GReening business
through the Enterprise
Europe Network
Linking energy efficiency with environmental
protection in production - good practice
Vanja Strle
Ljubljana, 23th of February 2011
European Commission
Enterprise and Industry
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Energy
efficiency
Use of
energy
Use of
fuels
Environmental
protection
Use of energy
transferable
mediums
Production
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• BETTER ENVIRONMENT
• LOWER COSTS
• BIGGER BENEFITS
Goals
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Goals
Energy
efficiency
Lower costs
- reduced energy use
- reduced use of fuels
- reduced use of energy
transferable mediums
- better working utilisation rate
Environmental
protection
/
Better environment
- lower emissions
- avoiding of penalties
- lower taxes
- lower fees
- better business occasions
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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
• 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
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:
• 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:
waste
energy
entryenergy
taken away
with cooling
taken away with
air emissions
melting
possibilities for waste heat use
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Production of insulation materials - stone wool/ cooling:
cooling of the coat
of hot blast cupola
waste
heat
regulation
room
heating
heat is
used for drive
of absorption
cooling system
cooling of
other users
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Production of insulation materials - stone wool/ air
emissions from melting:
hot waste
air emission
waste
heat
warmed air / O2 blowing
into the hot
blast cupola
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Production of insulation materials - stone wool/ air
emissions from melting:
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:
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:
Cupola furnaces (data from EMEP/CORINAR)
substance
CO
air emission: grams / ton of
melted
mg/ m3
material
10 – 100.000 30 – 300.000
Example for
capacity of 20
tons / day
(0,6 kg – 6.000
kg)/ day
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Production of insulation materials - stone wool/ air
emissions from melting - carbon monoxide:
Coke hot blast cupola:
Reactions
Energy
formation
/units
C (coke) + ½ O2
= CO
~ 1,1
C (coke) + O2 = CO2
~ 3,9
CO + ½ O2
~ 2,8
= CO2
Energy consumed (1,7
units)
C (coke) + CO2 = 2
CO
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Production of insulation materials - stone wool:
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:
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 =>
minimizing the operator’s costs and the emissions on the
global level:
high efficiency motors, variable speed drive,
minimizing of the reactive energy losses that cos φ 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
CaCO3
limestone
raw material –
acquisition,
preparation
slaked
lime

CO2
+
CaO

quicklime
 decarbonisation
burning in the lime kiln
in the range of
800- 1000-1200 -900 /°C
quicklime
treatment
different granulations
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Lime industry
Burning of the limestone in the lime kiln => 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
Burning of the limestone in the lime kiln => the right granulation of
the limestone in the kiln makes space between particles and
this aids:
better air circulation => reduction of excess air => saving the
fuel => less air emissions
better heat exchange between gases and particles => saving
the fuel => less air emissions
better burning => saving the fuel => less air emissions
better thermal oxidation of CO => less CO emissions is
produced => more energy is released
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Lime industry
Burning of the limestone in the lime kiln => 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
Burning of the limestone in the lime kiln:
emissions to air
fuel, air
preheating
zone
calcining
zone
~ 800 °C
900°C 1200°C
preheated air
cooling
zone
900°C =>
100°C
the direction of the limestone flow
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Lime industry
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
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 φ between the voltage and the current peaks lies
permanently between 0,95 – 0,99, minimising of compressed
air demand etc.) => 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
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
preheating
zone
calcining
zone
cooling
zone
~ 800 °C
900°C 900°C =>
1200°C
100°C
the direction of the limestone flow
washed / wet sand
production
of the sand
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3 - Cement industry
Basic steps:
calcination
clinkering process
raw material:
acquisition,
preparation
cement
cooling of clinker
grinding of clinker,
gypsum
and additives
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Cement industry: burning
CaCO3
1. step
limestone
CaO
2. step

CO2
 calcination
~ 800 - 900°C
+ (Silica, Al2O3, Fe2O3) 
+
CaO
+
quicklime
Ca-aluminates,
Ca-ferrites, Ca-silicates
clinkering process:
~1400°C - 1500°C
clinker
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Cement industry: fuels for the burning
Fuels used in rotary kiln for the clinker burning:
a)
solid fuels: e.g. coal, petcoke
b) liquid fuels: e.g. fuel oil
c)
gaseous fuels: e.g. natural gas
d)
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
fossil fuel
wastes
- the cost for the fuel
- using of natural fuel resources
- problems to achieve the reducing of CO2
- the profit for the waste removal
- saving the natural fuel resources
- less CO2 produced
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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 1200°C in the rotary kiln
(waste incineration: minimum 2 seconds at temperatures > 850°C
or minimum 2 seconds at temperatures 1100°C 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!