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2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation

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Page 1: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009

A TEC WORLDWIDE

World Leader in Cement Pyroprocess Technology

A TEC Company Presentation

Page 2: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 2

A TEC WORLDWIDE

Mexico, Puebla

China, Beijing

Poland, Chelm

India, Delhi

Malaysia, Kuala Lumpur

Headquarter, Austria

Page 3: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 3

A TEC ORGANIZATION CHART

Page 4: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 4

A TEC BOARD MEMBERS

Dipl. Ing. Friedrich Willitsch

Chief Technical Officer (CTO)

Heading Contract Management, Research

and Development, Process Technology

Dr. Günther Schwaiger

Chief Executive Officer (CEO) Heading Sales, Marketing and Finance

Page 5: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 5

A TEC MISSION

Page 6: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 6

A TEC – KEY ACCOUNTS

Client structure:

and many more…

Page 7: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 7

POWER OF A TEC

A TEC offers patented products,

innovative process technologies

and consulting service know-how.

Hands-on experience in planning,

implementation and plant operation -

A TEC is a reliable business partner.

Page 8: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 8

A TEC OPTIMIZATION

ENERGY

EFFICIENCY

ENVIRONMENT

Page 9: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 9

CEMENT PYROPROCESS

Page 10: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 10

A TEC CHINA

Page 11: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 11

A TEC CHINA

Page 12: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 12

A TEC CHINA

Page 13: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 13

A TEC PROJECT EXAMPLES

STRABAG Greenfield Plant, Hungary

Lafarge Wössingen, Germany

Belarusian Cement Plants, Belarus

W&P Wietersdorf, Austria

Cementizillo, Fanna, Italy

Cemex Assuit, Egypt

Al Safwa, Saudi Arabia

Page 14: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 14

STRABAG GREENFIELD PLANT

LimestoneCrusher

Quarry

Capacities

1000 t/h

ClayCrusher

Quarry250 t/h

Transport

railroad7000 t/d

Preblending

storage

2 x 15.000 t

Sand-storage

625 t

Iron-storage

625 t

Sand

Iron

Raw Mill 200 t/h

Raw Mill Silo

8.000 t

Coal/PetcokeCoal-storage

8.000 t

Coal Mill

15 t/h

Kiln Line

(Preheater,

Kiln,

Cooler)

2500 t/d

(104 t/h)

Clinker

Cement

mills

2 x 100t/h

Cement

Storage Limestone pure

10.000 t

Limestone

pure

Crusher 190 t/hGypsum

Additives

Cement Storage

4 x 10.000 t

Packing plant

125 t/h

Truck loading

2 x 200t/h

Rail loading

200t/h

Clinker storage

60.000 t

Page 15: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 15

STRABAG GREENFIELD PLANT

overall project management

plant arrangement, process design

complete tender support to client

sub-contracts negotiation

progress & quality assurance

interface and technical clarification

supervision services & training

Page 16: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 16

LAFARGE WÖSSINGEN

Project Scope – Main Plant Sections

Raw Mill and kiln Filter modification of ESP

Bypass Filter modification of ESP

Bypass Dust storage and dosing new

Conditioning tower new

Raw meal transport from silo to dosing new

Lime hydrate storage and dosing new

SNCR dosing systems new

Kiln – 2 reuse of usable kiln and kiln parts new

Burner and fuel dosing systems new

Clinker cooler new

Cooler Filter new

Clinker transport new

Page 17: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 17

LAFARGE WÖSSINGEN

Page 18: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 18

W & P – WIETERSDORF, AUSTRIA

Project Period: 16 months

Shut-Down: 69 days

New Preheater & Calciner

• New preheater complete

• New low-NOx calciner incl. Comb. Chamber

• New tertiary air duct,

• New hot gas duct

• New preheater fan

• Kiln shortening

• New kiln inlet sealing

• New kiln inlet chamber

Results

• Production increase from 1000 to 1777 t/d

• NOx <500 mg/nm³ (without SNCR)

Page 19: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 19

W & P – WIETERSDORF, AUSTRIA

Page 20: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 20

CEMEX – ASSIUT KILN 2+3, EGYPT

Project Period: 8 months

Shut-Down: 39 days

Modification on Preheater & Calciner

• Disassembly of preheater equipment

except

• Cyclone cone stage 2 & 4

• Meal pipes stage 2 & 4

• Installation of new preheater equipment

• Extension existing 2 string calciner

• New hot gas duct

Results:

• Production increase from 4000 to 4500

t/d with a shut down of only 39 days!!!

