24th Jan, 2013 in Mongolia under the framework of NAMAs

Effective Utilization of Fly-Ash

from Power Plant for Cement Production

YOSHIYUKI UENOYAMA
General Manager
g
Green-Innovation Business Promotion Department
TAIHEIYO CEMENT CORPORATION
yosiyuki_uenoyama@taiheiyo-cement.co.jp
Taiheiyo Cements activities span the world

Dalian(China)
USA
Qinhuandao(China) Japan
p ((11 p
plants))
Nanjing(China)
(C ) Korea

Vietnam
Philippines

Papua New Guinea

Oversea Sales: 22,649kt
22 649kt (2009)
U.S.A. 2,035 kt (9.0%)
China 4,766 kt (21.0%)
Korea 12,815 kt (56.6%)
Locations of Taiheiyo Groups cement plants Others 3,033 kt (13.4%)

Domestic
D ti Sales:
S l
14,829 kt + Export 5,009 kt 2
2013 TAIHEIYO CEMENT
Contents

Outline of dry process of cement production and energy efficiency

Recycling - utilization of by
by-products
products and industrial waste including coal fly ash

Taiheiyo's advanced technology for utilizing MSW incineration ash

Conclusion

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2013 TAIHEIYO CEMENT
Typical cement production process
Material flow
Fuel flow
1. Mining Gas flow
Coal
Stack
Dust
Stack
collector
Preheater
Belt conveyer
Iron Dust Coal mill
Clay
Limestone collector
slag
g minerals
3. Burning process
Rotary kiln
Raw mill
Homogenizing
H i i Clinker cooler
silo
Gypsum
Clinker
2. Raw material p
process Cement silo
4. Shipping silo Classifier

Finish mill 4. Finishing

4
Cement vessels Freighters Bulk trailers
Bags 2013 TAIHEIYO CEMENT
Raw material for cement
Cement is made from Limestone, Silica, Clay and Iron slag

Cl (d
Clay (dried)
i d) Silica Li
Limestone
t I
Iron slag
l

Limestone:
Occupying 70
70-80%
80% of total raw
materials and transported from a
mine by a belt conveyer, for
i t
instance

Iron slag:
By-product of iron manufacturing
Limestone mine
The composition of raw material
effects property of cement
5
Long distance belt conveyer 2013 TAIHEIYO CEMENT
Burning process
Excellent cement can be manufactured by burning at very high temperature of 1450 oC
1. Raw material is heated gradually by hot gas in the preheater
2 Preheated
2. P h t d raw material
t i l iis b
burned
d iin th
the rotary
t kiln
kil att a temperature
t t off 1450 oC
3. Approximately 30 min of burning, the raw material turns red-hot lava like lumps

Inside view of Rotary kiln operating at

Preheater (back) of 65m in height and
a very high temperature of 1450 oC
Rotary kiln (fore) of 5.4m in diameter,
95m in length, 3200 ton/day production
6
capacity, 250 kW powered
2013 TAIHEIYO CEMENT
Finishing process
Grinding clinker with gypsum into fine powder, that is cement

Clinker

Finish mill Classifier

Power required: 3875 kW
Gypsum Milli capacity:
Milling i 120 ton/h/h
To control setting Size: 4.6m dia. and 13.1m
time of cement

Cement 7
2013 TAIHEIYO CEMENT
Difference of wet-process kiln in energy efficiency
Providing slurred raw material directly into rotary kiln

Schematic wet-process cement kiln

7000
Specific required heat Specific production
6000 of kiln volume 120
r)

5000
(MJ/t-clinke

100

(kg/m3/h)
4000 80
3000 60
(

2000 40
1000 20
0
Wet-process
et p ocess DB-type
DB type SP type
SP-type NSP type
NSP-type
kiln kiln kiln kiln

Specific required heat and production on various types of kiln 8

2013 TAIHEIYO CEMENT
 Specific required energy and energy efficiency
(MJ/t-cement)
4500
Typical technology on heat efficiency
4000 - NSP type burning system
3500 - Five-cyclone cascaded preheater
Including alterative waste fuel - Air beam type clinker cooler
3000
- Pulverizing coal constant feeder
2500
Excluding alterative waste fuel - Automated quality monitoring
2000
70 75 80 85 90 95 00 05 09
(kWh/t-cement)
Transition of unit heat energy 130

120
Typical technology on power efficiency 110
Including waste heat
recovery power generation
- Vertical type mill 100
- Pre
Pre-grinding
grinding system 90
- High efficiency classifier
80 Excluding waste heat
- High efficiency blower fan recovery power generation
70
70 75 80 85 90 95 00 05 09

