European Commission Enterprise and Industry

1. Linking energy efficiency with environmental protection in production - good practice Vanja Strle Ljubljana, 23th of February 2011 European CommissionEnterprise and Industry

2. GReening business through the Enterprise Europe Network Energy efficiency Environmental protection Use of energy Use of energy transferable mediums Use of fuels Production

3. GReening business through the Enterprise Europe Network Enterprise Europe Network Goals • BETTER ENVIRONMENT • LOWER COSTS • BIGGER BENEFITS

4. Goals Energy efficiency Environmental protection Lower costs / Better environment • lower emissions • avoiding of penalties • lower taxes • lower fees • better business occasions • reduced energy use • reduced use of fuels • reduced use of energy • transferable mediums • - better working utilisation rate

5. DETAILED KNOWLEDGE OF THE ENERGIES FLOWS OPTIMISATION OF THE PRODUCTION PROCESS • reduced energy use • reduced use of fuels • reduced use of energytransferable mediums • better working utilisation rate • environmental benefits

6. EXAMPLES / Energy intensive industries: • Production of insulation materials • Lime industry • Cement industry

7. EXAMPLES / Energy intensive industries Critical points in this industries are industrial ovens: • the consumption of the fuel • the type of the fuel • the type of the burners • increasing the heat transfer • adding the oxygen in the process • measuring and regulation of the combustion process • fore-heating of the burning air and the oven bed material • isolation • recuperation of the waste heat • good maintaining

8. GReening business through the Enterprise Europe Network 1 - Production of insulation materials • isolation: heat, sound, fire • big consumption of energy source and energy • big production of greenhouse gas emission • important reducing of fuel consumption in isolated buildings The ratio - the production of greenhouse emission: production of stone wool : non-isolated buildings, 50 years 1 : 1000

9. GReening business through the Enterprise Europe Network Production of insulating materials - stone wool Production phases: • raw material preparation • melting • fiberisation of the melt • binder application • product mat formation • curing • cooling • product finishing

10. GReening business through the Enterprise Europe Network Production of insulation materials - stone wool/ melting: • oven: the coke hot blast cupola, • alumino-silicate rock, dolomite, technological scrap from stone wool (briquettes – to prevent flow of dust emissions (oven atmosphere, external air), quality of melted material, disturbing of the flow blowing into the oven), • ~1700 °C, • reductive conditions, • warmed air / O2 - blowing into the hot blast cupola

11. GReening business through the Enterprise Europe Network Production of insulation materials - stone wool/ melting - the energy flow: taken away with cooling entry- energy waste energy taken away with air emissions melting possibilities for waste heat use

12. GReening business through the Enterprise Europe Network Production of insulation materials - stone wool/ cooling: cooling of the coat of hot blast cupola waste heat regulation heat is used for drive of absorption cooling system cooling of other users room heating

13. GReening business through the Enterprise Europe Network Production of insulation materials - stone wool/ air emissions from melting: warmed air / O2 - blowing into the hot blast cupola hot waste air emission waste heat

14. GReening business through the Enterprise Europe Network Production of insulation materials - stone wool/ air emissions from melting: Different emission pollutants - need different cleaning approaches: • dust – bag filter, electrostatic precipitator, stone wool filter, • inorganic gas parameters like oxides of sulphur, oxides of nitrogen – are affected by the composition of the raw material and the quality of the coke, wet scrubber, • combustible gas parameters as volatile organic compounds, hydrogen sulphide, carbon monoxide – burned in incinerator (thermal oxidation)

15. GReening business through the Enterprise Europe Network Production of insulation materials - stone wool/ air emissions from melting - carbon monoxide: carbon monoxide – burned in incinerator: it has to be achieved as much as possible complete burning CO + ½ O2 = CO2 + En using of waste heat for near users minimizing of CO less needed fuel for incineration

16. GReening business through the Enterprise Europe Network Production of insulation materials - stone wool/ air emissions from melting - carbon monoxide: Cupola furnaces (data from EMEP/CORINAR)

17. GReening business through the Enterprise Europe Network Production of insulation materials - stone wool/ air emissions from melting - carbon monoxide: Coke hot blast cupola:

18. GReening business through the Enterprise Europe Network Production of insulation materials - stone wool: Other possible measures to reduce the consumption of the fuel andenergy and consequently also the air emissions - on the local and global level: • monitoring of the used fuel (coke, other fuels) • monitoring of the concentration of oxygen, carbon monoxide and carbon dioxide, which can show the efficiency of the burning • good isolation of the installations with warmed air and water • the process has to run continuously to prevent heat oscillations • working start and stop of the hot blast cupola has to be made progressive

19. GReening business through the Enterprise Europe Network Production of insulation materials - stone wool: Other possible measures to reduce the consumption of the fuel and energy and consequently also the air emissions - on the local and global level - saving the electric energy => minimizing the operator’s costs and the emissions on the global level: • high efficiency motors, variable speed drive, • minimizing of the reactive energy losses that cos φ between the voltage and the current peaks lies permanently between 0,95 – 0,99, • minimizing of compressed air demand, • Introducing a regular leak control program for compressed air system, • using of transporters with minimal rubbing

20. GReening business through the Enterprise Europe Network 2 - Lime industry CaCO3 CO2 + CaO limestone  decarbonisation  quicklime raw material – acquisition, preparation burning in the lime kiln in the range of 800- 1000-1200 -900 /°C quicklime treatment slaked lime different granulations

