Alternative fuel resource utilisation and optimisation/reduction in specific heat: Vijay Arumugam, thyssenkrupp Polysius

Good day to all of you. I'm Vij from Tsen Pius. We as Tsen Pius, we started more than a decade ago how to make the cement plan, which is gray to green. So this is a decade effort which comes with multitude of millions of investments in research and development. So what we did, we started off with five solutions. Each of its with its uniqueness, how to make the Simon industry to make from move from gray to green. I'm not going to touch on all the five today. US valuable clients from the associations from across Asia Pacific. I would like to touch on a single point, which is our polishes field substitution.

Even this I would like to split into a few format in the last one and a half days, all the speakers together with the agencies and seminar associations, everybody's talking that we are at the crossroad. One fuel prices are going up, is really affecting the operational expenses of the client. Second, every one of us, including we as OM supplier, we were forced to look into alternative options. How we can able to reduce the C2 emissions. So I would like to split my presentations into two. As the saying goes, if it stands still we are not moving anywhere. I would like to take two steps out. So I split my presentations into two topics.

One is where you as a valuable client can immediately make a potential savings. So one is we are talking about optimization and reduction in the specific heat Still's not working. So let us look into the pyro sections where most of the fuel energy is consumed. Typically this SM cement plant out of which we look at the most important are the critical part of the cooler, which is a static grade. So every one of us know the static grade has served several functions out of it. Three, I would like to point out the first we need to capture what is critical for the clinical quality, which is Alli and light qualities.

The second one, the most important thing which we targeted out which enhancing the recovery of the kiln take most of the heat back into the system so that you can recuperate the heat. Third, you have to evenly distribute the material across the cooler so that it has the uniform distribution and effective cooling. None of the energy which we put inside the kiln system, it is compromised in any way. So this is one of the r and d product which was comes out from our r and d lab, which we started implementing across this particular, this region where its cost is very sensitive, not only in other parts everywhere.

So this is a static grade which we try to reduce the size and we call this as double incline static grade. There are two different inclination which is a occurs in this particular static grade which helps to reduce the dead layer. So if you look at it, the first slope is 20 degrees. If you keep all the way to 20, the dead layer effect is coming much more higher, which directly affect the amount of recuperations. What you will have, it increases the pressure of the fence. So what we try to do, this is actually fabricated out of Vietnam and supplied to one of our clients in this country.

This particular aeration elements Is new, which gives very less resistance and also it has got the labyrinth seal. So the clink spillage is completely avoided. You don't need to have any conveyor which take the rid links out, but it's also helps to reduce the specific or the pressure drop. So when the pressure drop goes down, you end up having a smaller fans, which also reduces the electricity consumptions and this particular wear elements, which is a wear part. But we did provide almost five years of guarantee for this particular product. So this is original and after installations you can look at it here, this is the original piece and this is after three years of operations.

So it looks pretty new originally the static grade is looks in this position. Certainly we extend to a certain position where we can safely mount the static grid so the static grid can able to place exactly where it is supposed to be. And this is one of the installations erections, which is done. And this installations can be completed within your normal SH scheduled maintenance times. Okay? Some of the installations we completed in 10 days, some of the installations is goes into 14 days. Okay, so so far we have already signed eight contract four is already up and running. What are all the benefit we can bring to the customer?

You stated here the most important parameters is the clinker temperature before and after. You can look at the specific heat consumptions, how much it is reduced before and after. You can look at the secondary and the tertiary at temperatures. Okay, so this is an immediate benefit which client can able to reap. That's we call as a low lying fruit for the customer to reap. And very interestingly enough, most of the clients, all the four they have told us that I have to really thank the client is a very sensitive information switch it ask us to share, there's roughly about two to 3% capacity increase as well. We need a small simulations, which one of my para colleague is having it with him.

Any of the clients is interested. We can able to simulate instantly to see if your operating parameters. So what we considered here, one side is the earnings, the other side is the fuel cost savings. This is taken out of the references what we have and the other side is return of investment based on the four installations. What we come across, thanks to our cus customer, they share the informations. Your return on investment for this particular product you can see is a test customer. What I put it, I don't want to mention the actual clients. This is still, we are having the NDA that the investment cost is roughly about half a million euro.

And you can look at the ROI is less than one year to be precise is 11 months. Okay? Now let us take the next step. The next step is the alternative fuel. What we are talking about. Okay, so most of the time the primary things is that we need to reduce our carbon footprint. Coal prices are increasing. We need to prepare ourselves to do so. This rolled agendas, which I would like to quickly bring you through In the past, most of the time clients will go with very low investments. Whatever the fuel which is available, they will try to go with the minimal amount of thermal substitution rate.