Page 21: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 21

CEMEX – ASSIUT KILN 2+3, EGYPT

Page 22: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009

Please visit:

www.atec-ltd.com

THANK YOU FOR YOUR ATTENTION

Page 23: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009

A TEC WORLDWIDE

World Leader in Cement Pyroprocess Technology

A TEC Company Presentation

Page 24: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 2

A TEC WORLDWIDE

Mexico, Puebla

China, Beijing

Poland, Chelm

India, Delhi

Malaysia, Kuala Lumpur

Headquarter, Austria

Page 25: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 3

A TEC ORGANIZATION CHART

Page 26: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 4

A TEC BOARD MEMBERS

Dipl. Ing. Friedrich Willitsch

Chief Technical Officer (CTO)

Heading Contract Management, Research

and Development, Process Technology

Dr. Günther Schwaiger

Chief Executive Officer (CEO) Heading Sales, Marketing and Finance

Page 27: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 5

A TEC MISSION

Page 28: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 6

A TEC – KEY ACCOUNTS

Client structure:

and many more…

Page 29: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 7

POWER OF A TEC

A TEC offers patented products,

innovative process technologies

and consulting service know-how.

Hands-on experience in planning,

implementation and plant operation -

A TEC is a reliable business partner.

Page 30: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 8

A TEC OPTIMIZATION

ENERGY

EFFICIENCY

ENVIRONMENT

Page 31: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 9

CEMENT PYROPROCESS

Page 32: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 10

A TEC CHINA

Page 33: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 11

A TEC CHINA

Page 34: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 12

A TEC CHINA

Page 35: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 13

A TEC PROJECT EXAMPLES

STRABAG Greenfield Plant, Hungary

Lafarge Wössingen, Germany

Belarusian Cement Plants, Belarus

W&P Wietersdorf, Austria

Cementizillo, Fanna, Italy

Cemex Assuit, Egypt

Al Safwa, Saudi Arabia

Page 36: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 14

STRABAG GREENFIELD PLANT

LimestoneCrusher

Quarry

Capacities

1000 t/h

ClayCrusher

Quarry250 t/h

Transport

railroad7000 t/d

Preblending

storage

2 x 15.000 t

Sand-storage

625 t

Iron-storage

625 t

Sand

Iron

Raw Mill 200 t/h

Raw Mill Silo

8.000 t

Coal/PetcokeCoal-storage

8.000 t

Coal Mill

15 t/h

Kiln Line

(Preheater,

Kiln,

Cooler)

2500 t/d

(104 t/h)

Clinker

Cement

mills

2 x 100t/h

Cement

Storage Limestone pure

10.000 t

Limestone

pure

Crusher 190 t/hGypsum

Additives

Cement Storage

4 x 10.000 t

Packing plant

125 t/h

Truck loading

2 x 200t/h

Rail loading

200t/h

Clinker storage

60.000 t

Page 37: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 15

STRABAG GREENFIELD PLANT

overall project management

plant arrangement, process design

complete tender support to client

sub-contracts negotiation

progress & quality assurance

interface and technical clarification

supervision services & training

Page 38: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 16

LAFARGE WÖSSINGEN

Project Scope – Main Plant Sections

Raw Mill and kiln Filter modification of ESP

Bypass Filter modification of ESP

Bypass Dust storage and dosing new

Conditioning tower new

Raw meal transport from silo to dosing new

Lime hydrate storage and dosing new

SNCR dosing systems new

Kiln – 2 reuse of usable kiln and kiln parts new

Burner and fuel dosing systems new

Clinker cooler new

Cooler Filter new

Clinker transport new

Page 39: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 17

LAFARGE WÖSSINGEN

Page 40: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 18

W & P – WIETERSDORF, AUSTRIA

Project Period: 16 months

Shut-Down: 69 days

New Preheater & Calciner

• New preheater complete

• New low-NOx calciner incl. Comb. Chamber

• New tertiary air duct,

• New hot gas duct

• New preheater fan

• Kiln shortening

• New kiln inlet sealing

• New kiln inlet chamber

Results

• Production increase from 1000 to 1777 t/d

• NOx <500 mg/nm³ (without SNCR)

