari Recycling
answer questions about the company’s shredding equipment.
6: A busy scene at the Keith
Walking Floor stand, a producer of unloading and related equipment.
9: UNTHA shredding
technology‘s Daniel Wresnik explains an aspect of the company’s technology to an interested visitor.
10: A busy scene at
the impressive Grupo SPR stand, a Spanish manufacturer of waste processing and fuel preparation equipment. The company won the prize for best exhibition stand.
11: Schenck Process’
Leos Volesky (right) answers a visitor’s question.
12: Jason Titmus of
Thermoteknix Ltd, a producer of infra-red imaging equipment for the sector, poses on the company stand.
13: The BHS Europe, Nihot and
NRT stand had an interactive display.
ducers’ Association, next spoke about the development of AF in Spain. Average cement consump- tion in Spain in the last 50 years was 25Mt/yr. However, consump- tion spiked to more than 50Mt in 2007, and has plummeted to just over 10Mt in 2016, a demand level last seen in the 1960s, pre- cipitating a huge crisis in the cement and construction indus- try. Spain is the largest exporter of cement and clinker in Europe. In Spain, 29 of the 33 Spanish cement plants are authorised to use AF, and 77 types of waste have been authorised for use in Spain. The tonnage of AF used in Spain has plateaued at 0.7- 0.8Mt/yr for the last five years, at a TSR of around 24%. RDF is the mostly widely used AF, at over 250,000t/year, followed by tyres (100,000t), biomass and animal meal. De Haro pointed out that high disposal fees strongly drive the use of AF in the cement industry, and he suggested that stronger implementation and enforcement of regulations and fees will be the main driver of increased AF use in the coun- try. In Spain a realistic target has been set to use 30% TSR by 2020, 45% by 2030, and 70% by 2050.
Mrs Dalia Sakr of the Inter- national Finance Corporation spoke about the use of AF in Egypt, starting with the energy crisis of 2013 when gas supplies were diverted from the cement industry to the power industry. This caused a fall in production of 50% and this caused the in- dustry to move strongly towards not only increased use of coal
but also increased use of AF. Mrs Sakr introduced a major study of potential sources of AF in Egypt,
including RDF, agricultural waste, dried sewage sludge and tyre- derived fuel (TDF). Agricultural waste is the largest waste stream of more than 30 - 35Mt each year, but production is geographically widely spread and the material has relatively low CV. Each year Egypt generates more than 21Mt of mu-
nicipal waste, forecast to reach 35Mt by 2025. At the moment only around 0.5Mt is used each year, but the best case scenario would be to use around 5Mt/yr. Around 1Mt of sewage sludge is produced each year, but a major challenge is to reduce its mois- ture content to economic levels. The amount of tyres produced each year is estimated at around 300,000t, but only 10% of this amount is used by the cement in- dustry. On the AF demand side, the Egyptian cement industry has a TSR of only around 7% but the majority of cement plants in Egypt have active plans to start to use or to use more AF in the next five to ten years. One of the main problems is that a gigajoule of energy from AF is not appreci- ably less expensive than energy from coal or petcoke. The qual- ity and security of the supply is also an issue, and Mrs Sakr stated that regulatory support will be required to improve the qual- ity of waste-derived fuels. As in other countries, the enforcement and increase in tipping fees will strongly drive the availability of AF in Egypt.
In the event’s next session, on alternative fuels production ad- vances, Daniel Wresnik of Untha spoke about new trends in SRF production. Daniel suggested that a strong trend in the industry is towards single- step shredding. He introduced several completed
GLOBAL CEMENT: CONFERENCE REVIEW
14
15
16
17
19
20
21
14: ATS Group / Walter Materials
Handling’s Basri Ogut (left) answers questions from delegates from Al Rajhi Cement.
15: Animated discussions on
the Presona stand.
16: Enotec’s Yerey García Suárez
(left) and Juan Carlos Quintero Fernández.
17: The SPEX Europe stand. The
company makes specialist laboratory equipment.
18
18: A smiling Weima team. From
left to right: Patrick Henzler, Kay Schulte, Erik Hagen and visitor Andres Salazar of Eco Green Equipment.
