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From waste to a reliableco-processing
Case study Morocco
HANOI / 22nd August 2018, Dr Hubert Baier
LOESCHE Symposium Hanoi 2018 22.08.2018
Case study: Morocco
From waste to a reliable co-processing
Starting position
Waste assessment
Technical assessment
Designing the pre-treating process
Miscellaneous manner
01
05
04
03
02
LOESCHE Symposium Hanoi 2018 22.08.2018
At the beginning no reliable data
were available regarding:
▪ Source of waste
▪ Annual amount per capita
▪ Composition and potentials for
recycling or thermal use
▪ Legal framework
▪ Responsibilities
Starting position
0
500.000
1.000.000
1.500.000
2.000.000
2.500.000
3.000.000
0
50.000
100.000
150.000
200.000
250.000
300.000
350.000
TotalamountofexpectedHighCalorificFraction(HCF)
Annualamountperregion
region
3
LOESCHE Symposium Hanoi 2018 22.08.2018
Case study: Morocco
From waste to a reliable co-processing
Starting position
Waste assessment
Technical assessment
Designing the pre-treating process
Miscellaneous manner
01
05
04
03
02
LOESCHE Symposium Hanoi 2018 22.08.2018
Waste assessment on Temara landfill side, Morocco
5
Waste assessment
Example for urban Municipal Solid Waste
(MSW)
LOESCHE Symposium Hanoi 2018 22.08.20186
Portion and thermal potential of MSW
alumina
0,1%
residuals
0,2%
iron
0,2%
glass
0,7%
soil +
stones
1,9%
toiletries
6,6%
miscellaneous
7,9%
organic
62,3%
rubber + leather
0,4%
Pet-wrappings
0,3%
wood
0,4%
long living wrappings
0,9%
textiles
3,5%
paper, cardboard,
journals
6,0%
smooth plastics
8,8%
HCF 20,2%
HCF:
High Calorific Fraction
represents the combustible
portion of solid waste
Temara/ MA 2016
LOESCHE Symposium Hanoi 2018 22.08.20187
Composition and thermal potential
Pre-processing, fractions and qualities
8,8
14,4
16,8
24,3
0,0
5,0
10,0
15,0
20,0
25,0
30,0
0%
20%
40%
60%
80%
100%
calorificvalueMJ/kg
Sharesinmixture
organic paper, cardboard, journals long living wrappings
Pet-wrappings Styropor smooth plastics
hard plastics iron glass
soil + stones wood textiles
divers alumina rubber
LOESCHE Symposium Hanoi 2018 22.08.2018
High Calorific Fraction (HCF) for direct use in combustion chambers
▪ Grain size: < 300 mm
▪ Gross calorific value: ~ 14 - 17 MJ/kg
▪ Bulk density: 0,3 – 0,5 t/m3
or used as feedstock for RDF-production (2nd level)
Low grade calciner fuel (Residue Derived Fuel - RDF)
▪ grain size: 50 – 100 mm
▪ Gross calorific value: ~ 15 – 19 MJ/kg
▪ Bulk density: 0,2 – 0,4 t/m3
or used as feedstock for SRF-production (3. level)
High grade main burner fuel (Solid Recovered Fuel - SRF)
▪ Grain size: < 15 – 30 mm
▪ Gross calorific value: >> 20 MJ/kg (like lignite or higher)
▪ bulk density: 0,1 – 0,2 t/m3
8
Definition and specification of Solid Alternative Fuels
LOESCHE Symposium Hanoi 2018 22.08.2018
Starting position
Waste assessment
Technical assessment
Designing the pre-treating process
Miscellaneous manner
01
05
04
03
02
Case study: Morocco
From waste to a reliable co-processing
LOESCHE Symposium Hanoi 2018 22.08.2018
Technical assessment
10
▪ Exploring the locations of the cement
kilns and its potential for co-processing
▪ Detect technical and process faults
▪ Define basic conditions for the
specifications of the alternative fuel
▪ Calculating the logistical distance and
invest, supply during down times and
revisions, reception and storage etc.