Page 41: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 19

W & P – WIETERSDORF, AUSTRIA

Page 42: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 20

CEMEX – ASSIUT KILN 2+3, EGYPT

Project Period: 8 months

Shut-Down: 39 days

Modification on Preheater & Calciner

• Disassembly of preheater equipment

except

• Cyclone cone stage 2 & 4

• Meal pipes stage 2 & 4

• Installation of new preheater equipment

• Extension existing 2 string calciner

• New hot gas duct

Results:

• Production increase from 4000 to 4500

t/d with a shut down of only 39 days!!!

Page 43: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009 21

CEMEX – ASSIUT KILN 2+3, EGYPT

Page 44: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2009

Please visit:

www.atec-ltd.com

THANK YOU FOR YOUR ATTENTION

Page 45: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

1 Priviledged Information not to be copied. All rights reserved.

MUNICIPAL SOLID WASTE (MSW) REFUSE DERIVED FUEL (RDF)

EVENT: FICEM-APCAC Conference 2009

PLACE: Bogota

DATE: 2009Sept07

By Jonathan [email protected]

BASURA MUNICIPAL COMBUSTIBLE

Page 46: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

2

Who is A TEC?

Since 1996 A TEC has

improved the Pyro-process

with 17 patented innovations.

Austrian engineering company:

>10 years experience in alternative

fuels implementation

Page 47: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.3

TYPICAL ALTERNATIVE FUELS

1. Waste oil

2. Solvent

3. Contaminated and waste wood

4. Tire and rubber waste

5. Plastic waste

6. Thermal fraction of domestic waste

7. Thermal fraction of industrial waste

8. Animal meal

9. Sewage sludge

Page 48: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.4

RAW MATERIAL

Municipal Solid Waste … it’s free!

Page 49: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.5

TYPICAL FUELS CONTAMINANTS

Page 50: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.6

MSW COMPONENTS & TRAJECTORIES

Step 1

pre-crushing

max.

150mm

Step 2

drying,

hygienisation,

separation of fine

fraction ~20 min.

150 C

Step 3

cutting

60-80mm

Step 4

further

processing

depending on

requirements

Step 5

separation

of

impurities

Step 6

further

separation

depending on

requirements

Problematic

materials ~1%

Thermal

fraction calorific

value: 17-21

MJ/kg

Wa

ste

ma

teria

l

Exa

mp

le

Water ~31%

Organics ~9%Textiles ~7%Wood ~8%Plastics ~7%

Composite materials ~6%Paper ~6%Metal ~7%

Glass and inert materials ~7%

MTP

Page 51: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.7

BEHAVIOUR OF TRACE ELEMENTS

COMPONENTS in RDF: Behaviour in the Pyro-Process

Elements involved Components/ Carriers Transfer Details

Chrome, Zinc, Nickel,

Arsenic, Vanadium, etc.,

Sulfur from the fuel

Clinker mineral elements,

Low volatile metals

Sulfur component of fuel

Hardly volatile: mainly transfer into the clinker

TOC, Lead, Mercury

Sulfur from raw meal

Non burnt organics,

Products of combustion

Volatile: Mainly transfer into the preheater exhaust

gas

Thallium, Cadmium, Mercury Volatile trace metals

Linked to dust particles

Volatile: Likely build up of internal cycles.

Transfer into preheater exhaust dust, cycle builds

until overflow is picked up at filter and recirculated via

raw meal. Mixing filter dust to cement bleeds cycle.

Chlorine,

Sodium, Potassium

Halogens, alkalis,

residuals conveyed with

clinker

Build up of internal cycles likely:

By-pass system can bleed elements to external

disposal.

