Cement Plant in 2015 PDF

The Cement Plant in 2015
By
Ove Jepsen
Senior Vice President
The information contained or referenced in this presentation is confidential and proprietary to

FLSmidth and is protected by copyright or trade secret laws.
Historic Perspective
Where did we come from?
Where are we now?
Where do we go?

Maximum Kiln & VRM Capacity

16000
> 50 % ave.
increase per
decade
14000
12000
10000
8000
Kiln MTPD
VRM MTPH
(x 0.1)
6000
> 65 % ave.
increase per
decade
4000
2000
0
1950
1960
1970
1980
1990
2000
Year
2010
Trend for Energy Consumption in

Cement Production
1600
1400
Power consumption
kWh/MT (x 0.1)
> 5 % ave.
decrease per
decade
Fuel consumption
Kcal/Kg
1200
1000
800
600
> 9 % ave.
decrease per
decade
400
1950
1960
1970
1980
1990
2000
Year
2010
Trend for NOX & CO Emission

2500
NOx emission
mg/nm3 @ 10% O2
2000
ppm CO
1500
1000
500
0
1950
> 26 % ave.
decrease per
decade
> 49 % ave.
decrease per
decade
1960
1970
1980
Year
1990
2000

2010
Only Four Ways to Reduce Fuel Consumption:

Mineralized clinker
Add slag to the raw mix, which will reduce both the
heat of reaction and the CO2.
Change the heat of reaction (Reduce LSF)

Reduce the cooler loss:
- Which would increase the secondary and

tertiary temperatures drastically
- And give problems at the nose ring and TA
damper
Influence of Addition of Slag to Mix

1000
900
> 30 %
decrease
g CO2 /Kg
800
Kcal /Kg
> 14 %
decrease
700
600
0
10
20
30
40
% Slag in Mix
50
Alternative Fuels
The next generation cement plants will be designed for
using up to 100% alternative fuels:

- Liquid and solid waste
- Biomass (corn, algae, straw, etc.)

- Household waste
- Municipal waste

Low NOX ILC Calciner

with HOTDISCTM
Reactor
Waste
Air
Fuel

Raw
Meal
Input
Hybrid Calciner Concept

ILC
ILC
Downdraft
Calciner
HOTDISC
Environmental Challenges
Current
Projected
THC
20 ppm @ 7% O2
5-10 ppm @ 10% O2
Hg
40 g/nm3
< 20 g/nm3
NOx
1.95 lb/ST
< 1.0 lb/ST
SOX
0.3 3.0 lb/ST
< 1.33 lb/ST
Particulate
25 mg/nm3 (0.01 gr/scf)
< 0.172 lb/ST (~ 15 mg/nm3 )
How will CO2 tax/credits end up?
THC will be an enormous challenge

if coal mill exhaust is included.
Cement Plant Cogeneration & THC-control

SLC
3-stage
preheater
ILC HOTDISC
T>530oC
ROTAX-2
MMC cooler
Clinker
Fresh air
H2O into
Dual boilers
Vent
High
T/P
steam
Turbine
Raw mill
Stack
Steam heat
exchanger
THC Control from Raw Grinding
Clinker cooler
Fresh air
Heat
exchanger
Bag filter
Vent
Bag filter
Steam
heat exchanger
Raw
mill

RTO Plan View at TXI
200 ft
80 ft
Re-Therm RL
Regenerative Thermal Oxidizer
RTO
Inlet
Fresh Air
Fan
Combustion
Blower

Economy of Scrubber & RTO

RTO
Scrubber
Booster Fan
=
=
=
17.6 M $
11.5 M $
2.9 M $
31.0 M $
* Assume an internal interest and

depreciation of 15% for a 2 M STPY plant
Yearly Depreciation Expense

Operational Cost
TOTAL COST
=
2.33 $/ST
3.03 $/ST
5.36 $/ST

Gas Suspension Absorber

Sorbent
Mercury Roaster
Quench
Quench
To stack
Baghouse
dust
Calcium
chloride
Clean
Dust
to silo
To
finish
mill
Heat source
(bypass,
HGG)
TheCooler,
information contained
or referenced in this presentation is confidential and proprietary to
Mercury Roaster Efficiency
Total Stack Mercury Emission

