1. From 0 % to 80 % - Alternative fuelFrom 0 % to 80 % - Alternative fuel
usage in the Broceni cement plant
Dr. Uwe Lubjuhn, October 2015

2. Investment decision
Capital expenditure 275 mill. €
Start of construction 2007
Start of kiln in May 2009
Nominal clinker capacity 3500 t/d
Cement capacity 1,2 mill. t/a (new plant)
Decision from the start to use
alternative fuels (AF):
AF storage
AF handling & transport
Combustion chamber
Main burner for use of AF

3. Plant layout
KilnKiln lineline withwith
preheaterpreheater towertower
CCoaloal millmill
RawRaw millmill areaarea
CementCement millmill
RawRaw materialsmaterialsClinkerClinker silosilo
RawRaw millmill areaarea
CementCement millmill
AlternativeAlternative fuelsfuels

4. AAA of AF usage
Availability
Suitable waste in terms of amount, price/gate
fee and quality
AcceptanceAcceptance
Authorities, neighbours and public
stakeholders interested in environmental, H&S
and firefighting aspects
Application
Reception and storage, feeding and burning,
process and quality control

5. Availability
Suitable waste in terms of amount, price/gate
fee and quality
Conventional:
Municipal / household waste
Commercial waste
Industrial waste
Used tyresUsed tyres
Biomass:
Agricultural residues
Wood chips, wood waste
Meat and bone one meal,
Sewage sludge

6. Acceptance
Authorities, neighbours and public
stakeholders interested in environmental, H&S
and firefighting aspects
Emission prognosis
Emission monitoring
Dust
NOx
SO2SO2
Heavy metals incl. Hg
HCl, HF, CO, TOC
Organics
NH3
CO2-emissions
Type of wastes used
Air quality in storages
Fire alarm and protection systems
Inflammability / explosiveness of AF

7. Application
Reception and storage, feeding and burning,
process and quality control
Storage for bulk material
Storage for bales including debaler
Mechanical transport
Pneumatic transportPneumatic transport
Main burner for different types of fuel
Kiln inlet, calciner, combustion chamber
Chlorine-bypass
Bypass-dust handling
Use of bypass dust in cement
Use of bypass dust for binders
NOx abatement
SO2 abatement
Avoiding de-novosynthesis of dioxins

8. Alternative fuels in Latvia
Local Imported

9. Kiln and preheater (KHD / Germany)

10. Kiln line
PreheaterPreheaterPreheaterPreheater
Preheater tower with precalciner
and combustion chamber
CombustionCombustionCombustionCombustion ChamberChamberChamberChamberCombustionCombustionCombustionCombustion ChamberChamberChamberChamber
New KHD development for the use of
alternative fuels up to 70 mm particle
size
CoolerCoolerCoolerCooler
High
efficiency IKN cooler
KilnKilnKilnKiln
Short kiln with two
support stations and
tertiary air duct

11. Combustion
chamber:
Alternative fuels
up to 70 mm
Combustion chamber
Picture:Picture: InsideInside viewview combustioncombustion chamberchamber

12. Debaling
Bulk feeding
Feeding
Conveying
Alternative fuel feeding for combustion chamber
AF feeding system
Bulk feeding
Screening

13. SulphuricSulphuric Acid Tar Waste is transformed into bulk materialAcid Tar Waste is transformed into bulk material
Processing of SATW

14. Extraction Neutralization Transportation
SATW
Cement plant
Contaminated lake
SATW processing and usage
Storage
Recovery
Kiln Feed
Clinker
Primary
Fuels
Alternative
Fuels
Cement plant

15. Ventilation system for storage
Smelling air introduced into clinker cooler
and used as combustion air.

16. BagBag filtersfilters::
DustDust emmissionemmission
<< 20 mg/m³20 mg/m³
Best available technology
Picture: MainPicture: Main bagbag filterfilter
househouse / BK5/ BK5

17. SNCR:SNCR:
NONOxx emissionsemissions
< 500 mg/m³< 500 mg/m³
Best available technology
Picture:Picture: SNCRSNCR pumpspumps

18. PermanentPermanent displaydisplay ofof emissionemission
inin centralcentral controlcontrol roomroom
Continuous emission monitoring
Picture: ScreenPicture: Screen shotshot SiemensSiemens controlcontrol systemsystem

19. From 0 % to 80 %
80
100
HeatSubstitution[%] Alternative Fuels
0
20
40
60
HeatSubstitution[%]
2010 2011 2012 2013 2014 20152009

20. 900
1000
1100
1200
kgCO2/tclinker
Jun 08 3rd period Apr 12
Reduced CO2-footprint
Specific CO2 emissions according EU allocation rules for trading period 2013–2020
compared to real emissions Broceni
600
700
800
900
Broceni BK4 EU Benchmark Broceni BK5
kgCO2/tclinker
- 36 %

21. ModernModern clinkerclinker kilnkiln technologytechnology:: UseUse ofof alternativealternative fuelsfuels
COCO22--savings = 400.000 t/asavings = 400.000 t/a
CO2-improvements
EqualEqual toto emissionsemissions ofof moremore thanthan 200.000 modern200.000 modern carscars drivingdriving
20.000 km per20.000 km per yearyear

22. But everything starts with the people
Thank You!