Page 52: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.8

THE PROCESS

collection storage transport dosingprocessing

Operation Guidlines

& Adjustment

Process Design

& Evaluation

Combustion

Technology

Standard Alternative Fuel Preparation Technology

Production and process technology for utilization of alternative fuels

Page 53: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.9

THE PROCESS

Domestic or

Industrial

Solid Waste

optional

A TEC -

MTP

Hot air

(Clinker cooler)

Contaminated

gas

Storage

Untreated material

STORAGE

Storage

Material <

300mm

Material < 50mm

Storage

Sorting

Automatically or

hand-operated

Shredding

< 15 mm

Shredding

< 300 mm

Shredding

< 50 mm

A TEC rotary

combustion

chamber

Calciner section

& combustion

chamber

Main burner

Storage

Material < 15mm

Plant engineering from DELIVERY to

COMBUSTION is ONE concept…

300 mm = 12”

50 mm = 2”

15 mm = 5/8”

Page 54: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.10

THE PRODUCTION LEVEL

Typical Preheater Exhaust Gas Volumes

at 2% false air; 3300 kJ/kgcli

Approx. Gas Volume [Nm3/kgcli]

Coal 1,50 base

Heavy oil 1,60 + 6,6 %

RDF 10% moisture 1,65 + 10,0 %

Natural gas 1,70 + 13,3 %

Page 55: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.11

THE EFFICIENCY LEVELS

Reductionclinker production

Increase heat consumption

Moisture [t/t H2O] 2.00 [MJ/kg H2O] 2.10

False air [t/kNm³ air] 0.23 [MJ/Nm³ air] 1.00

Oxygen [% t/%O2] 5.50 [% MJ/%O2] 1.60

1t metric = 1.102 st 1 MJ/kg = 430 BTU/lb1 kNm3 = 35’000 ft3 STP 1 MJ = 950 BTU

OPTIMISATION IS ESSENTIAL !!!

1,0 [GJ] primary fuel 1,2 [GJ] alternative fuel

Page 56: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.12

REFERENCE PLANT FOTOS (1)

Drum separation plant

Hand sorting creates jobs

Page 57: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.13

REFERENCE PLANT FOTOS (2)

Plastic Waste arrives in tied bales

Bales on pan conveyor to Stage 1 shredder

Page 58: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.14

REFERENCE PLANT FOTOS (3)

Heat treatment eliminates bio-hazard

Page 59: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.15

REFERENCE PLANT FOTOS (4)

Feed chute to RSP combustion chamber

RSP Combustion Chamber

Page 60: A TEC WORLDWIDE · THANK YOU FOR YOUR ATTENTION. 2009 A TEC WORLDWIDE World Leader in Cement Pyroprocess Technology A TEC Company Presentation . 2009 2 A TEC WORLDWIDE Mexico, Puebla

Priviledged Information not to be copied. All rights reserved.16

PLANT DESIGN FOR 80% A.F.

TAD 4

TAD 3

TAD 2TAD 1

Bypass

Quench

Tires < 1,000 mm

MAIN BURNERPlastics, Animal Meal

Fine Coal

< 20 mm

COMBUSTION CHAMBERPlastics, Sewage Sludge, Fine Coal

< 50 mm

CALCINER

MIXING

CHAMBER

RSP-Technology in cooperation with Taiheiyo Engineering

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Priviledged Information not to be copied. All rights reserved.17

EXAMPLE ECONOMICS

Income 462‘200 USD

Costs - 466‘800 USD

Clinker production: 51‘500 t

Σ Fuel Cost = 0.09 USD/t clinker

Series1; 258'270

Series1; 88'456

Series1; 64'740 Series1;

49'002 Series1; 3'663

Series1; 2'708

INCOME; 462'246

Fuel COSTS (RED)

coal Supplier A

coal Supplier B

coal Supplier C

petcoke

saw mill waste

wood chips

fuel income

-381'358

-20'529

-19'287

-10'059 -31'013

COSTS; 466'839

Fuel INCOME (BLUE)

mixed plastic

waste plastic pipes

sewage sludge - dry

sewage sludge - non dried

reject paper

fuel costs

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18 Priviledged Information not to be copied. All rights reserved.

