From Waste to a Reliable Co-Processing

From waste to a reliableco-processing
Case study Morocco
HANOI / 22nd August 2018, Dr Hubert Baier

LOESCHE Symposium Hanoi 2018 22.08.2018
Case study: Morocco
From waste to a reliable co-processing
Starting position
Waste assessment
Technical assessment
Designing the pre-treating process
Miscellaneous manner
01
05
04
03
02

At the beginning no reliable data
were available regarding:
▪ Source of waste
▪ Annual amount per capita
▪ Composition and potentials for
recycling or thermal use
▪ Legal framework
▪ Responsibilities
Starting position
0
500.000
1.000.000
1.500.000
2.000.000
2.500.000
3.000.000
0
50.000
100.000
150.000
200.000
250.000
300.000
350.000
TotalamountofexpectedHighCalorificFraction(HCF)
Annualamountperregion
region
3

Waste assessment on Temara landfill side, Morocco
5
Waste assessment
Example for urban Municipal Solid Waste
(MSW)

Portion and thermal potential of MSW
alumina
0,1%
residuals
0,2%
iron
0,2%
glass
0,7%
soil +
stones
1,9%
toiletries
6,6%
miscellaneous
7,9%
organic
62,3%
rubber + leather
0,4%
Pet-wrappings
0,3%
wood
0,4%
long living wrappings
0,9%
textiles
3,5%
paper, cardboard,
journals
6,0%
smooth plastics
8,8%
HCF 20,2%
HCF:
High Calorific Fraction
represents the combustible
portion of solid waste
Temara/ MA 2016

Composition and thermal potential
Pre-processing, fractions and qualities
8,8
14,4
16,8
24,3
0,0
5,0
10,0
15,0
20,0
25,0
30,0
0%
20%
40%
60%
80%
100%
calorificvalueMJ/kg
Sharesinmixture
organic paper, cardboard, journals long living wrappings
Pet-wrappings Styropor smooth plastics
hard plastics iron glass
soil + stones wood textiles
divers alumina rubber

High Calorific Fraction (HCF) for direct use in combustion chambers
▪ Grain size: < 300 mm
▪ Gross calorific value: ~ 14 - 17 MJ/kg
▪ Bulk density: 0,3 – 0,5 t/m3
or used as feedstock for RDF-production (2nd level)
Low grade calciner fuel (Residue Derived Fuel - RDF)
▪ grain size: 50 – 100 mm
▪ Gross calorific value: ~ 15 – 19 MJ/kg
▪ Bulk density: 0,2 – 0,4 t/m3
or used as feedstock for SRF-production (3. level)
High grade main burner fuel (Solid Recovered Fuel - SRF)
▪ Grain size: < 15 – 30 mm
▪ Gross calorific value: >> 20 MJ/kg (like lignite or higher)
▪ bulk density: 0,1 – 0,2 t/m3
8
Definition and specification of Solid Alternative Fuels

Starting position
Waste assessment
Miscellaneous manner
01
05
04
03
02
Case study: Morocco

10
▪ Exploring the locations of the cement
kilns and its potential for co-processing
▪ Detect technical and process faults
▪ Define basic conditions for the
specifications of the alternative fuel
▪ Calculating the logistical distance and
invest, supply during down times and
revisions, reception and storage etc.

Substantial1
Objectives for ‘co-processing’
‘Co-processing’ is the substantial + thermal use of alternative resources
‘Substantial 1’ → suitable mineral waste as an alternative raw material
‘Thermal + substantial’ → using the fuels and its ashes for clinker formation
‘Substantial 2’ → mineral grinding compound in accordance to the cement standards
Substantial2
Thermal+
substantial

Fine ground
raw meal
cement clinker
Pre-combustion chamber:
supply with tertiar air ~1000°C
Kiln inlet:
approx. 900 - 1100°C
Calciner:
900 – 1000°C
Main burner:
Gas temperature: 2000°C
radiant heat: 1450°C
> 2 s retention time by law
Feeding alternative fuels
12