Transition of unit power 9

2013 TAIHEIYO CEMENT
The top runner on energy efficiency
180
ex
ption inde
160

140
Energy consump

120

100

80

60
Mexico
Japan

Italy

India

Spain

Korea
Thailand

Canada

China
Germany

Brazil

Weighted Av.
USA

W
Comparison of Energy consumption index on clinker and cement manufacturing
( ) WorldwideTrendsin
Reference:TheInternationalEnergyAgency(IEA),
EnergyUseandEfficiency2008
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2013 TAIHEIYO CEMENT
Business scheme of material recycling
Practically performed Waste to Resources business scheme on cement plants

Conservation of Prevention of global Elongation of landfill

natural resources warming service life

Natural
resources
Industrial clustering Recycling of municipal waste
Blastt furnace
Bl f
Steel plants

MSW
slag Incineration Separation and
ash Incineration

household
Coal fly ash
Coal fired
power plants Cement plants

Sewage sludge
Desulfurazation Raw Mixing
admixtures

General
gypsum materials
Limestone & slaked lime Admixtures

G
Others Incineration
Alterative fuel &
waste tires Incineration
raw materials ash
waste plastics

Cement and concrete products 11

2013 TAIHEIYO CEMENT
Utilizing by-products and waste
Why by-products and waste can be utilized at cement plants?

Because:

1 C
1. Cementt majorly
j l contains
t i CaO,
C O SiO2, Al2O3 and
dFFe2O3.
Waste containing such components may be used as raw material.

2. Combustible waste may be used as fuel for burning process in

the rotary kiln.

3. No secondary waste is generated because cinders of

combustible waste will be consumed as raw material.

4. Hazardous materials such as dioxin can be decomposed in the

rotary
t kiln
kil under
d ththe hi
high
h ttemperature
t off 1450 oC.
C
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2013 TAIHEIYO CEMENT
Chemical compositions of waste
The reason why by-products and waste can be utilized at cement plants

Composition of major elements (%)

Total Alkali
SiO2 Al2O3 Fe2O3 CaO Na2O eq.

Ordinary Portland Cement 20~23 3.8~5.8 2.5~3.6 63~65 0.3~0.7

Limestone ~4
4 ~2
2 ~2
2 47~55
47 55 ~0.2
0.2
Major
natural Clay 45~80 10~30 3~10 ~5 2~6
resources
Silica 70~95 2~10 ~5 ~2 0.5~3
Coal fly ash 40~65 10~30 3~10 5~20 0.5~20
By- Blast Furnace slag 20~45 10~20 ~5 30~60 0.1~0.5
products
and waste S
Sewage sludge 20 0
20~50 20 0
20~50 5~15
1 5~30
30 1
1~5
Casting sand 50~80 5~15 5~15 ~5 1~5

Clark numbers: O=49.5 Si=25.8 Al=7.56 Fe=4.70 Ca=3.39 ....

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2013 TAIHEIYO CEMENT
Fly- and Bottom-ash recycling on cement production
FY2009
Consumption
p of waste: Cement
26,290kt/y (451kg/t-cement)
Ref.: Japan Cement Association Milling Mixing

Dust-collector

Fly ash Clinker Gypsum

By-product
g ps m
gypsum

Organic Waste:
Limestone Drying
y g
Raw
Ra Waste plastic Waste oil
Silica Clay Grinding
Blending material Coal
Iron slag
Rotary Kiln
Coal

Bottom ash Fly ash

Other waste Clinker cooler
i l
materials Massive waste:
Sludge Sewage sludge
Tires MSW 14
2013 TAIHEIYO CEMENT
Cement industry as an MVP of recycling
Approximate 26 million tons of industrial waste including 6 million tons
of coal fly ash was recycled in cement industry in 2009

L dfill
Landfill
3% Others Cement
Others 15% 13%
16%
Export
15%
Total amount Total amount
Construction of recycling of recycling
material 17% 8,924 kt 1,056 kt Paper
Cement Reuse 32%
64% basement
15% Thermal
recycle Steel
10% 4%

Usage of coal fly ash Usage of waste tires

References: Japan Fly Ash Association and Japan Automobile Tyre Manufacturers Association
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2013 TAIHEIYO CEMENT
Utilizing by-products and waste
Organic waste is potentially used as fuel

Waste tires Waste plastics

Wood chips and other biomass Recycled oil 16

2013 TAIHEIYO CEMENT
Key technology of bypass system
Enables to utilize respectively inorganic waste as raw material and
organic waste as fuel, and to recover minor elements
Raw Gas flow
material Material/Fuel flow
400oC

Heat Dust
recovery collector
Preheater
boiler

Heat
recovery
boiler
Coal
Coal mill

1000oC

1450oC 250oC

Rotary
y kiln
Chloride bypass and minor
elements recovery system Clinker cooler Clinker 17
2013 TAIHEIYO CEMENT
Waste to Resources on MSW management