LOESCHE Symposium Hanoi 2018 22.08.201811
Substantial1
Objectives for ‘co-processing’
‘Co-processing’ is the substantial + thermal use of alternative resources
‘Substantial 1’ → suitable mineral waste as an alternative raw material
‘Thermal + substantial’ → using the fuels and its ashes for clinker formation
‘Substantial 2’ → mineral grinding compound in accordance to the cement standards
Substantial2
Thermal+
substantial
LOESCHE Symposium Hanoi 2018 22.08.2018
Fine ground
raw meal
cement clinker
Pre-combustion chamber:
supply with tertiar air ~1000°C
Kiln inlet:
approx. 900 - 1100°C
Calciner:
900 – 1000°C
Main burner:
Gas temperature: 2000°C
radiant heat: 1450°C
> 2 s retention time by law
Feeding alternative fuels
12
LOESCHE Symposium Hanoi 2018 22.08.201813
▪ Exploring the capabilities
▪ Individual process conditions
▪ Energy demand
▪ Chemistry and set points
▪ Design the pre-processing
▪ Best options for feeding AF
▪ Materials handling
▪ Air pollution control
Sensivity against coating
Technical assessment
LOESCHE Symposium Hanoi 2018 22.08.2018
Case Study: Morocco
From waste to a reliable co-processing
Starting position
Waste assessment
Technical assessment
Designing the pre-treating process
Miscellaneous matters
01
05
04
03
02
LOESCHE Symposium Hanoi 2018 22.08.201815
Results of the waste assessments
After the waste assessment it
becomes clear:
▪ Specific amount of MBT
▪ Each region will produce alternative
fuels in different quantities and
qualities
▪ The cement works have to execute
a reliable technical assessment
▪ All regions require sanitary landfill
▪ Waste assessment and the technical
assessment are the basis to design
the proper MBT
LOESCHE Symposium Hanoi 2018 22.08.2018
Insight into the waste conditioning
16
LOESCHE Symposium Hanoi 2018 22.08.2018
Insight into the waste conditioning
17
Air classifier
Near-Infrared (NIR) to separate PVC
Storage and blending
LOESCHE Symposium Hanoi 2018 22.08.201818
Pre-processing and supply (examplary)
Reception and shredding <300 mm Screening and ballistical separation
Manual sorting for valuables and PVC reduction
Baling HCF for further
processing
to AF-producers or cement workBaling valuables for
recycling
Sanitary
landfilling
Biological degradation
‚technical‘ compost
LOESCHE Symposium Hanoi 2018 22.08.201819
MSW
recyclables
biodegradable
landfill
combustibles HCF RDF Rocket Mill®
Main
burner
Calciner
Pre-processing by
splitting
Pre-processing and feeding
LOESCHE Symposium Hanoi 2018 22.08.201820
Division of work
LOESCHE Symposium Hanoi 2018 22.08.201821
▪ The cement industry will be integrated to the national waste management plan.
▪ The cement industry can become partner of a national allocation plan for reduction of greenhouse gas
emissions.
▪ A national assessment of the waste sector and the technical assessment of the cement industry will
balance, how and by whom the waste derived energy can be used best.
▪ Entire premises have to clarify the legal frame, the financial aspects and the logistic between waste access
area, pre-treating plant and cement work.
▪ And… the World Bank or the international Green Climate Fund are financing such projects in accordance
to their environmental, social and economical role.
In a nutshell
LOESCHE Symposium Hanoi 2018 22.08.2018
Case study: Morocco
From waste to a reliable co-processing
Starting position
Waste assessment
Technical assessment
Designing the pre-treating process
Miscellaneous matters
01
05
04
03
02
LOESCHE Symposium Hanoi 2018 22.08.201823
23
Regarding the large amount of ground limestone, the
pyroprocess is very tolerant.
But:
As higher the envisaged TSR is, the more the
conditioners and fuel suppliers have to respect the
requirements of the production process, its resulting
product and the air pollution control.
