March 2017 / Carl-Henrik Persson

Yara Environmental Technologies AB

carl-henrik.persson@yara.com

Emission Challenges in Cement Making

due to alternative Fuels

Presentation Contents

Yara’s start in environmental solutions

Yara at a glance

Different emissions from AFR

SNCR deNOx process and technology

CAPEX and OPEX for NOx reduction

The start 1997

in Cement:

NOx case in

Sweden

3

Reference Case: Sweden

Low NOx cement installation

In operation since 1997

Base NOx 1 200 mg/Nm3 at 8 % O2

To achieve this the system is designed with 12 injectors and 2

process units. The residence time in cement plants are short and a

large number of injectors are required

The plant has been running below 200 mg/Nm3 since start up and

no other cement plant in the world runs continuously at this level of

reduction, > 80 %

4

YARA’s Cement Customers and experience

5

Cement, 100 SNCR references

SNCR References in Europe,

USA, Australia and China

More than 200 inerting cement

references all over the world

Revenues and other income (2015)

EUR 12billion

Number of employees

> 12,900

Operations in more than

51 countries

Sales to about

150 countries

23.6 million tons Crop nutrients

4.9 million tons Industrial products

1.7 million tons Environmental solutions

YARA’s Key numbers

Crop nutrition products, solutions and knowledge to

20 millionfarmers

Helped our customers to reduce

1.4 milliontons of NOx per year(= total annual emissions in France)

Number of people we help feed with our crop nutrition solutions

240 million

Yara has a solid global presence

Yara plants

Joint venture

Sales offices

Development programs

R&D Units

Yara’s NOxCare® Product Portfolio

8

DeNOx Technologies

SNCR and HYBRID

- Boilers / Cogeneration

- Industrial applications

- Cement Industry

SCR

- Boilers / Cogeneration

- Industrial applications

- Diesel engines

- Marine

Reagent Handling and

Storage

Urea to Ammonia

DeNOx Reducing Agents

NOxCare® products:

- Anhydrous ammonia

- Aqueous ammonia

- Solid urea

- Urea solution

DeNOx Services

Technology services

Testing & Optimization

Upgrade & Modification

Spare parts & Maintenance

Catalyst Management

Operation & Maintenance

Training

Safety Services

Training Online & Customized

Inspection, Audit & Advisory

Negative effects of pollution on the environment and human

health must be prevented or kept at a minimum.

Air emissions from cement kilns burning alternative fuels cannot

be higher than those of cement kilns burning traditional fuels.

International and national regulations.

Additional emissions and negative impacts on

human health and the environment from AFR

must be avoided

27/03/2017 Page 9

Lots of different alternative fuels

27/03/2017 Page 10

Liquid fuels

Tar, chemical wastes, distillation residues, waste solvents,

used oils, wax suspensions, petrochemical waste, asphalt

slurry, paint waste, oil sludge

Solid fuels

Paper waste, rubber residues, pulp sludge, sewage sludge,

used tyres, battery cases, plastics residues, wood waste,

domestic refuse, rice husks, refuse derived fuel, nut shells,

oil-bearing soils, diapers, meat and bone meal, etc.

Adapted from Albino et al.

Greenhouse gases

27/03/2017 Page 11

Fuel type Net CO2 emission factor

(kg CO2/GJ)

Petcoke 101

Coal 96

Natural gas 54

Tyres 85

Waste oil 74

Plastic 75

MSW 9

Animal meal 0

Waste wood 0

The concentration of sulphur in substitute fuels (0.1–0.2%)

is generally much lower than the reference value in

conventional fossil fuels (3–5%).

In addition, the alkaline matrix of the clinker traps much of

the sulphur, thus keeping sulphur emissions below critical

levels.

There is still the possibility that sulphur may react with

different metals in raw meal, so metal and sulphur content

in fuels must be monitored closely.

Sulphur dioxide

27/03/2017 Page 12

Lawrence Berkeley Laboratory study

In general, the formation of NOx is related to the amount of

nitrogen in the fuel, the temperatures in the kiln, the

residence times and the types of burners.

Overall, alternative fuels do not lead to higher NOx

emissions.

Alternative fuels in the calciner has a longer combustion

time resulting in higher CO and thus less NOx.

Nitrogen oxides - NOx

27/03/2017 Page 13

Lawrence Berkeley Laboratory study

Chlorine-related concerns are the same whether

alternative or conventional fossil fuels are being used.

These concerns include both direct and indirect impacts

on cement kiln emissions and performance.