Development of
Community
MSW
AK (Applied Kiln)

Incinerators
Ash
processing
Incineration ash
Existing Cement Plants

Eco-cement Cement & Concrete

Eco-cement Plants
Landfill sites (extension of service life)
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2013 TAIHEIYO CEMENT
AKApplied Kiln System

Hidaka City:
P
Population
l ti 50
50,000
000
MSW 15,000 ton/y

Crushing and
separating

Incinerators
Aerobic bio
bio-
digester

Cement production
line making use of
digested
g MSW

19
Saitama Plant, TCC 2013 TAIHEIYO CEMENT
Ash processing systems
Fly Ash Washing System
(15,000 t/y)
Bottom
B tt Ash
A h Processing
P i
System (50,000 t/y)

Kumagaya Plant, TCC

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2013 TAIHEIYO CEMENT
Eco-cement plant

Futatsuduka Landfill, Tokyo

One third of MSW in Tokyo has been recycled as Eco-cement since 2006.
Tokyo Metropolitan Government has constructed the plant in their landfill site and
operation
ti hhas b
been commissioned
i i d tto TCC
TCCs subsidiary.
b idi
- Input MSW (as incineration ash) 300t/d 21
- Output Eco-cement 430t/d 2013 TAIHEIYO CEMENT
Conclusion
1. Coal fly ash generated at thermal power plants can be recycled as
alternative clay raw material in large quantities and continuously.

2. The cement manufacturing process with advanced quality and

process controls enables to recycle
p y by-products
yp and waste g
generated
by other industries as alterative raw material and fuel.

3 By means of installing Chloride bypass technology

3. technology, the cement plant
can recycle municipal solid waste (MSW) and its incinerated ash as
raw material.

4. Taiheiyo Cement has accumulated advanced technologies and

experiences related environment as mentioned above and energy
efficiency
ffi i as well,
ll and
d iintends
d to consult
l with
i h possible
ibl customers and
d
to provide such technologies.

Thank you for your attention. 22

2013 TAIHEIYO CEMENT

Th k
Thankyouforyourattention
f tt ti

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2013 TAIHEIYO CEMENT
Locations of Domestic Plants
Direct operation plant
Subsidiaryy and Affiliate
Total production capacity: 21,067 kt/y
Kamiiso
3,829

Myojo Ofunato
Eco-cement
1,763 2,032

Tsuruga Kumagaya
677 2,027

Fujiwara
F ji Saitama
S it
2,326 1,470

D.C.
D C
1,199

Oita
5,744
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2013 TAIHEIYO CEMENT
Recycling systems clustered on cement industry

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2013 TAIHEIYO CEMENT
Reducing CO2 Emission by utilizing waste as fuel

Energy
Fossil
Waste Fossil energy from
energy
waste

IIncine-
i Co-combustion
C b i
rators Cement plants
at cement plants

Reference: CEMBUREAU, Alternative Fuels in Cement Manufacture, 1997

http://www cembureau be/Documents/Publications/
http://www.cembureau.be/Documents/Publications/
Alternative_Fuels_in_Cement_Manufacture_CEMBUREAU_Brochure_EN.pdf
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2013 TAIHEIYO CEMENT
Utilizing by-products and waste
Transition of ratio of waste derived fuel
Reference: Japan Cement Association

Waste derived fuel

gy
sil energ

Fossil Energy
o of foss
Ratio

Fiscal Year

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2013 TAIHEIYO CEMENT
Technical configuration of AK System

Crushing and
Garbage separating
trucks
g
Bio-digester
Feed to
rotary kiln

MSW

1stt day
1 d 2nd
2 ddday 3rd
3 ddday Digested MSW
Garbage bags Aerobic MSW turns
tear and digestion cement raw
fragment quickly material and
develops fuel
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2013 TAIHEIYO CEMENT
Fly ash processing system

Water Fly Ash

Li id
Liquid
Gas
Dissolution tank

Belt filter
From incinerators

Filter Cake
Filtrate Rotary kiln
Decanter
Settling

Kiln Sewage
exhaust
Sand filter Hg remover
CO2 reactor Filter cake
Filter press
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2013 TAIHEIYO CEMENT
Advantages of Eco-cement

More ash can be recycled

Approximately 50% or more of incineration ash
and less natural limestone can be used as raw material.

Standards provide easy use of Eco-cement

Eco-cement
Eco cement is regulated in JIS (Japanese Industrial Standards)
Standards),
and can be used easily for practical purposes.

Heavy
H metals
t l can b
be recovered
d
Some of heavy metals, such as Cu, Pb and Zn can be recovered
from collected dust.

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2013 TAIHEIYO CEMENT