Both need a quality management to monitor and
control their processes, accordingly.
‘Quality’ ≠ ‘Quality’
LOESCHE Symposium Hanoi 2018 22.08.2018
Beforeflame
Delivery/discharge
Endofpre-treating/
beforeshipment
Wasteassessment
Receivingat
pre-treatment
In accordance to the permission and processIn accordance to the operational permission
Procedure of quality surveillance
24
LOESCHE Symposium Hanoi 2018 22.08.201825
▪ Legal framework is a ‘Code of Conduct’.
▪ Legal framework secures the investment.
▪ Quality surveillance is relevant to ensure the
production process, your product quality and
emissions.
▪ Competent authorities can monitor all steps
from waste to flame.
▪ Guaranties a safe and healthy environment.
Enforcement of legal framework
LOESCHE Symposium Hanoi 2018 22.08.2018
The project has successfully shown …
26
▪ Combustible portion of MSW is a reliable fuel and will reduce the
national GHG-emissions.
▪ Pre-processing can be designed in accordance to the requirements
of the cement manufacturing process.
▪ If done well, remaining ash complies with the clinker composition.
▪ AF comprises as less as possible of water, chlorine, alkalines or
other disturbing impurities.
▪ The dry-adsorbing effect in a lime based milieu cleans the exhaust
gas and inhibits the de-Novo-synthesis.
▪ High volatile heavy metals (i.e. Hg, Cd, Tl) were balanced in a trail
and comply with the EU-air pollution control standards.
▪ Non-volatile elements are trapped in the clinker formation or dust
bounded and suspended in modern filter systems.
LOESCHE Symposium Hanoi 2018 22.08.201827
Product
Environment
Process
Co-processing respects the requirements regarding…
THANK YOU
for your attention
LOESCHE GmbH
Hansaallee 243
D-40549 Düsseldorf
Tel.: +49 211 5353 - 0
Email: loesche@loesche.de

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From Waste to a Reliable Co-Processing

  • 1. From waste to a reliableco-processing Case study Morocco HANOI / 22nd August 2018, Dr Hubert Baier
  • 2. LOESCHE Symposium Hanoi 2018 22.08.2018 Case study: Morocco From waste to a reliable co-processing Starting position Waste assessment Technical assessment Designing the pre-treating process Miscellaneous manner 01 05 04 03 02
  • 3. LOESCHE Symposium Hanoi 2018 22.08.2018 At the beginning no reliable data were available regarding: ▪ Source of waste ▪ Annual amount per capita ▪ Composition and potentials for recycling or thermal use ▪ Legal framework ▪ Responsibilities Starting position 0 500.000 1.000.000 1.500.000 2.000.000 2.500.000 3.000.000 0 50.000 100.000 150.000 200.000 250.000 300.000 350.000 TotalamountofexpectedHighCalorificFraction(HCF) Annualamountperregion region 3
  • 4. LOESCHE Symposium Hanoi 2018 22.08.2018 Case study: Morocco From waste to a reliable co-processing Starting position Waste assessment Technical assessment Designing the pre-treating process Miscellaneous manner 01 05 04 03 02
  • 5. LOESCHE Symposium Hanoi 2018 22.08.2018 Waste assessment on Temara landfill side, Morocco 5 Waste assessment Example for urban Municipal Solid Waste (MSW)
  • 6. LOESCHE Symposium Hanoi 2018 22.08.20186 Portion and thermal potential of MSW alumina 0,1% residuals 0,2% iron 0,2% glass 0,7% soil + stones 1,9% toiletries 6,6% miscellaneous 7,9% organic 62,3% rubber + leather 0,4% Pet-wrappings 0,3% wood 0,4% long living wrappings 0,9% textiles 3,5% paper, cardboard, journals 6,0% smooth plastics 8,8% HCF 20,2% HCF: High Calorific Fraction represents the combustible portion of solid waste Temara/ MA 2016
