How to accelerate the creation of value, through the ......About Alterros Alternative Resource Recovery Solutions AFR - planning to implementation (strategy, waste market, financial

How to accelerate the How to accelerate the

creation of value,

through the recovery of

alternative resources

September 2010

Frederick De Raedt

Topics

�

� About Alterros

� Waste to co-processing

� Create

Microsoft Office

PowerPoint Slide Show

� Create

� Optimize and Grow

� Conclusion

© 2010 Alterros, LLC 2

About Alterros

� Alternative Resource Recovery Solutions

� AFR - planning to implementation (strategy, waste market, financial planning, pyro process, QA/QC, equipment selection ...)

� Service company: advisors and project managers; 80 yrs of field experience in cement managers; 80 yrs of field experience in cement and heavy industry

� Energy intensive industry (cement, lime, power, pulp & paper)

� Strategic partners: Cinar, Euremi and Equipment Pro


Alterros is the difference


From here …


From here …


…To Here

ECONOMYECONOMY


ECOLOGYECOLOGY

BENEFICIAL RE-USE

SOCIETYSOCIETY

Step #1

PASSION:PASSION: doing the right thing, right away doing the right thing, right away

and downright and downright right. Rightright. Right? …? …

= Recovery of alternative resources, through

the substitution of primary or fossil fuel and

Source: GTZ Guidelines

COCO--PROCESSINGPROCESSING

the substitution of primary or fossil fuel and

raw material

= Recovery of energy and minerals from waste

= Energy Intensive Industry

= 20% of total cost is fuel cost. Why not?

≠ Burning, (co-)incineration …© 2010 Alterros, LLC 8

Step #1

� AF can have + impact on e.g.:

� Can drop the NOx

� Reduce CO2 footprint

� Improve a local waste problem

COCO--PROCESSINGPROCESSING

� Improve a local waste problem

� As a general GOOD Practice guideline:-

� 50% burner TSR with < 10mms AF

� 50% calciner TSR with < 50mms AF

� 75%-90% is possible!


Only problems…

� constant variability & supply of the waste

� it smells, auto-burns

� angry neighbours

� plugging, explosions in bucket elevators

� tire wires in clinker cooler

� higher capex/opex costs

IsIs the the Cure?Cure?


� reducing conditions

� CO, SO2, NOx spikes

� upset kilns, rings

� inconsistent feed

� tramp metals, inert materials

� equipment doesn’t deliver

as promised

� lower ROI, NPV, payback

� mercury contamination

�…

Step #2 – How to get there M

atu

rity

The quick route

Quick???


Matu

rity

Time - Effort

Quick???

$

How does it happen?

1 or 2 local

sources of waste

buying equipment

process in kiln (where?)


How – The better way

Matu

rity

GG

The sustainable route

$$$


Matu

rity

Time - Effort

CC

OO

$

Create, Optimize and Grow


Create, Optimize and Grow


Create: the process

Basis: Why?

InternallyExecution

Remember:

� Service based business

� Devil is in the details

EE


Waste Market

External

Tactical

details

� Recurring process

� Checkpoints

EE

E

SS

Create: Which waste materials first?

Complexity

Revenue

Liquids� waste/used oils

� liquid paint residues

� petrochem. liquid waste

Solids� MSW/RDF� plastics, rubber� biomass� petcoke� carpet, textile Sludges


Revenue

liquid waste

� paint residues

� chlorinated solvents

� carpet, textile

� TDF� bone meal

� contaminated soils; Fuller earth� ASR� biohaz. waste

Sludges� tar/TDI� waxes� tank bottoms� drilling muds� animal fat

Gases� landfill gas

Create – Liquids

� 5-10% TSR

� USD 300,000


Create – Solids


� 3-8% TSR

� Or use tower elevator

� USD 250,000

Create – Preparation


� < 50 mm

� USD 500,000

QA/QC

� Never start an AFR program without QA/QC capabilities!!

� Stepped approach possible, waste based:

Step 1

• Basic setup (+ outsource)

• CV, moisture, CL, pH, ash


Step 1

Step 2

• Organics and heavy metals (+ outsource)

• Lab-mill, flashpoint, viscosity, mercury, GC

Step 3

• Trace elements, back-up equipment

• ICP, back-up equipment (min 2 of each)

Optimize and grow: examples

Case 1 - PH/PC increase usage of TDF:

Before:

� 26-30 m/s gas velocity

� 50% calciner firing

� TDF fallout: un-burnt TDF of shelf

After:

� 35 m/s

� 60%

� none (found tire wire stage 5-no issue)


TDF of shelf

� res. time (TDF): 0.85 s

20% TSR1.5-2 tph

stage 5-no issue)

� res. time (TDF): 2 s

55% TSR7-8 tph

Result:

+ 400%

$150K; 6 mos; ROI: 3 mos


Existing Injection Location

Higher Injection Location


Location Location

What:

� measuring campaign (plant assistance)

� modeled residence times

� TDF trajectory with MI-CFD

� installed refractory dam (created accelerator)

� injection point +4 m


***Drawings not scale

Conceptual Drawings of Additional Tertiary Duct/Calciner Restriction

We would like to model the effects of restricting the

tertiary outlets to the calciner as well an additional calciner

restriction.

We hope through these restrictions we gain more turbulence

and achieve higher substitution rates of TDF with less fall

through.

Please model the effects from the addition of1

1


Current Restriction in Riser Duct

Current Restriction in Riser Duct

Please model the effects from the addition of

1 and 2. Please refer to the following worksheets

for required information.2

1


Case 2 - LK increase usage of whole tires:Before:

� 2-3 car size tires/rev.

� 0.5 truck tire/rev

� insert life of 6-7 mos

-> 1,260 C; 37%, L/D 28.75 (norm. 32)

After:

� 6 car size tires/rev

� 1 truck tire/rev

� 9-10 months

� none

� none


32)

� truck tire wires in cooler

� feed issued w/ green tires

12% TSR2.5 ti/rev

30% TSR6 ti/rev

Result:

+ 200%

$650K; 9 mos; ROI: 11 mos

� none


What:

� new design of injection chutes

� optimized handling process (no new belts)

� optimized fuel loop (Linkman): moved temp. profile

� replaced tire singulator

� installed refractory dam; new design insert


� installed refractory dam; new design insert


Case 3 - TDF Shredding optimization:




Conclusions

To be successful, the following ground rules apply:

1. Doing the right thing, right away and downright right

2. Service business attitude


2. Service business attitude

3. Commitment to all 3 legs of sustainability

4. Start with or go back to the basics; 50%+ TSR is not hard

5. Talk to professionals

6. Have fun. Is a worthy cause

Les agradecemos su atencion, y esperamos poder ayudarlos a


y esperamos poder ayudarlos a crear, optimizar, o crecer su

programa de recursos alternativos

“We strive for our customers to view us

as a professional, out-of-the-box

thinking, focused and long-term partner


thinking, focused and long-term partner

with a quality-driven service attitude.”

Como acelerar la Como acelerar la

generación de valor a

través de la recuperación

de recursos

AlternativosSeptember 2010

Frederick De Raedt

Alterros LLC2232 S. Main Street #347

Ann Arbor, Michigan 48103U.S.A.

Phone: +1 (734) 395.7878www.alterros.com

How to accelerate the creation of value, through the ......About Alterros Alternative Resource Recovery Solutions AFR - planning to implementation (strategy, waste market, financial

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