Energy efficiency with environmental protection in production

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Linking energy efficiency with environmental
protection in production - good practice Vanja
Strle Ljubljana, 23th of February 2011
European CommissionEnterprise and Industry
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Energy efficiency
Environmental protection
Use of energy
Use of fuels
Use of energy transferable mediums
Production
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Goals

• BETTER ENVIRONMENT
• LOWER COSTS
• BIGGER BENEFITS

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Goals
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Energy efficiency
Environmental protection
Lower costs / Better environment

• lower emissions
• avoiding of penalties
• lower taxes
• lower fees
• better business occasions

• reduced energy use
• reduced use of fuels
• reduced use of energy
• transferable mediums
• - better working utilisation rate

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DETAILED KNOWLEDGE OF THE ENERGIES FLOWS
OPTIMISATION OF THE PRODUCTION PROCESS

• reduced energy use
• reduced use of fuels
• reduced use of energy transferable mediums
• better working utilisation rate
• environmental benefits

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• EXAMPLES / Energy intensive industries
• Production of insulation materials
• Lime industry
• Cement industry

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• EXAMPLES / Energy intensive industries
• Critical points in this industries are industrial
  ovens
• the consumption of the fuel
• the type of the fuel
• the type of the burners
• increasing the heat transfer
• adding the oxygen in the process
• measuring and regulation of the combustion
  process
• fore-heating of the burning air and the oven bed
  material
• isolation
• recuperation of the waste heat
• good maintaining

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1 - Production of insulation materials
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• isolation heat, sound, fire
• big consumption of energy source and energy
• big production of greenhouse gas emission
• important reducing of fuel consumption in
  isolated buildings
• The ratio - the production of greenhouse
  emission
• production of stone wool non-isolated
  buildings, 50 years
• 1 1000

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Production of insulating materials - stone wool
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• Production phases
• raw material preparation
• melting
• fiberisation of the melt
• binder application
• product mat formation
• curing
• cooling
• product finishing

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Production of insulation materials - stone wool/
melting
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• oven the coke hot blast cupola,
• alumino-silicate rock, dolomite, technological
  scrap from stone wool (briquettes to prevent
  flow of dust emissions (oven atmosphere, external
  air), quality of melted material, disturbing of
  the flow blowing into the oven),
• 1700 C,
• reductive conditions,
• warmed air / O2 - blowing into the hot blast
  cupola

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Production of insulation materials - stone wool/
melting - the energy flow
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taken away with cooling
entry- energy
waste energy
taken away with air emissions
melting
possibilities for waste heat use
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Production of insulation materials - stone wool/
cooling
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cooling of the coat of hot blast cupola
waste heat
regulation
heat is used for drive of absorption cooling
system
cooling of other users
room heating
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Production of insulation materials - stone wool/
air emissions from melting
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warmed air / O2 - blowing into the hot blast
cupola
hot waste air emission
waste heat
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Production of insulation materials - stone wool/
air emissions from melting
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• Different emission pollutants - need different
  cleaning approaches
• dust bag filter, electrostatic precipitator,
  stone wool filter,
• inorganic gas parameters like oxides of sulphur,
  oxides of nitrogen are affected by the
  composition of the raw material and the quality
  of the coke, wet scrubber,
• combustible gas parameters as volatile organic
  compounds, hydrogen sulphide, carbon monoxide
  burned in incinerator (thermal oxidation)

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Production of insulation materials - stone wool/
air emissions from melting - carbon monoxide
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• carbon monoxide burned in incinerator it
  has to be achieved
• as much as possible complete burning
• CO ½ O2 CO2

En
using of waste heat for near users
minimizing of CO
less needed fuel for incineration
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Production of insulation materials - stone wool/
air emissions from melting - carbon monoxide
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Cupola furnaces (data from EMEP/CORINAR)
substance air emission mg/ m3 grams / ton of melted material Example for capacity of 20 tons / day
CO 10 100.000 30 300.000 (0,6 kg 6.000 kg)/ day
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Production of insulation materials - stone wool/
air emissions from melting - carbon monoxide
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Coke hot blast cupola
Reactions Energy formation /units
C (coke) ½ O2 CO 1,1
C (coke) O2 CO2 3,9
CO ½ O2 CO2 2,8
Energy consumed (1,7 units)
C (coke) CO2 2 CO
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Production of insulation materials - stone wool
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• Other possible measures to reduce the consumption
  of the fuel and energy and consequently also the
  air emissions - on the local and global level
• monitoring of the used fuel (coke, other fuels)
• monitoring of the concentration of oxygen, carbon
  monoxide and carbon dioxide, which can show the
  efficiency of the burning
• good isolation of the installations with warmed
  air and water
• the process has to run continuously to prevent
  heat oscillations
• working start and stop of the hot blast cupola
  has to be made progressive

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Production of insulation materials - stone wool
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• Other possible measures to reduce the consumption
  of the fuel and energy and consequently also the
  air emissions - on the local and global level -
  saving the electric energy gt minimizing the
  operators costs and the emissions on the global
  level
• high efficiency motors, variable speed drive,
• minimizing of the reactive energy losses that cos
  f between the voltage and the current peaks lies
  permanently between 0,95 0,99,
• minimizing of compressed air demand,
• Introducing a regular leak control program for
  compressed air system,
• using of transporters with minimal rubbing