  • 7. LOESCHE Symposium Hanoi 2018 22.08.20187 Composition and thermal potential Pre-processing, fractions and qualities 8,8 14,4 16,8 24,3 0,0 5,0 10,0 15,0 20,0 25,0 30,0 0% 20% 40% 60% 80% 100% calorificvalueMJ/kg Sharesinmixture organic paper, cardboard, journals long living wrappings Pet-wrappings Styropor smooth plastics hard plastics iron glass soil + stones wood textiles divers alumina rubber
  • 8. LOESCHE Symposium Hanoi 2018 22.08.2018 High Calorific Fraction (HCF) for direct use in combustion chambers ▪ Grain size: < 300 mm ▪ Gross calorific value: ~ 14 - 17 MJ/kg ▪ Bulk density: 0,3 – 0,5 t/m3 or used as feedstock for RDF-production (2nd level) Low grade calciner fuel (Residue Derived Fuel - RDF) ▪ grain size: 50 – 100 mm ▪ Gross calorific value: ~ 15 – 19 MJ/kg ▪ Bulk density: 0,2 – 0,4 t/m3 or used as feedstock for SRF-production (3. level) High grade main burner fuel (Solid Recovered Fuel - SRF) ▪ Grain size: < 15 – 30 mm ▪ Gross calorific value: >> 20 MJ/kg (like lignite or higher) ▪ bulk density: 0,1 – 0,2 t/m3 8 Definition and specification of Solid Alternative Fuels
  • 9. LOESCHE Symposium Hanoi 2018 22.08.2018 Starting position Waste assessment Technical assessment Designing the pre-treating process Miscellaneous manner 01 05 04 03 02 Case study: Morocco From waste to a reliable co-processing
  • 10. LOESCHE Symposium Hanoi 2018 22.08.2018 Technical assessment 10 ▪ Exploring the locations of the cement kilns and its potential for co-processing ▪ Detect technical and process faults ▪ Define basic conditions for the specifications of the alternative fuel ▪ Calculating the logistical distance and invest, supply during down times and revisions, reception and storage etc.
  • 11. LOESCHE Symposium Hanoi 2018 22.08.201811 Substantial1 Objectives for ‘co-processing’ ‘Co-processing’ is the substantial + thermal use of alternative resources ‘Substantial 1’ → suitable mineral waste as an alternative raw material ‘Thermal + substantial’ → using the fuels and its ashes for clinker formation ‘Substantial 2’ → mineral grinding compound in accordance to the cement standards Substantial2 Thermal+ substantial
  • 12. LOESCHE Symposium Hanoi 2018 22.08.2018 Fine ground raw meal cement clinker Pre-combustion chamber: supply with tertiar air ~1000°C Kiln inlet: approx. 900 - 1100°C Calciner: 900 – 1000°C Main burner: Gas temperature: 2000°C radiant heat: 1450°C > 2 s retention time by law Feeding alternative fuels 12
  • 13. LOESCHE Symposium Hanoi 2018 22.08.201813 ▪ Exploring the capabilities ▪ Individual process conditions ▪ Energy demand ▪ Chemistry and set points ▪ Design the pre-processing ▪ Best options for feeding AF ▪ Materials handling ▪ Air pollution control Sensivity against coating Technical assessment
  • 14. LOESCHE Symposium Hanoi 2018 22.08.2018 Case Study: Morocco From waste to a reliable co-processing Starting position Waste assessment Technical assessment Designing the pre-treating process Miscellaneous matters 01 05 04 03 02
  • 15. LOESCHE Symposium Hanoi 2018 22.08.201815 Results of the waste assessments After the waste assessment it becomes clear: ▪ Specific amount of MBT ▪ Each region will produce alternative fuels in different quantities and qualities ▪ The cement works have to execute a reliable technical assessment ▪ All regions require sanitary landfill ▪ Waste assessment and the technical assessment are the basis to design the proper MBT
  • 16. LOESCHE Symposium Hanoi 2018 22.08.2018 Insight into the waste conditioning 16
  • 17. LOESCHE Symposium Hanoi 2018 22.08.2018 Insight into the waste conditioning 17 Air classifier Near-Infrared (NIR) to separate PVC Storage and blending