But most of the time client unable to go further is because the limitations end of the day us valuable client, you need to rely on the quality of clink of what you produce and that cement is sellable. Okay? That cannot be compromised at all costs. Now the presence, what happened and the future, okay? So what we are trying to say is that most modernized plants are people across Europe. Some part of Asia people look for maximum amount of substitution rates. They want to use whatever the fuel which is available right now that is not the target. Whatever the fuel which may be available in the future, they also have to prepare themself.

So it's more or less a future proof what the customer is demanding from us. Okay? And whenever you started to use alternative fuel, the lowest emissions have to be guaranteed without jeopardizing the operation and the process stability. So what are the typical fuels? We are looking at every one of our clients in this room and across the regions in the world. They know there's a multitude of fuels which is available, which we can use it comfortably. But weather, all this fuels comes with certain characteristics, certain advantages, certain disadvantages. And the most important thing is availability.

So the availability is as long as the community lives, we produce waste and that is what we are looking at. We are looking at especially the household waste and the commercial and industrial waste, how to use it effectively. Okay? These are all some of the fuels which customer used to prepare themselves. And there are countries where the customer is buying the fuel which is readily prepared for them to use. So there are different qualities which is available out of which we as an om supplier, our main purpose is to look at where people do not want to touch. This is low quality and very low quality fuel.

But whether size we need to prepare to the so fine so that we can put it directly, no, we are looking at material in the size of 300 by 330 m m in three dimensional. And look at the the moisture content. It's also very high because this comes from municipal solid waste. So looking at customer perspective, every piece of equipment, the moment we bring it inside the cement plan, that is an investment cost, which is CapEx spare part need to be maintained and that is a spare part regime and also maintenance regime. Okay? So in a customer, in a customer perspective, this are all the typical value chain we are looking at.

You need to get the fuel from somewhere, you store it somewhere or bring it to your factory. You need to store it and feed. Finally you bring it to where you can burn comfortably. So this is a typical alternative fuel preparation chain. Most of the people are very familiar with it. There is multitude of preparation. I'm not saying that preparation is not required. Preparation is mandatory because end of the day we need to maintain the process stability and availability of the plant. Okay? So these are all the typical chains. What we are trying to say is that Bulk of this equipment is not necessary. Okay?

Every piece of equipment you bring in, you end up doing investments, maintenance, the rest. So what we are trying to say is that try to have a minimal amount of preparation and maximize the utilization of waste, which you are going to get it or which you're going to buy it. Okay? So here is just a single stage of shredding and one stage of seeding in order to remove metallic components and the biodegradable items. Okay? So this is a fuel which is as fired in one of our Cal calcis. You can see the quality of what they, what is the kind of quality we are having. But this fuel is comes out of one stage of shredding and one stage of saving. That's it. Nothing more than that.

Now let us look at one of our product which I would like to pitch. Now there is a small video which we would like to bring. We would like to set a standard what can be burned in a cement plant, 160 years of expertise which comes. Now what we are trying to say is that having three to five seconds of residence times is something which all cement operators would love to have to have more than five seconds to go up to seven or eight. We need to extend the cals sign. Here we are talking about a residence time of 1000 seconds. Okay? It's a small piece of equipment. One small step for a man, a giant leap for a mankind. One small step in the cals is a giant leap for combustion. Okay?

So to put it that way, what Neil Armstrong has mentioned, okay, it's a small piece of combustor which can be easily fitted into the cals. We will try to bring in the combustion air from the cooler and we will try to take the alternative fuel through double pendulum flaps because every amount of F air which goes into the system is compromised on the heat consumptions of the kiln, which we have to, we as an om supplier or a designer, we have to completely aware and minimize the amount of Fal air intake. And this entire field, which is comes inside the static grade, is equipped with our patented technology, which is called air blast conveying system.

This air push the fuel from one step to other because that is the basis of pyrolysis. The moment the moist material goes inside, the moisture is taken out. The moment the moisture is taken out from the fuel, the fuel is getting lighter. The lighter fuel is agitated from steps to step. Make sure that every context surface is available on the fuel surface is completely exposed to the heat and end of the day the the whatever the amount of heat energy which is resides in the fuel is completely taken into the calci strip or into the process. What is remains on the refractory is completely after pyrolysis, which is the cha. The cha is the ones which remains okay.

And you can see that some of the refractory installations, what we have seen in, in, in our installations after several years of operations, we can still see the refractory is not heavily contaminated or damaged. Okay? And the most important thing is that here, whenever we started to burn at that particular point of inter junction, we have to have a very proper control of the combustion because the combustion and the energy efficiency is what dictates the amount of calcination which is required. And we have to bring in the heated raw material as a temperature controller. This acts in both ways.

