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Warm up
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Production and Storage of solid alternative fuels for
substitution rates of over 30% in the Cement industry
presented by Peter Windmoeller
Agenda
background of the company VECOPLAN and the speaker
example 15t/hr substitution, detail
example MSW, conceptual
example wood, conceptual
questions
35 slides total, Test after slide 23, please keep pen and paper ready.
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Turnover
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in Mio.
Export quota: ~ 70%
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Employees
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Stable growth
Focus on education: 37 apprentices in 2008
(Germany)
328 Anges tellte
28 Aus zubildende
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Markets
Vecoplan AG and its affiliated companies
develop, produce and market machinery and
plants for the processing of
_ wood and biomass
_ plastics,
_ paper,
_ municipal and industrial waste,
_ specialty materials.
Vecoplans products and solutions are able to
cover the whole recycling process of these and
other materials.
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Products and services
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Single shaft shredders Double shaft shredders Chippers
Conveying technology Screening technology Separation technology
Sorting technology (intelligent) Storage sytems Full in house engineering
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Constant R&D
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HiTorc - Drive VAZ - Shredder
Film and fiber rotor Flipper
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Clients (partial)
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background of the speaker
As independent representative:
VECOPLAN cement industry
UniGear, specialty gears and gear box repairs
As partner in LOGEQUIP:
AirStream, fan upgrades
Darimec, girth gears
unitherm, burners
Iteca, process control
other
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example Ciment Quebec
processing on site
Customer: Cement plant, 1000000t/a, dry process
Status: in operation since August 2009
Capacity: over 20t/hr
dry insustrial waste
majority autofluff
Addition for
preparation and
storage of
alternative fuels
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Concept (not final layout)
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Receiving and preshredding
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Preshredder
Waste 0 - >1500 mm
Waste 0 200 (250) mm
Reality check:
Walking
floor
unloading
manual
feed
opening
Door to
rotor open
Discharge
with
cleaning
cvoneyor
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FE separation and screening
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FE separation and Screening
FE Parts
<50 (60) mm 50 (60) 120 mm
120 -200 mm
Reality check:
Covered
screen
area
Discharge
small
fraction
Collecting
conveyor
to storage
system
Discharge
large
fraction
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Density separation
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Density separation
Light fraction Heavy fraction
Reality check:
Discharge
to
vibrating
Vibrating
to belt
Heavy
discharge
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Reshredding
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Reshredding
RDF fuel to
storrage
Reality check:
2 reshredders
Collecting
conveyor
to storage
system
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Storage
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Not just storage but intelligent storage!
Input: sorting into different fuel qualities
Output: blending into a most possible consistent quality,
managed by kiln control operators.
low
medium
high
Reality check:
2 infeed
conveyor
Fuel in
storage
system
Discharge
system
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What does this mean from the viewpoint
of the control room? (assuming 35% substitution rate)
BTU
PVC
Coal fracti on (65%)
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COAL highquality mediumquality low quality BLENDED
l ow qual i ty
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COAL highquality mediumquality low quality BLENDED
medi um qual i ty
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COAL highquality mediumquality low quality BLENDED
hi gh qual i ty
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COAL high quality mediumquality low quality BLENDED
Coal / RDF bl end
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COAL high quality mediumquality low quality BLENDED
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Intelligent storage is part of the production!
AFTER blending
NOT after grinding
Where is the final point of the fuel preparation line?
(Rethorical) Test question:
Vecoplan philosophy:
Fuel production Fuel storage
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Final consideration: Future expansion, fill
the gaps
End fluff example, you made it 2/3!
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example MSW
green field layout
processed off site by separate entity
only receiving and storage at the cement plant
Customer: J V in North America
Status: quote on hold
Capacity: 60t/hr at MSW processing
expected yield(dry, light, high BTU): 20%
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Material preparation, first location =landfill
60t/hr
20t/hr
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Receiving and storage, second location =cement plant
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example wood
integration in existing plant layout
receiving of preshredded green wood
screening and processing on site
drying by others
Customer: cement plant in North America
Status: project to be downsized due to EPA
Capacities: 15t/hr out of the dryer (24/7)
receiving 120t/hr
3 day on site storage of green chips
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Receiving, storage and processing
(integrate into existing plant layout)
Vecobelt
Rail track
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Vecobelt
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Vecobelt, 155 m (about 450)
eliminateobstacles
on the gound
Extend Veco belt
into tower,
eleiminate tower
extensioins
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It is realistic??? (2008 figures)
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RecentpatterninuseofRDF
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Does it pay???
1t/hr coal replacement
* 7500hrs/year operation
=7500t/year coal replacement
* 20USD/t cost advantage over fossil fuel
=150000USD/year fuel cost reduction per ton replaced
Alternative fuel projects strongly benefit from economies of scale
Bigger is better regarding
1. Economics, payback
2. Project management, very limited technological risk
3. Process control / operations, constant part of fuel mix
That depends (please use your own numbers)
Other considerations:
Gate fees for HazMat
Carbon tax
Sustainability
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What do the neighbours say???
Lafarge, Woessingen, Germany: target 2009 : 100% subsittution rate =>
(85% more realistic)
Negative fuel costs
Germanyhas an
average population
density which is higher
than in most regions in
the US
The Green Party
is a constant part of
the federal and
regional parliaments
since over 20 years
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Thank you for your attention
please quietly wake your neighbour
Questions welcome!
Come and see us
At booth #7
Peter Windmoeller
+1 514 887 7172