Please visit www.atec-ltd.com

THANK YOU FOR YOUR

ATTENTION

A TEC AMERICA

11 Poniente No. 2702 Dept. 5

Col. La Paz, 72160 Puebla, MEXICO

Tel.: +52 222 889 7907

E-Mail: [email protected]

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Presentation - HURRIVANE/ 1

.09.2009

FICEM-APCAC Cement

Industry Technical

Conference

2009 Bogotá, Colombia

Dipl. Ing. Pedro Montes de Oca

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Presentation - HURRIVANE/ 2

.09.2009

1. Introducción – Efectos al tener mayor volumen de gas

2. Tecnología del HURRIVANE

a) Funcionamiento

b) Efectos en torre de precalentador

c) Ejemplo de ahorro

3. Aumento de eficiencia

4. Cementos Progreso Planta San Miguel

a) Instalación Horno 1

b) Instalación Horno 2

Tratando con mas gas de escape

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.09.2009

1. Introducción –

Efectos del gas

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.09.2009

Efectos del gas

Más volumen de gas

Más kW en el ID-Fan

Más Costos

Tecnología ATEC para contrarestar estos efectos =

1. INTRODUCTION – ALTERNATIVE FUEL

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.09.2009

2. HURRIVANE –

Tecnología

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.09.2009

HURRIVANE Típico

1. Se agrega al tubo de inmersión del ciclón

2. Vanes en dirección del flujo

3. Reducción de la pérdida de presión

a) Reducción de kW ID Fan

b) Reducción Energía Específica

1. INTRODUCTION – ALTERNATIVE FUEL

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Presentation - HURRIVANE/ 7

.09.2009

1. INTRODUCTION – ALTERNATIVE FUEL

Sin

HURRIVANE

Con

HURRIVANE

delta

Presión estática [mbar] -72 -68 -4

Gas Temp [°C] 320 320 0

Caudal Gas [Nm3/h] 207’667 207’667 0

Caudal Gas [Am3/h] 538’535 536’260 -2275

N

A

A

N

N

A

T

T

p

p

V

V

Efectos en torre de precalentador:

Reducción de dP menos volumen de gas

La reducción de presión gracias al

HURRIVANE se refleja en el volumen

de gas que tira el ventilador principal

Ejemplo 1: Producción Constante

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.09.2009

Efectos en torre de precalentador:

Reducción de dP menos aire falso

1. INTRODUCTION – ALTERNATIVE FUEL

sin

HURRIVANE

Con

HURRIVANE

delta

Presión estática[mbar] -72 -68 -4

Cantidad Gas [Am3/h] 538535 536260 -2275

Aire falso [Am3/h] 26927 26816 -114

AAir,

N Air,

N ρΔp2ρ

AkVAir False

La reducción de presión gracias al

HURRIVANE se refleja en la cantidad de aire falso

Ejemplo 1: Producción Constante

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.09.2009

Efectos en torre de precalentador

Menos ∆P & menor gas → menos kW ID Fan

1. INTRODUCTION – ALTERNATIVE FUEL

Sin

HURRIVANE

Con HURRIVANE delta

Cantidad gas [Am3/kg cli.] 538535 536260 -2275

kW ID Fan 1346 1274 -73

kWh/t cli. 11.54 10.92 -0.62

Energía en ID-Fan -5%

η

ΔPVkW A

La reducción de presión, menor gas y menor aire falso gracias

al HURRIVANE se refleja en un ahorro de energía del 5% en

el ID-Fan

Ejemplo 1: Producción Constante

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.09.2009

Efectos en torre de precalentador

kW Id Fan = const → Aumento de producción

1. INTRODUCTION – ALTERNATIVE FUEL

Sin

HURRIVANE

Con

HURRIVANE

delta

Gas [Am3/kg cli] 538535 536260 -2275

kW ID Fan 1346 1274 -73

kWh/t cli. 11.54 10.92 -0.62

kWh/t cli. 0.62 0.62 +5%

Ejemplo 2: Aumento de producción

Por lo tanto:

73 kW permiten aumento de producción del 5%

o reducción de kWh/t cli del 5%

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Presentation - HURRIVANE/ 11