It's not only acts as a temperature control, it is also helps to avoid any untoward incidences, even in terms of a power breakout. And the rest of the things, the fuel can be completely extinguished without jeopardizing the safety of the equipment and the installations. Okay, so what is the beautiful salient points are the advantages of this particular system. The moment the equipment started to rotate, we have thermal and mechanical stress and this particular piece of equipment, there is no moving parts at all inside the hot zone. Okay? Complete combustion of the ultra Costas particle to maximize the thermal substitution rate is guaranteed separation effects on the grid.

Because of the air blasts conveying system, we try to agitate the fuel as much as possible. An extra air which is going inside is more or less acting as a a multi-stage combustion, which helps Is drying an incineration temperature control using hot main. The most important point which I love to mention is steady and easy process control. The most important part is that whenever customers stop for installations, you you can able to do the entire installations while during the plant is up and running. Okay? This is one of the plant, this is the type of fuel which the customer used before they have to finally shred it in such a way.

It's a very fine fluff material which is goes into the cals sign and this is what the quality of fuel, what they are firing right now because of this beautiful piece of missionary which is in the Calci. Now look at some of the thermal substitution rates. Whenever we talk about material, which is feed directly into the calci, there are always limitations which occurs. But we as an om plant designer, we would like to give our valuable client the ultimate flexibility. What you will ask for, one is a particle size and the second is a gas retention time. You look at one of the CFD simulations, what we did, how far the client can able to go on direct feeding. Obviously there are limitations.

Even the fine fluff material. If you started to feed directly, you can see the material started to come down into the K limb, which causes an absolute processed chaos. Okay? Now look at is more or less this slide is quite repetitive. Why I would like to mention in this that based on the fuel quality, what you are getting it fine fluff material, the cost is also eventually goes up here. The cost base is very high for the customer. But if you look at especially the quality which you can able to fire inside my piece of equipment, you literally either somebody pay for you or you'll get it for a minimal amount of money. Now look at the references.

What are all the references which is made available to us today? We are quite blessed to have such a reliable technology. As of now we have 20 in installations. Hopefully today or tomorrow we will sign another two. We are waiting for the adobe mark to be signed and these all the installations which is up and running, okay? We will try to put all the heat, which is the capacity of the, of the installations across. You can see most of it is comes with very high high moisture content of material. This is not only dedicated to a certain quality but is multitude of material which can be brought inside.

That means this particular system is future proof is not only intended for today but it is for tomorrow as well. Whatever the fuel which is available today, as we all know, 10, 15 years ago, Petco is a reliable options as an alternative fuel. Now Petco price, there are companies across, across the, the region within the region I would like to mention Petronas, they will try to auction the pet cook, huh? So the price is also increasing. Tire is available, but tire is steadily available throughout every region. I doubt. Okay? As such, this installations is dictates that how flexible the system can be.

So these are all the references if you put it into categorically to show you that across the globe we do have our references, which is up and running. So this is one of the reference which I would like to highlight to you. The customer is really struggling to even reach close to 20% of tsr, but the client is having an SLC cals and they would like to bring in the shredded tire chip. They are unable to go more than 20% because the process getting in stable. They are unable to do anything. So the customer come back to us and they, and they asking how to make sure that this is done. And then the most important thing is that here it has to be fed.

It has to be fed in the, in a proper way that they would like to reach maximum substitution rate in the right duct. We bring in one of our smallest step combustor, which we ever designed. We bring it inside. Within two weeks of time, the customer can be able to reach 100% thermal substitution rate in the rice duct. And the taking over certificate was signed immediately after commission. So the customer has nicknamed it in such a way that they call this as preto the nickname which was given to this beautiful machine by the client. The second success story, there are many out of 20. I don't want to, I've only picked up a few to, just to demonstrate.

This is one of the world's largest waste core processing facility as of now. The client is handling close to 4,100 tons per day of municipal solid waste and the customer is using in all four of their kilts. So I have the privilege to ask the acceptance from the client to mention what all the capacities they have. There are two lines, 7,500 tons per day. I L C 1,800 tons per day. The last line is one 10,000 tons per day clinical line. Okay? This particular project complete E P C is supplied by Lucius, right from the material conveying all the way until to firing. Okay? And the most important thing is that this is, there are three lines. Number one, two, and three, four is on the other side.

So we are talking about installations. How to minimize the amount of installation which is needed. Okay? So what we come up with, can you able to see here, this is an adapter piece. This adapter piece is designed at the exact location and this adapter piece can be installed in a cals signer. The moment the adapter piece is fixed into position, the rest of all other installations you can carry on while the plant is up and running without jeopardizing the safety for the equipment and the people walking around it. Once every insulation is done, you do the dry test.

