Bath Plant

Biomass Use in the Cement Sector A Fuel Users Perspective

April 14, 2011

Outline

Cement 101 Cement and Concrete Primer Biomass Fuels a cement industry perspective Cement 2020 whats next in the development process

Photos: Front slide, hemp produced for trial; Above Shredded mixed biomass for the trial: Below Close up of shredded biomass mix

About Lafarge Canada

Lafarge Canada is part of the Lafarge Group, headquartered in Paris, France. Lafarge is the world leader in building materials, with topranking positions in all of its businesses: Cement, Aggregates & Concrete, and Gypsum. Lafarge is ranked 6th in the Carbon Disclosure Project, for the sixth year in a row is listed in the Global 100 most Sustainable Corporations in the World, and entered the global Dow Jones Sustainability Index in 2010 in recognition of its sustainable development actions. With the worlds leading building materials research facility, Lafarge places innovation at the heart of its priorities, working for sustainable construction and architectural creativity. With 78,000 employees in 78 countries, Lafarge posted sales of 15.8 billion Euros in 2009. Lafarge Canada is the largest cement producer in Canada.

Cement 101

Our product

Cement is to concrete as yeast is to dough Cement is the glue that holds concrete together More concrete sold per year than all other building materials combined. Excellent Environmental features

Long lasting LEED building materials Low embodied energy

Lime
LIMESTONE

Major Oxides CaO SiO2 Al2O3 Fe2O3

Silica Alumina

CLAY FLYASH IRON

Iron

The Cement Manufacturing Process

Kiln Feed: 79% Limestone 16% Shale 3% Slag 2% Sand / Silica Rock

(calcium source - CaO) (silica and alumina source-SiO2, Al2O3) (iron source - Fe2O3 (silica source - SiO2)
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Minor elements present in kiln feed: Sulphur, chloride, sodium, potassium Calcination of limestone CaCO3 CaO + CO2 Clinkering: CaO + SiO2 + Al2O3 + Fe2O3

(60% of GHG emissions)

Calcium Silicates + Calcium Aluminates Calcium Alumino-ferrite

Cement: Clinker + gypsum + limestone (+ flyash + slag)

cement

Typical Cement Kiln

Kiln
The burner heat

source is at the discharge end of the kiln, so the feed gets hotter as it moves its way down the kiln
Flame

temperature is 2300C
At 1450C

clinker material pours out the end of the kiln into the cooler

Important Cement 101 Implications for Ag Fuels

Ash components are partitioned (sequestered) into the product (see cobalt example below) Unique combustion conditions (high temperatures, ultra-long residence times) Systems are sized and designed for coal use At 5% of the worlds CO2 emissions, the opportunity is huge. Ideas to emerge out of Cement 2020 could be adopted worldwide (e.g. 40% reduction in CO2 from cement industry is equivalent to removing Canadas CO2 emissions.
Inputs Outputs

(Coal/Coke)/biomass (90:10) Cobalt 26.0

Raw mix

Stack Emissions

Clinker by difference 533

Partitioning Factors

506.8

0.126

99.976%

Biomass Fuel Opportunities & Challenges

Photo of the injection of biomass into the kiln during the biomass demonstration test in October, 2010 Results will be made available at www.cement2020.com

What are the important questions for fuel use?

Chemistry

C-H ratio
Lower Heating value Refractory compounds

CxHy + (x+0.5y)O2 => xCO2 + (0.5y) H2O

Coal is typically 6080% carbon while biomass is 40-50% carbon.

Particle size Ash & metals

Partitioning Effects on product quality

Cobalt example 99.98% sequestered in cement Wood can be 50% moisture A pile of coal will require 2.5-3 same size piles of biomass for the same energy value.

Free moisture

Practical Matters

Note: We may end up consuming more energy when using biomass

Storage Transportation Reliability of Supply Processing

Challenge 1: Producing biomass fuels Supply

Forest
Slash, Harvest

These technologies may be applicable to a variety of feedstock sources.

Processing
Baling / Shredding Pelletization Torrefaction Liquefaction Pyrolysis Gasification

Fuel Product
Solid
Power, Steel, Cement, Home, Greenhouse, other thermal

Purpose Grown
Crops, Agriforest, stover

Liquid
Transportation, Thermal, Power

Waste / Byproduct
Pulp & paper, post consumer, biosolids, other

Gas
Power, Home, Commercial, other thermal

A brief aside what is a Gigajoule???