19: Lindner Recyclingtech’s
Gerd Tischner (left) and Marco Egger (right) proudly display the company’s Award for most innovative technology for alternative fuels use.
20: Discussions aplenty on the
stand of Finnish waste bale opening and wrapping systems manufacturer Cross Wrap Oy.
21: Westeria Fördertechnik’s
Felix Poth (right) in discussion with delegates.
projects including Geocycle projects in Vietnam, the US and Mexico. Requests from the industry led to the company to develop the XR mobil-e mobile shredder. Both the mobile and stationary shredders use slow- running single shaft shredding for rough, medium and fine shredding of waste.
Next, Eric Plantié of Precimeca introduced the tyre- shredding capabilities of his company, which include both stationary and mobile tyre shred- ders. The company has striven towards clean-cut and homo- geneous size of chips as well as a consistent output through the lifetime of the knives and no exposed beading wires that could lead to the clogging of the dosing system. Tyre supply is not prone to seasonality of supply and offers 25-30MJ/kg (6-7000kcal/kg), allowing nearly 1:1 substitution by weight with coal or petcoke. TDF has a bulk
density of around 0.5t/m3, is al-
most incompressible and can be stored outside with no ill-effects. TDF has a chlorine content of <0.1%, and sulphur content of less than 1.5%, making it a relatively easy-to-use alternative fuel. Eric mentioned a case study of a LafargeHolcim cement plant with a TSR of 60% using 70,000t of AF, of which 3000t is whole tyres and 15,000t was imported tyre chips of inferior quality. The plant specified that, instead of using imported chips, a new tyre shredder would have to produce 10t/hr of clean cut product, at a particle size of lower than 50mm. The plant settled on a fully-auto- matic stationary tyre shredder with two high-torque low-speed shearing rotors, capable of ac- cepting tyres up to a maximum diameter of 1200mm. The ro- tors will automatically reverse rotation direction to prevent any potential jam. The system includes a tyre chip classifier to ensure that all output is of below 50mm chip size.
Neville Roberts of fuel-
producer N+P next spoke on the subject of SubCoal SRF pellets. N+P has a reference plant at Delfzijl in the Netherlands for SubCoal production, and pellets have been shown to be hydro- phobic, while being capable of being co-ground with coal. SubCoal has a CV of 23.8MJ/ kg, and can be transported in containers, with no de-baling required at the end user, unlike some other types of AF. Loesche vertical roller mills and Atritor grinding systems have both been used to grind SubCoal pellets. N+P is busy setting up SubCoal production facilities closer to a number of cement industry users around Europe, includ- ing a new Euro14m 120,000t/ yr production plant at Teesport, near Middlesborough in the UK. SubCoal pellets from the plant will have moisture content of less than 8%, with CV of more than 20GJ/t, with the majority of the output of the plant...
22
23
24
See more
http://bit.ly/ 2lDXSkrScan the QR code below or enter the bit.ly code into your brower to read more about the
CemFuels Conference & Exhibition, see the con-
ference photo gallery and access the video....
GLOBAL CEMENT: CONFERENCE REVIEW
www.GlobalCement.com Global Cement Magazine March 2017 37
25
26
22: Entsorga’s Camilla Bonetti
(left) and Piotr Laube (right) on the company stand.
23: Borja Alonso (left) and
Tim Hamer of alternative fuel processing and handling equipment producer Vecoplan smile for the camera.
24: Alternative fuel feeding and
dosing experts from Di Matteo Förderanlagen. Right to left: Luigi Di Matteo, Clelia Di Matteo, Svetoslav Chopov and Roberto Dombrower (Colombian representative).
25: Jakob Overgaard (centre)
and Per Cederberg (right) of ReTec Miljø answer a question from a visitor to their stand.
26: Discussions on the Metso
Denmark stand.
27: Thomas Jennewein of
FLSmidth Pfister explains the company’s feeding and dosing systems to interested visitors.
28: Rubén Sánchez
Veiga of Cementos Cosmos (centre) visits burner manufacturer FCT Combustion.