1. MVW LECHTENBERG&PARTNER
2ND ALTERNATIVE FUELS SYMPOSIUM
Mete Emre ERGÜÇLÜ
TurkishCementManufacturers Association
BaştaşBaşkentÇimentoSanayiveTicaret AŞ
15.10.2015
«Turkish Cement Industry
recognizes Alternative Fuels As A Key Lever for
its Sustainability»
PART I: GENERAL REVIEW

2. 1. Framework
2
• TurkishCementIndustryandTCMA
• Use of Alternative Resources
o Alternative Fuels
o Alternative Raw Materials

3. TurkishCementIndustry
3

4. TurkishCementIndustry
• Cement Industry
o 1911  20.000 ton/year
o 2014  74,400 Mton/year
o 2014  69 Cement Plant
(50 integrated)
o In Europe 1.,
o In the World 5.
• Fınancially,
o % 77 local capital
o Share of foreigners % 23 (France,
Italy, Germany, Brazil ve Greece)
o 15.000employee
o Financial Turnover 4 Billion US-$
o Export 600 million US-$
4

5. TurkishCementManufacturers’Association
5
TCMA
Establishment 1957 – Official Representative of Industry
Place Ankara
Number of
Employee
69
Supported Articles
Production
Quality
Trainning
Environment
Technology
Contacts
(Local and abroad)
Private Sector
Government
Public
Non-Governmental Organizations

6. TurkishCementManufacturers’Association
6
TCMA
Memberships
and
Cooperations
1972- CEMBUREAU (European Cement Association) Member
2009- EUPAVE (European Concrete Paving Association) Associated
Member
2009- AUCBM (Arab Union for Cement and Building Materials) –
Cooperation Protocol
2010- CMA (Indian Cement Association) – Cooperation Protocol
2011- CCA (China Cement Association) – Cooperation Protocol

7. TurkishCementManufacturers’Association
http://www.tcma.org.tr/ 7

8. TurkishCementManufacturers’Association
TCMA
COMMITIES
Natural Sources
and Process
Natural
Sources
RD, Quality
and
Commercial
Enterprises
Process
Products-
Economical
Analysis
Concrete
Roads,
Innovation
Lobby,
Publicity
Relationship
between
Members and
Non-
Governmental
Organizations
Sustainable
Production
8
Climate Change
and Energy
Environmental
Legislation
GHG Climate
Change
AF/ARM
Energy

9. Use of Waste in Cement Industry
Main Purpose
Cement
Production
Additionally
Useof
Waste
Use of Wastes Insteadof
Conventional Fuels and Raw
Materials
10
• In Turkey, Cement Plants are making efforts to become a
solution partner in the Turkish Waste Management
Policies.

10. UseofWasteinTurkishCementIndustry
• Started at 2004 (AF and ARM)
Beginning
• Licensed Plants; 35/49
• Thermal Substitution Rate
• Permitted Capacity: % 40 (with co-incineration license)
• Average Thermal Substitution: % 3,71 (2014)
Existing
State
• 2004-2010 : General Regulation on Use of Alternative Fuels
(Abrogated)
• 2010 : Waste Incineration Regulation
• 2011 : Non-Hazardous Waste Regulation
• 2014 : RDF, AF and AFR Regulation
Legislations
10

11. UseofWasteinTurkishCementIndustry
• Waste Oil
• Tyres
• Refuse Derived Fuels
- Non-Hazardous
- Hazardous
• Mineral Based
Wastes
- Iron
- Aluminate
- Calcium
- Silica
Non-Hazardous Waste
By-products
Clinker
Production
Cement Production
11
Alternative Fuels Alternative Raw Materials Additives
Hazardous Non-Hazardous Non-Hazardous Hazardous

12. Turkish Cement Industry was a solution partner for waste
management activities with 1,6 mton AF and AFR.
UseofWasteinTurkishCementIndustry
Numbers of
Out of Scope
codes: 435
Numbers of waste
codes for cement
industry: 404
Determined by Ministry
AF and AFR
12
RDF
275/404
AFR
137/404
AF
247/404
Numbers of Codes: 839

13. World Data for AF - 2012
Total: ~%15
(waste+biomass)
Kaynak: http://www.wbcsdcement.org/GNR-2012/index.html
13

14. EU Data for AF (28 Countries) - 2012
Kaynak: http://www.wbcsdcement.org/GNR-2012/index.html
Total: ~%37
(waste+biomass)
14

15. UseofAlternativeFuelsinTurkishCementIndustry
15
Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study

16. UseofAlternativeFuelsinTurkishCementIndustry
Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study
18

17. UseofAlternativeFuelsinTurkishCementIndustry
19
Total AF 566.800 ton for 2014
Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study

18. UseofAlternativeRawMaterialsinTurkishCementIndustry
2010 2011 2012 2013
21
Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study