Reduction with Roaster(%)
80%
70%
60%
50%
40%
30%
Reduction in Mercury
with Roaster (%)
20%
10%
0%
0%
10%
20%
30%
40%
50%
60%
70%
Main Baghouse Mercury Adsorption (%)

80%
90%
100%
Coal mill
gases
Mercury Removal
Kiln/
raw mill
gases
Main filter
Stack
Filter for
carbon removal
Recycled
carbon
Activated carbon/
lime injection
To waste
CO2 From Cement Production

Assume: 700 Kcal/Kg, 100 kWh/MT
Raw
Raw
0.56
0.56 Kg/Kg
Kg/Kg clinker
clinker
59%
59%
Total = 0.94 Kg/Kg clinker
Power
Power
0.10
0.10 Kg/Kg
Kg/Kg clinker
clinker
11%
11%
Coal
Coal
0.28
0.28 Kg/Kg
Kg/Kg clinker
clinker
30%
30%
Minimum Possible Carbon Footprint for Clinker

Production without CO2 Sequestration
Assume: 0.94 Kg CO2/Kg clinker
Alternative Fuel
Change in Kg CO2/Kg Clinker
100 % bio/waste fuel
- 0.28
Power from cogeneration,

wind and bio fuel
- 0.10
Using 42 % slag in raw mix
- 0.29
Correction for double dipping

due to fuel reduction with slag
+ 0.04
Total reduction of Kg CO2/Kg clinker:
- 0.63


Alternative Fuel
Change in Kg CO2/Kg Clinker
100 Remaining
% bio/wastecarbon
fuel
footprint:
- 0.28
0.31 Kg CO
2/Kg clinker
Power from cogeneration,

wind and bio fuel
- 0.10
Using 42 % slag in raw mix
- 0.29
Correction for double dipping

due to fuel reduction with slag
+ 0.04
A reduction of 67%
- 0.63


Remaining carbon footprint:
0.31 Kg CO2/Kg clinker
A reduction of 67%
To reduce CO2 even further,

and achieve a negative carbon footprint,
- 0.63
we need.....

CO2 absorption by algae growth

Algae Growth Ponds

Converting CO2 into Green Algae Growth

Assume: 90% of CO2 is converted to algae:
90% of 0.94 Kg CO2/Kg clinker
Kg CO2
Kg C
0.846
Kg clinker
12
0.846 Kg CO2/Kg clinker
44 Kg CO2
= 0.231
Kg C
in algae
form
Kg clinker
Pure Carbon has ~ 9,000 Kcal/Kg:
0.231
Kg C
Kg clinker
X 9,000
Kcal
Kg C
2,077

Kcal
Kg clinker

We use 750 Kcal/Kg clinker in the process, so
2,077
Kcal
Kg clinker
=
=
=
from
algae
1,327
463
750
used in
process
Kcal
Kg clinker
Kcal
Kg clinker
left for power

generation
kWh
T clinker


We typically use 95 kWh/T clinker, so
463
kWh
left
over
T clinker
367
95
kWh
T clinker
kWh
T clinker
is available for production of UV light

and/or to sell back to grid
used in
process
Economy for a 1 Mta Plant

Fuel:
750 Kcal
Kg clinker
1 Ton coal
6500 Kcal
$95.00
1 Ton coal
= $10,961,500 Year
Total Savings = $20,461,500
/year
Power:
95 kWh
T clinker
$0.10
kWh
= $9,500,000
1 Mta
Year

1 Mta

Of the 367 kWh/T of power, use 67 kWh/T to produce UV
light and sell remaining to grid:
Additional
Income
300 kWh
X 1 Mta
T clinker
kWh
Total Savings = $20,461,500/year
=
$0.10
$30,000,000 Year