.09.2009

3. Aumento de eficiencia

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.09.2009

4. POTENTIAL COST REDUCTION

Cálculo de posibles ahorros

Process Data Plant Data

Gas amount at ID Fan 1.78 [Nm3/kg cli] Clinker Production 2800[t/d]Current T at ID-Fan 320 [°C] Level above Sea 800[m]

dp Stage 2 1500 [Pa] Fuel cons. 3538[kJ/kg cli]

dp with HV 30 [%] Prod. Days/year 321[days]

Static Pressure ID Fan -72 [mbar] Energy costs 0.10[USD/kWh]Cp Gas PH Outlet 1.523 [kJ/Nm³ K]O2 Top Stage 5 [%]ID Fan efficiency 0.8 [-]Temperature top stage 348 [°C]Gas amount at pH Outlet 1.69 [Nm3/kg cli]Pressure top stage -69 [mbar]Temperature water injection 25 [°C]

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.09.2009

4. POTENTIAL COST REDUCTION

Cálculo de posibles ahorros (2)

SavingsProduction Increase when kW at ID-Fan = const

Pressure drop reduction 450[Pa]

Gas amount at ID Fan 2,745[Am3/h]

kW ID Fan 88[kW]Productionincrease 2.14[t/h]

kWh ID Fan 0.75[kWh/t cli]

Savings kWh 2,106kWh/day

Savings kWh 675,979kWh/year

Savings USD 67,598USD/ year

En este caso la ganancia de 88 kW en el ID-Fan permite:

Un ahorro de 0.75 kWh/ t cli

o un aumento de producción del 2%

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.09.2009

4. Referencias en

Planta San Miguel de

Cementos Progreso

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.09.2009

a). Rendimiento constante

Cementos Progreso:

Efectos en horno 1

Delta 0.11 -77.8 -55.96 -93 -65.7 0.0671 1.35

6% ahorro energético específico

Se consumen 66 kW menos en el ventilador

Reducción de caída de presión de 55.96 mm H20

Alimentación

constante kW en

Ventilador

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.09.2009

2. Aumento de rendimiento.

Esta opción no se ha evaluado debido a nivel de demanda

del mercado, pero si se asume un incremento del 3% como

en horno 2, la mejora esperada sería:

Cementos Progreso: Efectos en horno 1

Alimentación futuro + 2.45 t/h

Consumo específico - 0.62 kWh/t cli

Clinker futuro + 1.49 t/h

Aumento de producción + 3%

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.09.2009

a) Rendimiento Constante:

1.35 kWh/t clinker menos implica un

ahorro anual de US$ 80,272. (TRT 80%).

b) Aumento 3% Rendimiento:

Este escenario dependerá de la demanda

del mercado y de la ganancia en cada

tonelada vendida

Cementos Progreso:

Ventajas económicas en horno 1

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.09.2009

Cementos Progreso: Efectos en horno 2

a) Rendimiento constante.

12.4% ahorro energético específico

Delta 0.1 -2.7 -59.6 -193.6 -163 0.04 -2

kWh en

Ventilador

Alimentación

constante

Se consumen 162 kW menos en el ventilador

Reducción de caída de presión de 59.6 mm H20

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.09.2009

b) Aumento de Rendimiento

Cementos Progreso:

Efectos en horno 2Producción de

clinker

Caída de

presión

Delta 4.2 16.3 47.5 -11.4 16 2.55 -0.3

aumento de producción del 3.2%

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.09.2009

Cementos Progreso:

Ventajas Económicas horno 2

b) Aumento de

Rendimiento

a) Rendimiento

constante.

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.09.2009 www.atec-ltd.com

Thank you

for your attention!ENERGY

EFFICIENCY

ENVIRONMENT

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A TEC > Dealing with more Chlorine / 11 ATEC/JF: Confidential Information

Dealing with More Chlorine

Tratando con más Cloruro

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A TEC > Dealing with more Chlorine / 2

REASONS FOR USING A BYPASS IN THE CEMENT INDUSTRY

Raw meal which have high contents of chlorine,

alkalis and sulphur

Using a high amount of alternative fuels

containing chlorine & sulphur

Build ups and heavy coating in the area of the

kiln riser duct and meal pipe to the kiln

Strict environmental regulations

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A TEC > Dealing with more Chlorine / 3