Chlorine in feed materials can lead to the formation of

acid gases, and there is a risk of increased corrosion if

these gases build up on the kiln surface. Provided that

chlorine content stays below 0.5%, these risks are

minimal.

If the chlorine content of the fuel rises above that level, it

may be necessary to operate a bypass on the flue gas to

limit the chloride concentration in clinker.

Chlorine

27/03/2017 Page 14

Lawrence Berkeley Laboratory study

Heavy metal concerns are essentially the same for both

alternative fuels and traditional fossil fuels.

Non-volatile heavy metals are effectively incorporated in

the clinker.

Semi-volatile metals are captured in the clinker stream or

dust.

Highly volatile metals such as mercury and cadmium are

an exception: the best approach is to limit their

concentration in raw materials and fuels.

Heavy metals

27/03/2017 Page 15

Lawrence Berkeley Laboratory study

The formation of dioxins and furans is a recognized concern for cement

manufacturing regardless of the fuel used.

The high temperatures and long residence time typical of cement kilns can

repress formation of these compounds, as they form more readily at lower

temperatures.

Limiting the concentration of organics in raw materials and quickly cooling

the exhaust gases in the kilns also reduces formation.

Numerous studies comparing dioxin formation rates between alternative

fuels and traditional fuels in cement manufacturing have found no

significant difference in emissions.

Dioxins and furans

27/03/2017 Page 16

Lawrence Berkeley Laboratory study

For other emissions, the European Commission have summarized assumed

impacts of waste co-processing as follows:

Dust emissions and carbon monoxide are largely unaffected by co-

processing wastes.

The alkaline kiln environment removes hydrogen chloride and hydrogen

fluoride produced during firing.

There is no correlation between the use of alternative fuels and total

organic compound emissions levels.

Other emissions

27/03/2017 Page 17

Lawrence Berkeley Laboratory study

Example of profile from a cement kiln

using waste-derived fuels

27/03/2017 Page 18

Lawrence Berkeley Laboratory study

SNCR process

NH3 + NOx N2 + H2O

850º C

1000º C

19

SNCR system

PU reagent injectionStorage

Tank

PMR PMW

CMM

PMR = Pump module for reagent

PMW = Pump module for water

Unloading

pump

Combustion

chamber /

Boiler

Process control

Reagent mixing

& distribution

Injector – Optimum location and design

Impact on operational costs

21

Injector designed for atomizing and cooling with compressed air and equipped with quick release coupling for easy inspection.

Find optimum location between

kiln inlet and last cyclone

After secondary combustion

Modular design vs built on site

- Well proven standard modules

- shorter lead time

Tank module

Injector

Pump Module Reduction

agent PMR

Pump Module Reduction

agent PMW

Control and Management

Module; CMM

Process Unit, PU

22

Fast installation and commissioning

27/03/2017 Page 23

Total lead time from order to startup ≈ 4-6 months

Reduction agent

Alternative reduction agents for SNCR

Ammonium hydroxide - NH4OH

Urea - NH2CONH2

24

25

Higher performance with Ammonia solution

Up to 90% reduction of NOx emission with ammonia

(Urea 30 – 50% reduction)

High efficiency = low consumption and operational costs

(+35 - 100 Million INR / year higher cost with urea)

Low emission of ammonia slip

Low emission of laughing gas (N2O)

CAPEX and OPEX – SNCR deNOx Example

26

4300 ton clinker per day

Flue gas flow 400 000 Nm3/h dry @ 10% O2

Average base NOx 1100 mg/Nm3 dry @ 10% O2

NOx with reduction 500 mg/Nm3 dry @ 10% O2

25% ammonia solution consumption 415 kg/h (expected)

Price example in Europe 200 EUR/ton

8000 hours per year 662 400 EUR/year

Compressed air consumption 40 m3/h x 0,015 EUR/m3

8000 hours per year 4 800 EUR/year

Soft water for flushing <500 EUR/year

Power for the SNCR 2 kW x 0,10 EUR/kWh

8000 hour per year 1 600 EUR/year

Wear parts 1 200 EUR/year

Maintenance man hours 20 hours per year x 25 EUR/hour

Per year 500 EUR/year

TOTAL operation cost 671 000 EUR/year (58 000 000 INR)

CAPEX 500 000 - 600 000 EUR

Tailored DeNOx Solutions:

solving the problems before

they occur

Best Value DeNOx offer:

Optimizing the customers’

DeNOx costs over time

2 commercial summary messages for NOxCare

Thank you!