Once the dry test is finished already, all you have to do is then just remove the adapter piece so that the fuel can be directly fed into the Sina. Okay? So just to show you a glimpse of what kind of difficulty the client had and how successfully we overcome it. You can see even the plastic cover is not open. This photo is taken by me. Okay? So even the plastic cover is not, this is real, real thrash this, it's a real thrash, okay? You can see that the more than 50% of moisture content, which is a very low quality municipal solid waste, okay?

And the most important point which I would like to emphasize again, is more than my pleasure to do so kill operation remains stable, unchanged clinker capacities and their emission levels, Right? Let us look at some of the case studies. So we are in Vietnam, Vietnam seminar Association in vab M did present it. So we took this opportunity as our office is located in this region. So we want to be more specific when it comes to specific, this is one of the landfill which is called sen. So SEN received close to 5,000 tons of waste from Hanoi and we did a study, this is the dump side. Out of this 5,000 tons of waste per day, let us remove 55 to 60% of whatever the fuel which is cannot able to use.

Okay? Out of which 1,800 tons per day of R D F, which is high calorific fraction, it can be brought into the cement plants if needed. So what we do, we quickly come up with a business case because end of the day we are talking about dollars and cents. No money, no honey. Okay? So put it that way. We come up with an assumptions. We took a capacity of 4,000 tons per day. As of now the coal price is stood around anything in the range of about 150 US dollar per ton. It varies except Indonesia is slightly different. RD F price. If you want to prepare the RD F price, if you want to directly feed inside the calina, it'll be anything in the range of about 65 to 80 US dollar per ton.

Bear us, if you want to buy a quality, which you want to put it into our equipment, all you need is 20 US dollar per ton, which is something like a tipping fee. Hmm? Or this money somebody pays you as a owner. T S R rate, we are aiming 85%. If you want to look at my piece of equipment, which I'll took a rough calculations based on the geopolitical situation right now I consider the price everything out of German or European origin. But as our presence is here, we also can able to bring down the cost drastically. Cause most of the fabrication we can able to do out of Vietnam are from the region. So for the investments here, we are talking about 8 million years dollar.

With this scenario then we simulate the business case you as a valuable client, if you put in your money of 8 million US dollar, your rate of internal rate of written or investments written is less than three years. The rest of the period you will end up making money. That is the base point. So out of which I I I need to dwell a bit more onto it. These are all the assumptions for your case. If any of the clients is more interested, we can able to sit down together with you and then we can go through the entire business case calculations. One 50 years dollar per ton eight US dollar transportation of RD F 20 US dollar per ton here, the RD F and waste usage.

500 tons of RDF per day, which you can able to have 165,000 RDF per year. What you have to pay, then you can look at the savings on the coal 240 tons of coal is what you save every day on a daily basis. Okay? So now come back to SEN side. If our beloved government and authorities in Vietnam, if they would like to step on into SEN to do something in instead of incinerating it, cuz incineration the moment everything goes into the atmosphere then we come back. How we are going to handle this. So when we look at this from the SEN waste facility within 10 kilometer radius, 100 kilometer radius from Nussen side, there are 17 cement plants.

If you look at 100 to 150 kilometer distance, there are 10 cement plants put together. They're all together 27 cement plants, which is ready to accept the waste. If the authorities and the Vietnam regulations can enable our valuable client to utilize it effectively, it is also helps on the client side. It's also on the environment side. We can able to accelerate the CO2 reduction in a greater way. Summary. So let me summarize for today, Due to the high fuel cost, there is a global trend. We need to save the money. Our client would like to make the money. That is our intention, huh? So that is the prime motive for us to do something.

The traditional way of direct feeding to Cal Center is limited and it comes with disadvantages. We do not want to leave our customer with the limited options. We would like to give you as much flexibility as possible to fire whatever is available in the market. You feel free to choose. You are not su succumb to supply chain. You are completely free to use it, okay? Traditional industrial organic waste is limited everywhere. Look at some of the countries as of now, they are using a very high fluff material, but their primary dry factor is that such a material is available on a longer period. Certainly no. So they're looking at how we we can able to improve further.

That's why my humble suggestion to the floor. Please prepare yourself for the future proof and the future proof investments and the equipment and the technology is here with us. Okay? The proposed step combustor maximum fuel substitution rate is guaranteed optimum combustion com conditions. We give you the lowest possible emissions which you can able to achieve reduction in carbon footprint. No need to say that. That's why we are all here for kiln operations remains stable. This is one of the points which I love to hear from my clients. Can be installed during operation connected during your regulat shutdown. Okay? Has a short written of investment time as a valuable client.

As we all know, the one lead constant in this world is a change with 160, more than one 60 years of expertise. The engineering, what we made together with you all is ready for tomorrow. So with this note ready for any question and answers on the floor. Thomas, Thank you very much aj. Thank you.