Of the 367 kWh/T of power, use 67 kWh/T to produce UV
light and sell remaining to grid:
Total Savings
= $20,461,500
300 kWh = $30,000,000
$0.10
Additional
Additional
Income
X
X 1 Mta
Income =
T clinker
kWh
$50,461,500/year
=
$30,000,000 Year
From investing in equipment to

produce green algae

Simple Flow Diagram

CO2
Water
UV-light
Growth
tank
Baghouse
Algae slurry
To power plant
Drier
Algae cake
To pyro

Filter
Press
Reduction of CO2 Taxes by Absorbing CO2 in

Algae (90%)
40
Million $/Y/MT
CO2 Tax Savings
50
30
20
CO2 tax
savings
10
0
0
10
20
30
40
50
CO2 Tax US $/t

60
Low Cost Plant

OFF
300 T
Dust
Premix
Raw
mill
335 TPH
PH
GYP
300 T
5000
TPD
Kiln
Sweetner
Cooler
75 T
Coal
CLK
1000 T
Coal
mill
CEM
MILL
25 TPH
220 TPH
Pack &
unload
Cement dome
100,000 T
(20 days)

The Ultimate Cement Plant
Combine the low cost layout with:

Algae growth
(negative CO2 emission and negative fuel and power
cost)
Add-on environmentally friendly equipment
(for an almost zero emissions plant)
Cogeneration from all waste heat
Result will be a totally green cement plant


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The Cement Plant in 2015

The information contained or referenced in this presentation is confidential and proprietary to

Where did we come from?

Where are we now?

The information contained or referenced in this presentation is confidential and proprietary to

Maximum Kiln & VRM Capacity

Trend for Energy Consumption in

Trend for NOX & CO Emission

The information contained or referenced in this presentation is confidential and proprietary to

Only Four Ways to Reduce Fuel Consumption:

heat of reaction and the CO2.

Change the heat of reaction (Reduce LSF)

- Which would increase the secondary and

Influence of Addition of Slag to Mix

using up to 100% alternative fuels:

- Biomass (corn, algae, straw, etc.)

The information contained or referenced in this presentation is confidential and proprietary to

Low NOX ILC Calciner

The information contained or referenced in this presentation is confidential and proprietary to

Hybrid Calciner Concept

5-10 ppm @ 10% O2

< 1.0 lb/ST

0.3 3.0 lb/ST

< 1.33 lb/ST

25 mg/nm3 (0.01 gr/scf)

< 0.172 lb/ST (~ 15 mg/nm3 )

How will CO2 tax/credits end up?

THC will be an enormous challenge

Cement Plant Cogeneration & THC-control

THC Control from Raw Grinding

The information contained or referenced in this presentation is confidential and proprietary to

RTO Plan View at TXI

The information contained or referenced in this presentation is confidential and proprietary to

Economy of Scrubber & RTO

* Assume an internal interest and

Yearly Depreciation Expense

The information contained or referenced in this presentation is confidential and proprietary to

Gas Suspension Absorber

The information contained or referenced in this presentation is confidential and proprietary to

Mercury Roaster Efficiency

Total Stack Mercury Emission

Main Baghouse Mercury Adsorption (%)

CO2 From Cement Production

Total = 0.94 Kg/Kg clinker

Minimum Possible Carbon Footprint for Clinker

Change in Kg CO2/Kg Clinker

100 % bio/waste fuel

Power from cogeneration,

Using 42 % slag in raw mix

Correction for double dipping

Total reduction of Kg CO2/Kg clinker:

The information contained or referenced in this presentation is confidential and proprietary to

Minimum Possible Carbon Footprint for Clinker

Change in Kg CO2/Kg Clinker

Power from cogeneration,

Using 42 % slag in raw mix

Correction for double dipping

Total reduction of Kg CO2/Kg clinker:

The information contained or referenced in this presentation is confidential and proprietary to

Minimum Possible Carbon Footprint for Clinker

Remaining carbon footprint:

0.31 Kg CO2/Kg clinker