19. UseofAlternativeRawMaterialsinTurkishCementIndustry
22
Reference: Ministry of Energy and Natural Resources – 2014 Benchmarking Study

20. TurkishCementIndustry–AF/AFRPapers
Documents:
• Position Paper
• AF/AFR Users' Manual (Technical Advice Document)
http://www.tcma.org.tr/index.php?page=habergoster&hbrID=305
20

21. MVW LECHTENBERG&PARTNER
2ND ALTERNATIVE FUELS SYMPOSIUM
PART II: TECHNICAL APPLICATIONS AND
OPPORTUNITIES

22. Scope
22
• Recovered Waste: Examples
• Costs and Controls
• Acceptance and Analysis opportunities
• Alternative Fuels
• Preparation
• Feedingg
• Fire&ExplosionPrecautions
• Alternative Raw Materials
• Suggestions

23. RECOVERED WASTES:
EXAMPLES
23

24. Use of AF and ARM
5
Co-Incineration GRINDING
Clinker Cement
Conventional Fuels
Coal, petcoke, fuel- oil,
natural gas
Alternative Fuels
 RDF
 Waste Tyres
 Waste Oils
 Sewage Sludges
 Impregnated w.
 Plastics
 Solvents
 Waste Paint
Conventional RM
Limestone, clay, marn
Alternative
RM
 Mineral Mud (Ca)
 Foundry Sand (Si)
 Waste Bricks
 Pirit (Fe), Grit
Grinding
Additives
Conventional:
Gypsum,
Anhydride
ARM
 Artificial Gypsum
Active Grinding
Additives:
Conventional:
Pozzolan
ARM
 Slag (by-product)
 Fly Ash (by-product)

25. Use of AF
Cement Plant
Co-Incineration
REFUSE DERIVED
FUEL
RDF Productionin
Cement Plants
PurchasedRDF
ALTERNATIVE
FUEL
25

26. Waste to AF/ARM
Wastes
Non-Hazardous
IndustrialWaste
Impregnated
Waste
AF/ARM
Waste Tyres
Sewage
Sludge
RDF
TDF
Dried Sludge
26

27. COSTS AND CONTROLS
10

28. Additional Costs of AF/ARM
InvestmentCosts
• Storage
• Preparation
• Feeding
• Laboratory
• Precautions for Fire
& Explosion
• HS Measurements
• Process Control
Additional Costs
• Production Loss
• Increasing Specific
Heat
• Maintenance
• Additional labor
• Emission
Measurements
COSTS
İlgili taraflar, çimento sektörünün alternatif yakıt ve Alternatif Hammadde
kullanımından kaynaklanan ilave maliyetler hakkında yeterince bilgi sahibi değildir!
28

29. Emission Measurements
29
• InstantMeasurements
o Inallstacks
o By Authorized Measurement Companies
• Continuous Measurements:
o FlueGases
o Dust
o TOC
• PeriodicalMeasurements
o Flue Gas, Dust, TOC and;
o Heavy Metals
o PCDD,PCDF andPAHs
• Online Monitoring
o From 31.12.2014

30. ALTERNATIVEFUELS
ACCEPTANCECRITERIAAND
ANALYSIS
30

31. Acceptance Criteria and Analysis
• First Control
- Physical Control
- Sampling
- Accordance of Acceptance Criteria
• Analysis
- Calorific Value
- Chlorine
- Water Content
- Heavy Metals
- Other Parameters
• Acceptance
- Physical Control
- Analysis of Output Material 31

32. Properties of RDF
• Chemical and Physical Criteria of RDF/SRF (RDF, AF and ARM Regulation)
32

33. ALTERNATIVE
FUELS
PREPARATION
20

34. RDFPlants
34
5 Cement Plants have own RDF Plants.
2 Cement Plants have TDF Preparation Plant.

35. RDF–RefuseDerivedFuel
35

36. Sludge Dryers
36
Acceptance
Transfer Systems

37. Sludge Dryers
37
Dryer Belts
Dried Sludge Silo

38. 38
ALTERNATIVE
FUELS FEEDING
SYSTEMS

39. Dried Sludge Feedig System
Granulated Dried
Sludge
Pneumatic System
39

40. SRF Feeding
Bale Opener Machine
31

41. Covered Belt (to the Calciner)
41

42. FirstAutomaticalFeedingSysteminTurkey- 2009
• Capacity: 15 ton/hr
 Automatical Weighing
and Dosing System
 Regular and Constant
Feeding Rate
 Automatical
Manupulation
42

43. Feeding System -Storage
• Crane System
Crane System determines storage and feeding manupulations with its
automation system.
43

44. Dosing system
• Automatical
Weighing System
System determines all
movements according to
setted feeding rate.
44

45. Belts
• Tube Belt
 It reaches to 52 m height
with 300 m length
 Not affected geographical
conditions (wind, rain etc.)
 Carries 0,1-0,4 ton/m3
density
45