GAS TAKE OFF DUCT

Main Advantages:

Big take off area

Low take off velocity

Particles < 10 µm

• No cyclones needed

• Gas can be used for raw meal

drying to reduce thermal losses

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A TEC > Dealing with more Chlorine / 4

QUENCHING CHAMBER

Made completely of metal

(no lining required)

Cooling in 1 step to 200 C

Minimum space requirement

Simple & trustworthy operation

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A TEC > Dealing with more Chlorine / 5

STANDARD BYPASS SYSTEM

Comp. Air

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Coating/Build Up Conditions

original

operation

operation

without bypass

operation with

bypass

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A TEC > Dealing with more Chlorine / 7

Bypass Rate Efficiency

5...10 % bypass rate is sufficient for chloride bypass systems

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A TEC > Dealing with more Chlorine / 8

A TEC Bypassat

Castle Cement

Bypass Dust Cyclone and Ducting

bypass

cyclone

1st stage

quench

2nd stage

quench

mixed gas

duct to filter

coarse dust

return

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A TEC > Dealing with more Chlorine / 9

refractory liningrefractory lining

refractory liningrefractory lining

Design

< 1,5 % Cl in hot meal

Design

< 1,5 % Cl in hot meal

Operating RangeOperating Range

gas from preheatergas from preheater

reserves onto required

design data

reserves onto required

design data

Design Data for GuarantiesDesign Data for Guaranties

CASTLE BYPASS SYSTEM

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A TEC > Dealing with more Chlorine / 10

Quench Chamber

Main Shut Off

Damper

Quench Air

Shut Off

Damper

Quench

Chamber

Quench Fan

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A TEC > Dealing with more Chlorine / 11

Quench Chamber Emergency Air

Generator starts

on power failure to

run fan to keep

equipment

downstream of

emergency shut

off valve cool

Emergency Fan

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A TEC > Dealing with more Chlorine / 12

Bag Filter / Silo Arrangement

Mounted directly on top of 120 m3 (approx 70 ton) Silo.

Sweeping Auger screws dust out to centre discharge

Screw & Rotary Feeder to Loading Head

Wagon loading 30tph

Water Spray on dust at loading head

Discharge capacity 30 t/h

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A TEC > Dealing with more Chlorine / 13

Bag house

Bypass dust silo

Truck loading

station

Some details:

Mounted directly on top of

120 m3 (approx 70 ton) Silo.

Sweeping Auger screws dust

out to centre discharge

Screw & Rotary Feeder to

Loading Head

Truck loading 30tph

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A TEC > Dealing with more Chlorine / 14

Silo Discharge

Auger Drive

Auger Rotation

Shutoff Slide

Rotary Feeder

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Loading Spout

Water Sprays on Loading

Head to control dust

Dust from Bag Filter goes to

Quarry

Alternative uses for dust

such as washing out chloride

& reusing dust currently

under examination

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Performance Test Result

• Cl in bypass dust 14%

• Cl in dust return to hot meal chutes 3.5%

• Cl in raw materials 0.0083%, clinker basis

• Gas flow at kiln inlet approx. 80,000 Nm3/hr

• Bypass % of gas flow at kiln inlet 8 %

• Dust in gas at input to quench chamber 0.25 kg/Nm3

• Dust to quench chamber 38 te/day

• Dust out of quench chamber (including KCl) 45 te/day

• Dust to waste 22.5 te/day

• Dust return to hot meal chute 22.5 te/day

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Operational Results Today

Operation Period since start up: 30 months

Total unscheduled maintenance: insignificant

Total bypass dust saved from depositing: approx. 20‘000 tons

Total waste utilised for alternative fuel: approx. 165‘000 tons

Chloride in bypass dust: average 12% to 16%

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A TEC > Dealing with more Chlorine / 18

Priviledged Information not to be copied. All rights reserved.

Please visit www.atec-ltd.com

THANK YOU FOR YOUR

ATTENTION

11 Poniente No. 2702 Dept. 5

Col. La Paz, 72160 Puebla, MEXICO

Tel.: +52 222 889 7907

E-Mail: [email protected]