Prague 2004

Prague 2004

Plant Data Kilns 2 x 1,300 tpd clinker

Vertical Coal Mill 15 tph

Cement Mills 3 x 100 tph + 1 x 30 tph

Own Quarries for Marl, Limestone and Sand

Reserves of Raw Materials: Approximately 30 Years for marl and limestone

Insulation Material Production Plant

RMC Plant

Number of Employees: 574

Location of “USJE”

• Located in the southeastern part of Skopje

• 3.5 km. from the center of the town

• Surrounded by civilian houses

The location of the factory brings up the:

ENVIRONMENTALENVIRONMENTAL QUESTIONQUESTION

The manufacturing of the cement influences the environment

• Excavation of the raw materials changes the landscape• Transportation of the raw materials as a source of dust• The production of clinker has the biggest impact on

the environment– Big usage of energy– Air emissions ( dust, SO2, NOx, CO…)

• Storage of clinker, grinding of clinker and packing of cement are also dust sources

The environmental impact of the working processes of “USJE” has been

mitigated through the technicaltechnical and technologicaltechnological

interventions

These improvements are accomplishedaccomplished through the years

• 1993 – Two concrete silos for clinker (25000 tones each) with a closed belt

conveyer and a complete dedusting system

• 1993 – Electrostatic precipitator for clinker cooler (each kiln has it)

• 1997 – Gasification of the boiler room for production of steam

• 1999 – Bag filters for cement mills 4, 5 & 6

• 1999 – Bag filter for rotary Kiln No. 3

• 2001 – Vertical mill for petcoke, with bag filter and system for fire protection

• 2003 – Bag filter for rotary Kiln No. 4

• 2004 – Puzzolana substituted by Fly Ash

Continuous Emissions Monitoring

• Installation of a network which connects all measuring instruments– Instruments for dust measurement installed on:

• Coal Mills• Cement Mills• Raw Mill Preparation• Exhaust Gases

– Instruments for measurement of SO2, NOx, and flow installed on:

• Stack

• August 2004 – integration of all “in – situ” signals in the network (company “SICK” has installed the software program

“MEAC 2000”)

• ON – LINE regular reporting on a 30 min basis

Trial use of shredded tyres as an alternative fuel in rotary Kiln No. 4

Phase 1:Phase 1: Getting necessary permissions

Phase 2:Phase 2: ACTION PLAN – Internal preparation of the plant

Phase 3:Phase 3: Experimental testing:

15th – 17th September 2004

Phase 4:Phase 4: Results from the testing

Environmental Legislation

• Current Law in force– Limit values:

• SO2 = 400 mg/Nm3 ( mean 67,9-USJE )

• NOx = 1300 mg/Nm3 (mean 834,6-USJE)

• Dust = 50 mg/Nm3 (mean 15,8-USJE)

• Proposed version that is in Parliamentary procedure adjusted to the EU Law

To comply with BAT

• Raw materials handling and storage– Pre-blending system– Excess clinker storage

• Fuel preparation– Bag filter for the horizontal coal mill

• Process– Process optimisation

– NOx reduction

To comply with BAT

• Process (cont.)– Electricity use optimisation– ESP reconstruction or bag filters for cement

mills– Bag filters for clinker coolers– Noise reduction

• EMS establishing– ISO 14000

Cost/Benefit Analysis for BAT compliance

• Estimated total Investment costs 6.100.000 (consultants estimation)

• Estimated Difference in Operation Costs - 475.000 year (consultants estimation)

(Only SNCR increases operation costs)

Conclusion

1. Applying BAT will have an impact on the competitiveness of the company due to a long pay-back period

2. The impact can be minimised by allowing a reasonable number of years for successive investment