46. Belts
• Width: 1,6 m
• Length: 150 m
46

47. Waste Tyres
47

48. Shredded Tyres Automatical Feeding Systems
48

49. Burning Technologies
• HOTDISC Technology
49

50. Burning Technologies
Rotary
Weightfeeders
50

51. 47
ALTERNATIVE FUELS
FIRE PRECAUTIONS

52. Fire Precautions
• Sprinkler System
52

53. Fire Precautions
• Thermo elements
(Adjusted 60-65 °C)
53
• Belt Sprinkler System

54. Fire Precautions
• Automation System
54

55. Fire Precautions
• CO2 Systems
55

56. USE OF
ALTERNATIVE RAW
MATERIALS
56

57. Criteria for ARM
57
Basic Principles;
• Must content main elements (calcium, silica, alumina and iron)
• Calorific value recommended under 2500 kcal/kg (fire
precautions)
• Must be non-hazardous (legal),

58. Frequently used ARM
58
1. Waste Roof Tiles (Clay – Al, Si)
2. Waste Marbles (Limestone – CaCO3)
3. Foundry Sans (Silica – Si)
4. Calcite Fines (Limestone – CaCO3)
5. Waste Gypsum (Natural Gypsum - CaSO4)
6. Grit (Iron – Fe2O3)
7. Waste Ceramic Tiles (Clay – Al, Si)
8. Waste Vitrification (Clay)
9. Non-Calorific Value Treatment Sludge (depends on type of wwtp
and process)

59. The Target of Cement Industry:
Increasing use of AF and ARM
Suggestions
59

60. Suggestions
60
 Pretreatment of waste by waste producers
 Establishing of pretreatment plants
 Increasıng RDF Production by Industrial Zones
 RDF Production with domestic solid waste
 Increasıng use of dried sewage sludge by Municipalities
 Metropolitan Municipalities - Business Models
 Expectations from Metropolitan Municipalities
 Expectations from Ministry of Environment

61. Pretreatment of Wastes
Increasing
use of AF
• WastesfromRDFRegulation
• Example:
- Animal Wastes
- Sewage Sludge
Pretreatment
Plants
• Establishmentof PretreatmentPlants
- Mechanical Processes (shredding, pelleting etc.)
- Drying
Cement
Plants
• Use of processed wastes as Alternative Fuels
61

62. Increasıng RDF Production by Industrial Zones
Increasing
use of AF
• Wastes of Industrial Zones
- Non-HazardousWastes
- HazardousWastes
RDF
• RDFProduction
- RDF send to Cement Plants
Cement
Plants
• Use of Alternative Fuels
62

63. RDF Production with domestic solid waste
Solid Waste
by
Municipalities
• Extremely not recommended establishment of incineration plants by
municipalities which have high investment and operation costs.
RDF Production
with MBT
Plants
• Establishment of MBT Plants nearby Municipality Landfills.
• SRF production by domestic solid wastes
• Low investment and operational cost
Cement
Plants
• Use of Alternative Fuels
63

64. Increasıng use of dried sewage sludge by
Municipalities
Wet Sewage
Sludge
• Extremely not recommended establishment of incineration plants by
municipalities which have high investment and operation costs.
Dried
Sewage
Sludge
Production
• Establishment of sewage sludge drying units in WWTP by
Municipalities
Cement
Plants
• Use of Alternative Fuels
64

65. Metropolitan Municipalities - Business Models
TechnicalSupport
andBussiness
Models
65
• Giving technical support to
Municipalities about Pretreatment and
Sewage Sludge Drying Units
• Giving support for establishment of
business models (as in Europe).

66. Expectations from Municipalities
• Instead of incineration plants which have high
investment and operational costs.
Using potential
of Cement
Industry
• hazardous and non-hazardous wastes which have
calorific value and non-hazardous wastes which
have mineral content, should not be accepted to
the landfills.
Rearrangement of
Acceptance Criteria
of Landfills
• Rearrangement of landfill fees according to
investment and operational costs.
Taking
Precautions in
Economical
Issues 69

67. Expectations from Ministry
•Establishment a system and/or economical model for polluter
pays principle because of investment/operational costs of
cement industry.
Applying
Polluter Pays
Principle
•Abolition of 40 % thermal substitutionratein WasteIncineration
Regulation (for non-hazardous wastes)
The abolition
of 40 % Limit
•Reviewing project approvals of incineration plantsReviewing Project
Approvals
•Determination of a national policy
•Adding co-incineration option to Integrated Waste
Management Plans
•Being solution partner in National Waste Management Plan
Being
Solution
Partner 79

68. Thanks…
emre.erguclu@vicat.com.tr
www.tcma.org.tr
68