Practical Aspect of Alternative Fuels Usage

Mark MutterCement Performance International

Practical Aspect of Alternative Fuels Usage

Aims of PresentationThe alternative views of alternative fuelsSuccess with alternative fuels – technical vs. human factorsAlternative fuels trialsOperating with multiple alternative fuelsThe public perspectiveSummary

The alternative views of alternative fuels

• The Corporate View• The Operational View• The Quality View• The Regulators View• The Public View

Success with Alternative Fuels

• What are the key factors in using alternative fuels?– Technical and Quality Aspects?– Public Relations Programme?– Regulatory aspects?– Supply and specification issues?– Financial Issues?

The key to Alternative Fuels Success

Solving the human aspects is at least as important as solving the technical aspectsEx: Relationships with the regulator

Relationships with the suppliersBuy-in from employeesBuy-in from engineering, quarry etc

Alternative Fuels Trials

• Relationship and communication with the regulator– Length of trial and optimisation period– Agreeing baseline periods– Procedures– Maintaining flexibility– Agreeing “special” trials– Interpretation of the results– The “what if” scenarios

Alternative Fuels Trials

• Relationships with fuels (and materials) suppliers – Does the supplier understand the cement manufacturing process?– What quality control procedures are in place?– Will the material suit the trial equipment?– Who is responsible for the trial equipment?– Is there sufficient supply of material for the trial?– What about other materials suppliers – coal, coke, bauxite etc.?

Alternative Fuels Trials

• Employees and in-house relationships – Employees could and should be the best form of PR– Quarry must be informed of the importance of consistent feed– Engineering need to understand the materials handling characteristics– Kiln burners need to understand the objectives of the trial

Alternative Fuels Trials

•Timing of trials – Good forecast of clinker stock to last through the trial– Anticipate drop in output/some off spec– How long to optimise the process?– All resources available – engineering and equipment– What are the other environmentally “sensitive” parts of the plant – what actions can be taken to reduce the impact?

Operating with multiple alternative fuels• The plants with negative or neutral fuels costs tend to be those operating with a number of alternative fuels• Fuels tend to start off at negative cost and then tend towards zero as other uses are found for them• Therefore need a long term programme to replace those with low revenue with newer, high revenue streams• Quantities do not have to be large as long as they have a CV and are contributing to revenue

Operating with multiple alternative fuels

• Upside

– reduced operating costs– carbon neutral fuels– reduction in landfill/incineration– gives flexibility– increases the learning within the organisation and the willingness to take on new fuels

Operating with multiple alternative fuels

• Downside– Management of the fuels requires resource– Impact upon laboratory testing and storage of samples– Impact upon emissions when one fuel is not available– Inter-works competition for fuels– Variable overall “fuel mix” quality– Loss of output/increased fuel consumption

Operating with multiple alternative fuels – an example

Resource required to ensure supply

Proven technology but fats in summer

Negative but decreasingCompetition

Variable phosphateGood NOx reduction

Animal meal

Good delivery schedule in place

Unsuitable feeding system from supplier

Very negativeCO creation good for NOxNot good for build-up

Tyres/car frag

In house supplierDependent upon chemical industry

Management of tank farm –safety and environment

Negative but stable

Good CVStabilized flameMultiple points of injection

RLF

ManagementHandlingCostProcessFuel

Operating with multiple alternative fuels – an example

Simple – take what available

Same as RLFSlightly negative

Good NOx reductionHigher fuel consumption

Waste water

Availability dependent upon refinery

Simple – as per petcoke

Highly negative but low volume

Caused high NOx

Refinery coke

ManagementHandlingCostProcessFuel

The public perspective

• Use of Alternative Fuels still not understood• Still seen as using cement kilns as incinerators• Other factors get dragged into the discussion• Generally the regulator gets stuck in the middle• Need to be open and honest with the public• Environmental improvements on the back of the fuels – should not be greedy!• Make sure the plant is in order before starting trial!

The public perspective - tools

• Employees and getting the message right• Plant visits and public exhibitions• ISO 14001/EMAS Schemes• Sponsorship of local events• General good communications with the community• Appreciation of history

Summary

• The human relationships are as important (if not more) than thetechnical issues.• Need a long term programme to ensure that there is a steady stream of materials to use• The plant needs to be in order before a trial is started• Ensure that the suppliers are on board• Make sure all of the plant personnel understand the objectives of the trials• Support the regulators and do not put them in a difficult position

Practical Aspect of Alternative Fuels Usage

Mark MutterCement Performance International