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2 - Lime industry
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• CaCO3 ? CO2
  CaO
• limestone ? decarbonisation ?
  quicklime

raw material acquisition, preparation
burning in the lime kiln in the range of 800-
1000-1200 -900 /C
quicklime treatment
slaked lime
different granulations
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Lime industry
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• Burning of the limestone in the lime kiln gt to
  use the best combination - the choice of the
  fuel, type of the kiln, position of the burners,
  affects on fuel consumption and emissions, as
  well as on the quality of the product
• gas, liquid fuel, solid fuel, waste fuels
• shaft kilns, rotary kilns, other kilns
• internal burners, external burners, special
  burners for waste fuel, centralized burners etc

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Lime industry
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• Burning of the limestone in the lime kiln gt the
  right granulation of the limestone in the kiln
  makes space between particles and this aids
• better air circulation gt reduction of excess air
  gt saving the fuel gt less air emissions
• better heat exchange between gases and particles
  gt saving the fuel gt less air emissions
• better burning gt saving the fuel gt less air
  emissions
• better thermal oxidation of CO gt less CO
  emissions is produced gt more energy is released

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Lime industry
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• Burning of the limestone in the lime kiln gt the
  previous cleaning of the limestone
• better conditions to make free space in the kiln
  between particles
• less impurities have positive impact on the
  composition of the air emissions
• easier regulation of the excess air, so not too
  much heat escapes with it through the chimney

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Lime industry
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• Burning of the limestone in the lime kiln

fuel, air
preheated air
emissions to air
preheating zone
calcining zone
cooling zone
900C - 1200C
800 C
900C gt 100C
the direction of the limestone flow
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Lime industry
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• Other possible measures to reduce the consumption
  of the fuel and energy in the lime industry and
  consequently also the air emissions
• monitoring of the used fuel
• monitoring of the concentration of oxygen, carbon
  monoxide and carbon dioxide, which can show the
  efficiency of the burning
• monitoring for controlling of good combustion of
  the fuel
• regulation of burners
• good isolation of lime kiln and installations
  with hot air
• the process has to run continuously to prevent
  heat oscillations
• working start and stop of the lime kiln has to be
  made progressive

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Lime industry
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• Other possible measures to reduce the consumption
  of the fuel and energy in the lime industry and
  consequently also the air emissions
• saving the electric energy (high efficiency
  motors, variable speed drivers, minimising of the
  reactive energy losses that cos f between the
  voltage and the current peaks lies permanently
  between 0,95 0,99, minimising of compressed air
  demand etc.) gt minimising of the emissions on
  the global level
• use of waste hot air coming from preheating zone
  of lime kiln for the drying

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Lime industry
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• Use of waste hot air from preheating zone of lime
  kiln for the drying

emissions to air
cleaning-2
fuel, air
preheated air
DRYING, cleaning-1
production of the sand
preheating zone
calcining zone
cooling zone
900C - 1200C
800 C
900C gt 100C
the direction of the limestone flow
washed / wet sand
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3 - Cement industry

• Basic steps

calcination
clinkering process
raw material acquisition, preparation
cooling of clinker
grinding of clinker, gypsum and additives
cement
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Cement industry burning
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1. step
CaCO3 ? CO2 CaO
limestone ? calcination
quicklime
800 - 900C
2. step
CaO (Silica, Al2O3, Fe2O3) ?
Ca-aluminates,
Ca-ferrites,
Ca-silicates clinkering process
clinker
1400C - 1500C
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Cement industry fuels for the burning
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• Fuels used in rotary kiln for the clinker
  burning
• solid fuels e.g. coal, petcoke
• liquid fuels e.g. fuel oil
• gaseous fuels e.g. natural gas
• wastes e.g. used tyres, waste oils, plastics
  etc. / the high temperatures and long residence
  times in the kiln system implies considerable
  potential for the destruction of organic
  substances

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Cement industry fuels for the burning
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• the cost for the fuel
• using of natural fuel resources
• problems to achieve the reducing of CO2

fossil fuel

• the profit for the waste removal
• saving the natural fuel resources
• less CO2 produced

wastes
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Cement industry wastes as a fuel for the burning
process

• Additional advantages for using waste as a fuel
  comparison with the waste incineration
• - in the rotary kiln are better conditions
  as in the waste incineration / gas retention
  times of about 8 seconds at temperatures above
  1200C in the rotary kiln
• (waste incineration minimum 2 seconds at
  temperatures gt 850C or minimum 2 seconds at
  temperatures 1100C for halogens)
• maximum temperatures achieved in the rotary kiln
  2000 C
• oxidising gas atmosphere in the rotary kiln
• uniform burnout conditions in the rotary kiln

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Cement industry wastes as a fuel for the burning
process

• Aditional advantages for using waste as a fuel
  comparison with the waste incineration
• destruction of organic substances due to the high
  temperatures at sufficiently long retention time
• sorption of gaseous components (e.g. HF, HCl,
  SO2) on alkaline reactants
• short retention time of exhaust gases in the
  temperature range in which PCDD/F can arise
• chemical-minerological incorporation of the heavy
  metals into the clinker
• complete utilisation of the ashe as a clinker
  component

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Cement industry wastes as a fuel for the burning
process

• Final conclusions about using waste as a fuel in
  the burning process in cement industry
• saving the natural fuel resources (less fuel
  used)
• less CO2 emissions
• controlled removal of the waste
• better environmental conditions for waste removal
  as in the waste incineration (less problematic
  air emissions) of course cleaning device for air
  emissions has to be used as in waste incineration
• complete utilisation of the ash of the burned
  waste, as a clinker component

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Thanks for your attention!