A unit of energy, 1 million joules = GJ It is accepted practice to compare prices of fuels, apples to apples, using $/GJ 1 GJ = 278 kW.h. * 1 GJ = 947,817 BTU

* As energy released which, with

electricity efficiency etc would not equal the electricity delivered to an end user.

Some mathematics (for illustration)

Start with 1 Acre 4 tonnes per Acre = 4 Tonnes 18 GJ/Tonne [dry] = 72 GJ/acre Revenue of $150/ac = $2.08/GJ

Price to produce bales on the farm?

Pelletization = $50/tne = $2.8/GJ Transportation of pellets

These are all assumptions and can be adjusted in the privacy of your own home.

30 tonnes = 540 GJ/truck [minus water] Cost at $5/loaded km = $0.93/GJ/100km

Price FOB to fuel user 200 km away is $6.74/GJ Excludes additional costs at fuel users site

Clearing the air on pellets

Doing the math assuming loose biomass at 20 tonnes per truck load results in a transportation cost of $1.4/GJ/100 km (also and importantly avoids on site cost to re-grind pellets, if necessary) Breakeven is over 400 km assuming 1% of land within a 400 km radius1.24 million tonnes of biomass available Advantages of pellets

Recognized product Good for systems designed to use pellets Economical at long transportation distances Some benefit in heating value (GJ/tonne) [Drier] Improved conveyability

Disadvantages

Cost & must be stored in covered storage Cement kilns prefer smaller particle size fuel Dusting and off-gassing

Challenge 2: Cost of Biomass Fuels

Fuel Type
Gasoline Natural Gas Grown Biomass Coal Coke

Cost per Gigajoule

$24 $5-$12 $6-$10 (OMAFRA est) $3-$5 $2-$4

Note: Coal releases about 90 kg CO2/GJ; a Cap & Trade cost of $50/tne CO2 will add about $4.5/GJ to the cost of coal.
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Challenge 3: the Quality of Biomass as a Fuel [Orknow thy enemy]

Characteristic $/GJ Energy Density Shipping % Ash Ash Chemistry Availability CO2 Emissions Other Emissions Water Use Storage Coal $3-$5 32 GJ/m3 Boat 5-20% Useful High 100% Present 0.16 m3/GJ Outdoor Biomass $6-$10 13 GJ/m3 Truck 3-10% Neutral Low-Moderate <10% Lower (caution) Variable, TBD Covered?

Problems to be solved (and how Cement 2020 is working on them)

How to improve biomass fuel quality

Food vs Fuel

Use waste heat Carbonization? Torrefaction?

Policy development

Emissions from combustion

How to create biomass ready fuel infrastructure

Start with biomass byproducts, co-products Continue crop development research (yield improvement)

Less of an issue when replacing fossil fuels, especially coal biomass demonstration For unsophisticated cases, standards around biomass use and associated emission controls Gasification for home use?

Water use

Include water in LCAs

Other social aspects

Cost

Local fuel is a big positive Trucks vs boats Land use and biodiversity Community involvement

What is the case for government subsidies?

Cement 2020

Life Cycle Assessment of ag biomass and other sources

Carbon Water

Greener Fuel Screening Protocol Landscape issues with land conversion to biomass production How best to use waste heat

Electricity? Carbonization? Both?

Road map

Implementation in 2012

Partners

Thank you to NRCan and Environment Canada for their financial support

Lafarge, SVI, WWF Canada, NRCan, MOE, Env. Canada, Queens, RMC, Portland Cement Association

Steering Committee

Rob Cumming, Brian Gasiorowski, Warren Mabee, Sebnem Madrali, Andrew Pollard, Glynn Robinson, Steven Price

Researcher and Contributors

Darko Matovic, Ted Grandmaison, Tom Carpenter, John Chandler, Sam Fujimoto, Sharon Regan, Goni Boulama, Mike Lepage, International Review Team, Lafarge Engineer Team

Project Management

Ron Quick, Alison Obenauf, David Hyndman, Anjali Varma, Sarah Harrison

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