▪ Exploring the capabilities
▪ Individual process conditions
▪ Energy demand
▪ Chemistry and set points
▪ Design the pre-processing
▪ Best options for feeding AF
▪ Materials handling
▪ Air pollution control
Sensivity against coating

Case Study: Morocco
Starting position
Waste assessment
Miscellaneous matters
01
05
04
03
02

Results of the waste assessments
After the waste assessment it
becomes clear:
▪ Specific amount of MBT
▪ Each region will produce alternative
fuels in different quantities and
qualities
▪ The cement works have to execute
a reliable technical assessment
▪ All regions require sanitary landfill
▪ Waste assessment and the technical
assessment are the basis to design
the proper MBT

Insight into the waste conditioning
16

Insight into the waste conditioning
17
Air classifier
Near-Infrared (NIR) to separate PVC
Storage and blending

Pre-processing and supply (examplary)
Reception and shredding <300 mm Screening and ballistical separation
Manual sorting for valuables and PVC reduction
Baling HCF for further
processing
to AF-producers or cement workBaling valuables for
recycling
Sanitary
landfilling
Biological degradation
‚technical‘ compost

MSW
recyclables
biodegradable
landfill
combustibles HCF RDF Rocket Mill®
Main
burner
Calciner
Pre-processing by
splitting
Pre-processing and feeding

Division of work

▪ The cement industry will be integrated to the national waste management plan.
▪ The cement industry can become partner of a national allocation plan for reduction of greenhouse gas
emissions.
▪ A national assessment of the waste sector and the technical assessment of the cement industry will
balance, how and by whom the waste derived energy can be used best.
▪ Entire premises have to clarify the legal frame, the financial aspects and the logistic between waste access
area, pre-treating plant and cement work.
▪ And… the World Bank or the international Green Climate Fund are financing such projects in accordance
to their environmental, social and economical role.
In a nutshell

Case study: Morocco
Starting position
Waste assessment
Miscellaneous matters
01
05
04
03
02

23
Regarding the large amount of ground limestone, the
pyroprocess is very tolerant.
But:
As higher the envisaged TSR is, the more the
conditioners and fuel suppliers have to respect the
requirements of the production process, its resulting
product and the air pollution control.
Both need a quality management to monitor and
control their processes, accordingly.
‘Quality’ ≠ ‘Quality’

Beforeflame
Delivery/discharge
Endofpre-treating/
beforeshipment
Wasteassessment
Receivingat
pre-treatment
In accordance to the permission and processIn accordance to the operational permission
Procedure of quality surveillance
24

▪ Legal framework is a ‘Code of Conduct’.
▪ Legal framework secures the investment.
▪ Quality surveillance is relevant to ensure the
production process, your product quality and
emissions.
▪ Competent authorities can monitor all steps
from waste to flame.
▪ Guaranties a safe and healthy environment.
Enforcement of legal framework

The project has successfully shown …
26
▪ Combustible portion of MSW is a reliable fuel and will reduce the
national GHG-emissions.
▪ Pre-processing can be designed in accordance to the requirements
of the cement manufacturing process.
▪ If done well, remaining ash complies with the clinker composition.
▪ AF comprises as less as possible of water, chlorine, alkalines or
other disturbing impurities.
▪ The dry-adsorbing effect in a lime based milieu cleans the exhaust
gas and inhibits the de-Novo-synthesis.
▪ High volatile heavy metals (i.e. Hg, Cd, Tl) were balanced in a trail
and comply with the EU-air pollution control standards.
▪ Non-volatile elements are trapped in the clinker formation or dust
bounded and suspended in modern filter systems.

Product
Environment
Process
Co-processing respects the requirements regarding…

THANK YOU
for your attention
LOESCHE GmbH
Hansaallee 243
D-40549 Düsseldorf
Tel.: +49 211 5353 - 0
Email: loesche@loesche.de

From Waste to a Reliable Co-Processing

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