  • 18. LOESCHE Symposium Hanoi 2018 22.08.201818 Pre-processing and supply (examplary) Reception and shredding <300 mm Screening and ballistical separation Manual sorting for valuables and PVC reduction Baling HCF for further processing to AF-producers or cement workBaling valuables for recycling Sanitary landfilling Biological degradation ‚technical‘ compost
  • 19. LOESCHE Symposium Hanoi 2018 22.08.201819 MSW recyclables biodegradable landfill combustibles HCF RDF Rocket Mill® Main burner Calciner Pre-processing by splitting Pre-processing and feeding
  • 20. LOESCHE Symposium Hanoi 2018 22.08.201820 Division of work
  • 21. LOESCHE Symposium Hanoi 2018 22.08.201821 ▪ The cement industry will be integrated to the national waste management plan. ▪ The cement industry can become partner of a national allocation plan for reduction of greenhouse gas emissions. ▪ A national assessment of the waste sector and the technical assessment of the cement industry will balance, how and by whom the waste derived energy can be used best. ▪ Entire premises have to clarify the legal frame, the financial aspects and the logistic between waste access area, pre-treating plant and cement work. ▪ And… the World Bank or the international Green Climate Fund are financing such projects in accordance to their environmental, social and economical role. In a nutshell
  • 22. LOESCHE Symposium Hanoi 2018 22.08.2018 Case study: Morocco From waste to a reliable co-processing Starting position Waste assessment Technical assessment Designing the pre-treating process Miscellaneous matters 01 05 04 03 02
  • 23. LOESCHE Symposium Hanoi 2018 22.08.201823 23 Regarding the large amount of ground limestone, the pyroprocess is very tolerant. But: As higher the envisaged TSR is, the more the conditioners and fuel suppliers have to respect the requirements of the production process, its resulting product and the air pollution control. Both need a quality management to monitor and control their processes, accordingly. ‘Quality’ ≠ ‘Quality’
  • 24. LOESCHE Symposium Hanoi 2018 22.08.2018 Beforeflame Delivery/discharge Endofpre-treating/ beforeshipment Wasteassessment Receivingat pre-treatment In accordance to the permission and processIn accordance to the operational permission Procedure of quality surveillance 24
  • 25. LOESCHE Symposium Hanoi 2018 22.08.201825 ▪ Legal framework is a ‘Code of Conduct’. ▪ Legal framework secures the investment. ▪ Quality surveillance is relevant to ensure the production process, your product quality and emissions. ▪ Competent authorities can monitor all steps from waste to flame. ▪ Guaranties a safe and healthy environment. Enforcement of legal framework
  • 26. LOESCHE Symposium Hanoi 2018 22.08.2018 The project has successfully shown … 26 ▪ Combustible portion of MSW is a reliable fuel and will reduce the national GHG-emissions. ▪ Pre-processing can be designed in accordance to the requirements of the cement manufacturing process. ▪ If done well, remaining ash complies with the clinker composition. ▪ AF comprises as less as possible of water, chlorine, alkalines or other disturbing impurities. ▪ The dry-adsorbing effect in a lime based milieu cleans the exhaust gas and inhibits the de-Novo-synthesis. ▪ High volatile heavy metals (i.e. Hg, Cd, Tl) were balanced in a trail and comply with the EU-air pollution control standards. ▪ Non-volatile elements are trapped in the clinker formation or dust bounded and suspended in modern filter systems.
  • 27. LOESCHE Symposium Hanoi 2018 22.08.201827 Product Environment Process Co-processing respects the requirements regarding…
  • 28. THANK YOU for your attention LOESCHE GmbH Hansaallee 243 D-40549 Düsseldorf Tel.: +49 211 5353 - 0 Email: loesche@loesche.de