Ishikawajima-Harima Heavy Industries Co.,Ltd.

13 September 2006

Renewable Energy/Energy Efficiency and the CDM Workshop

held in Jakarta Indonesia

EFB Carbonising and Its Utilisation

in Cement Manufacturing

for GHG Reduction

by Masato Tamura

Siapa IHI ? Who is IHI ?

Didirikan/Established : December, 1853Modal/Capital : 590,218 (Thousands of US dollars)Sales tahunan/Annual sales : 5,530,628 (Thousands of US dollars)Pegawai/Employees : 7,386Pabrik/Works : 13 in JapanPerusahan utama/Major affiliated companies : 99 in JapanKantor, subsidiari /Offices, Subsidiaries & JV : 58 in Overseas

(as of Mar. 2005)

Jet engines Shield tunneling machine Power station

Contoh produk utama/Examples of Major products

1USD = \110

2

Planned PROJECT

- EFB Carbonising and Its Utilisation in Cement Manufacturing for GHG Reduction -

3

Palm Oil Mill ： Oil Production Process

FFB Steaming Fruit Press

EFB

Palm Crude Oil

Core oil

Fibre Shell

Power Boiler

Incinerator

Seed

Waste

4

Cement factory ： Cement producing process

Limestone

Cement Kiln

Plaster

Clay

Silica

COAL

Cooler

Pulveriser Cement

130kg/ton-cement

6,000kcal/kg

Iron material

5

Carbonising plant

External Heating type Kiln

Raw Materials

Dust collector

Carbonising fuel

Heating gasHeating gas Pyrolysis gas

6

Carbonising process

Carbonising furnace

Combustion chamber

Boiler

Gas cooler

Bagfilter

Stack

iron・aluminum separatorDechlorine Dechlorine

EquipmentEquipment

Pelletiser

Carbonised fuel

Iron ・Aluminum

Limestone

Active carbon

Flying ash

Ash pot

Residence time1hr

Heating gas temp. 550℃

Flue gas temp.160℃

Pyrolysis gas temp.

430 ～ 470℃

Cl<0.5%

φ5 ～ 20mmpellet

WasteWaste

Flue gasFlue gas

Carbonised fuelCarbonised fuel

Pyrolysis gasPyrolysis gas

Iron, Iron, AluminumAluminum

Firing temp.

>850℃

Air heater

Gas cooler

waste

Down sizing<□150mm

crusher

(option)

Char Char DischargerDischarger

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Carbonising Process

Stack

ＥＦＢ

Dryer

Carbonised fuel

BagFiltre

Flues

CarboniserＥＦＢ Pyrolysis gas

BoilerCombustion

chambre

Inside of the combustion chambre

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Operating trend data

0

200

400

600

800

1000

1200

0:00 3:00 6:00 9:00 12:00 15:00 18:00 21:00

Time

Tem

pera

ture

,℃

0

40

80

120

160

200

240

Oil

cons

umpt

ion,

l/h

Gas temperature at Combustion chamber outlet

Oil consumption

No external fuel

Possible Operation without external fuelsIt is possible to operate with only waste calorie It is possible to operate with only waste calorie withoutwithout any external fuels. any external fuels.

　 　 •• 　　 DryerDryer 　 　： 　 　： Direct heating by hot flue gas from Combustion chamberDirect heating by hot flue gas from Combustion chamber

　 　 •• 　　 CarboniserCarboniser 　： 　： In-direct heating by hot flue gas from Combustion chamberIn-direct heating by hot flue gas from Combustion chamber

　 　 •• Combustion chamber Combustion chamber 　： 　： High temperature firing of pyrolysis gasHigh temperature firing of pyrolysis gas

Operating without external fuels

Without external fuel

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Property of Carbonised fuel from waste

Fuel properties

Fuel A B C Coal

HHV 20.16 MJ/kg(4,816 kcal/kg)

16.95 MJ/kg(4,050 kcal/kg)

19.17 MJ/kg(4,579 kcal/kg)

27.55 MJ/kg(6,580 kcal/kg)

Water 1.9 wt% 5.7 wt% 2.6 wt% 0.2～ 0.3 wt%

Ash 31.4 wt% 35.1 wt% 33.3 wt% 13.1～ 25.1 wt/%

Volatile matter 23.2 wt% 18.3 wt% 20.6 wt% 29.8～ 33.4 wt%

Fixed carbon 43.5 wt% 40.9 wt% 43.5 wt% 41.3～ 46.8 wt/%

Fuel ratio 1.9 2.2 2.1 1.5～ 2.5

35.1 ％31.4 ％

15.8 ％

33.3 ％

43.5 ％ 43.5 ％54.6 ％

40.9 ％

23.2 ％ 27.0 ％20.6 ％18.3 ％

2.02.21.9

2.1

0％

20％

40％

60％

80％

100％

A炭化物 B炭化物 C炭化物 石炭

含有

率

0.0

1.0

2.0

3.0

4.0

5.0

燃料

比

揮発分固定炭素灰分

水分燃料比

Volatile matter

Fixed carbon

Ash

Water

Fuel ratio

Fu

el r

atio

Coal

Carbonised fuel

A B C

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Combustibility of waste Carbonised fuel

• • Fuel ratioFuel ratio

• • Ignition and burnout propertiesIgnition and burnout properties

• • Combustion speedCombustion speed

炭化物の燃焼時間と燃焼率の関係

0

20

40

60

80

100

120

0.0 0.5 1.0 1.5 [s]燃焼時間

[%]

燃焼

率

D 400℃ 1.1)炭化物 （ ， E 450℃ 1.7炭化物 （ ， ）F 450℃ 2.4炭化物 （ ， ） ( 2.0)石炭 － ，

(Carbonised temp. ， obtained Fuel ratio ）

Similar combustion performance with CoalSimilar combustion performance with Coal

Residence time [s]

Coal

Carbonising temp. [OC]

D

F

E

Fu

el r

atio

Bu

rnou

t [%

]

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Combination of Palm Oil Mill and Cement Industry

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Palm Oil Mill

Compress

Cement Factory

Grinding

Steaming

Carboniser

Palm Oil

Powergeneration

Bio-Fuel

EFB

Shell/Fibre

Cement Kiln

Coal

Transportation

Cement

Plaster

Pulverising

FFB

Palm Oil Mill

Compress

Cement Factory

GrindingGrinding

Steaming

CarboniserCarboniser

Palm OilPalm Oil

Bio-Fuel

Shell/Fibre

Cement KilnCement Kiln

Coal

Transportation

CementCement

PlasterPlaster

Pulverising

FFB

CO2 from Bio-Fuel

CO2 from Coal

Example of Expected Results

CO2 Reduction ：　 32,350 ton-CO2/year　 replacement of Waste EFB 　 68,400 ton/year

8,840 ton-CO2e/year　 reduction of CH4 from land-fill EFB 　 6,840 ton/y

ear

68,400 ton/year EFB will be 13,680 ton/year carbonised fuel.

It can be expected more than 20MJ/kg calorific value.

Case study of one Palm Oil Mill in sumatra

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Expected Future Planning

Farm Waste

Low rank coal

Forest Waste

Food Waste

Carboniser

High Grade

Export to foreign Country

Cement Industry

Power Generation

Steel manufacturingCarbonised Fuel

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