21. GReening business through the Enterprise Europe Network Lime industry Burning of the limestone in the lime kiln => to use the best combination - the choice of the fuel, type of the kiln, position of the burners, affects on fuel consumption and emissions, as well as on the quality of the product: • gas, liquid fuel, solid fuel, waste fuels • shaft kilns, rotary kilns, other kilns • internal burners, external burners, special burners for waste fuel, centralized burners etc

22. GReening business through the Enterprise Europe Network Lime industry Burning of the limestone in the lime kiln => the right granulation of the limestone in the kiln makes space between particles and this aids: • better air circulation => reduction of excess air => saving the fuel => less air emissions • better heat exchange between gases and particles => saving the fuel => less air emissions • better burning => saving the fuel => less air emissions • better thermal oxidation of CO => less CO emissions is produced => more energy is released

23. GReening business through the Enterprise Europe Network Lime industry Burning of the limestone in the lime kiln => the previous cleaning of the limestone: • better conditions to make free space in the kiln between particles • less impurities have positive impact on the composition of the air emissions • easier regulation of the excess air, so not too much heat escapes with it through the chimney

24. GReening business through the Enterprise Europe Network Lime industry fuel, air preheated air emissions to air Burning of the limestone in the lime kiln: preheating zone calcining zone cooling zone 900°C - 1200°C ~ 800 °C 900°C => 100°C the direction of the limestone flow

25. GReening business through the Enterprise Europe Network Lime industry Other possible measures to reduce the consumption of the fuel and energy in the lime industry and consequently also the air emissions: • monitoring of the used fuel • monitoring of the concentration of oxygen, carbon monoxide and carbon dioxide, which can show the efficiency of the burning • monitoring for controlling of good combustion of the fuel • regulation of burners • good isolation of lime kiln and installations with hot air • the process has to run continuously to prevent heat oscillations • working start and stop of the lime kiln has to be made progressive

26. GReening business through the Enterprise Europe Network Lime industry Other possible measures to reduce the consumption of the fuel and energy in the lime industry and consequently also the air emissions: • saving the electric energy (high efficiency motors, variable speed drivers, minimising of the reactive energy losses that cos φ between the voltage and the current peaks lies permanently between 0,95 – 0,99, minimising of compressed air demand etc.) => minimising of the emissions on the global level • use of waste hot air coming from preheating zone of lime kiln for the drying

27. GReening business through the Enterprise Europe Network Lime industry emissions to air cleaning-2 fuel, air preheated air Use of waste hot air from preheating zone of lime kiln for thedrying: DRYING, cleaning-1 production of the sand preheating zone calcining zone cooling zone 900°C - 1200°C ~ 800 °C 900°C => 100°C the direction of the limestone flow washed / wet sand

28. GReening business through the Enterprise Europe Network 3 - Cement industry Basic steps: calcination clinkering process raw material: acquisition, preparation cooling of clinker grinding of clinker, gypsum and additives cement

29. GReening business through the Enterprise Europe Network Cement industry: burning 1. step CaCO3 CO2 + CaO limestone calcination + quicklime ~ 800 - 900°C 2. step CaO + (Silica, Al2O3, Fe2O3) Ca-aluminates, Ca-ferrites, Ca-silicates clinkering process: clinker ~1400°C - 1500°C

30. GReening business through the Enterprise Europe Network Cement industry: fuels for the burning Fuels used in rotary kiln for the clinker burning: • solid fuels: e.g. coal, petcoke • liquid fuels: e.g. fuel oil • gaseous fuels: e.g. natural gas • wastes: e.g. used tyres, waste oils, plastics etc. / the high temperatures and long residence times in the kiln system implies considerable potential for the destruction of organic substances

31. GReening business through the Enterprise Europe Network Cement industry: fuels for the burning • the cost for the fuel • using of natural fuel resources • problems to achieve the reducing of CO2 fossil fuel • the profit for the waste removal • saving the natural fuel resources • less CO2 produced wastes

32. GReening business through the Enterprise Europe Network Cement industry: wastes as a fuel for the burning process Additional advantages for using waste as a fuel – comparison with the waste incineration: - in the rotary kiln are better conditions as in the waste incineration / gas retention times of about 8 seconds at temperatures above 1200°C in the rotary kiln (waste incineration: minimum 2 seconds at temperatures > 850°C or minimum 2 seconds attemperatures1100°C for halogens) • maximum temperatures achieved in the rotary kiln~2000 °C • oxidising gas atmosphere in the rotary kiln • uniform burnout conditions in the rotary kiln

33. GReening business through the Enterprise Europe Network Cement industry: wastes as a fuel for the burning process Aditional advantages for using waste as a fuel – comparison with the waste incineration: • destruction of organic substances due to the high temperatures at sufficiently long retention time • sorption of gaseous components (e.g. HF, HCl, SO2) on alkaline reactants • short retention time of exhaust gases in the temperature range in which PCDD/F can arise • chemical-minerological incorporation of the heavy metals into the clinker • complete utilisation of the ashe as a clinker component

34. GReening business through the Enterprise Europe Network Cement industry: wastes as a fuel for the burning process Final conclusions about using waste as a fuel in the burning process in cement industry: • saving the natural fuel resources (less fuel used) • less CO2 emissions • controlled removal of the waste • better environmental conditions for waste removal as in the waste incineration (less problematic air emissions); of course cleaning device for air emissions has to be used as in waste incineration • complete utilisation of the ash of the burned waste, as a clinker component

35. Thanks for your attention!