National Cement Company. P.S.

C
Dubai

LOESCHE SYMPOSIUM:
Cost saving as result of conversion from HFO to
pulverized coal

Presented by: Eng. Radwan Mouakat

Dsseldorf, 25.09.2014

National Cement Company P.S.C

Dubai

Dubai City in year 1976

Dubai City Today

Today in the heart of Dubai City

National Cement Co.
P.S.C Dubai Works

National Cement Co. Works in brief

Commissioned wet
process in 1978
Converted to dry
process in 1987

National Cement Co. Works in brief

Current capacity 4000

tpd
Original heat source
was HFO
Conversion to coal
firing since 2012

Fuel price from 2004 to 2012 (USD/TON)

Consumption of fuel per ton of clinker

Challenges
Rising price of heavy oil and gas
Difficult market conditions
Strong impact on production costs
Cost reduction challenge
Decision cost saving conversion from HFO to
pulverized coal

Selection
A Strategic Decision
Selection of the Coal grinding Company

For cost saving as result of conversion from

HFO to pulverized coal

Concepts and Considerations

Coal Grinding Plant

Concepts and
Considerations

Processing
Design latest regulations regarding constructions
Lay-out and operation of coal handling facilities
Safety regulations
Modern fuel efficient kiln types
Drying of coal
Grindability of coal meal fineness
Mill for grinding of coal

Conditions
Arrangement of coal grinding plant:
There are various factors have to be taken into
considerations when arranging a coal grinding plant:
Quality of coal
Supply of hot air for drying
Type and numbers of Kiln
Investment cost
Maintenance cost
Reliability

Conditions
Based on evaluation of these matters, decision can be
made regarding the following:
Direct, semi-direct or indirect firing
Inert or non-inert operation
Ball mill or Vertical Roller Mill
Bag Filter or EP for possible dedusting
Instrumentation & automation of the coal grinding plant
Filters and coal mills silos

Conditions
Coal stacking and storing
Other Safety precautions, the following tips should
be considered:
Feeding arrangement, to ensure steady feed of raw
coal to the mill.
Horizontal surfaces, where coal may settle. Ducts
should have proper inclinations (min. 60 upwards
and 45downwards.)
Gas velocity in ducts (min. 20m/sec.)

Conditions
Mill separator, duct between separator and filter, filter and
coal meal silos should be fitted with pressure relief valve,
which must open to the outside air, not inside the buildings.
The installations mechanical and electrical equipment to be
well maintained for future maintenance.

Buildings and equipment should be kept clean

Common sense: To consider the operation, designed
plant which is in accordance with current industrial
standards, to reduce risks.

Benefits

Lower energy consumption

Higher drying capacity
Output capacity can easily be varied within a wide range
corresponding to the fuel consumption of the Kilns
Fast feed output response
Accept larger feed sizes up to 80mm
Lower noise level
Requires less building volume

Challenges

Larger quantity of air to be dedusted

Less suitable for abrasive coal. Wear parts are
expensive and replacement causes downtime.
Sensitive to variations in feed rate and feed
quantity

Result of selection and evaluation

A Strategic Decision
Selection of the Coal grinding Company

LOESCHE GmbH
For cost saving as result of conversion from HFO
to pulverized coal

Beginning in 2012

Why LOESCHE Vertical Roller Mill

One Compact System, comprising grinding,
drying and classification
Stable running conditions, hence easy to
operate
Easy to maintain and reduced specific wear
rates

Highly energy efficient

Very flexible grinding system

LOESCHE Coal Mill in the City of Dubai

Mill Type: LM 28.2 D
Feed Material: Hard Coal
Throughput (design): 40 tph
Product Fineness: 12%R90m
Drive Capacity: 600 kW
Commissioned: 2012

National Cement Co. Coal Mill Building

Share Vertical Mills for Coal Grinding

Numbers represent the year 2007/08

LOESCHE Mill Flow-sheet

Pulverized Coal Dosing

Dosing Unit
Type
Material
Capacity
Application
Commissioning
Bulk Density
Distance of Feed
Line

DRW 4.12/2

DRW 4.12/2

Rotor weigh feeder

Rotor weigh feeder

Coal Dust

Coal Dust

16,2 t/h

17,8 t/h

Calciner

Main Burner

02.05.2012

02.05.2012

0,35 0,6 t/m3

0,35 0,6 t/m3

70m

123m

Raw coal specifications

S.NO

SPECIFICATIONS

UNIT

SPECIFICATION

YEAR
2013

YEAR
2014

01

TOTAL MOISTURE

MAX - 8.50

7.58

8.93

02

INHERENT MOISTURE

MAX - 3.50

1.60

1.86

03

GROSS CALORIFIC VALUE

Kcal/k
g

MIN - 6400

6438.11

6549.72

04

SULPHUR

MAX - 1.00

0.60

0.61

05

ASH CONTENT

MAX - 16.00

15.91

15.01

06

VOLATILE MATTER

MAX - 26.00

28.02

29.00

Coal price for the year 2012

Market prices for coal 2013 & 2014

Coal consumption
COAL CONSUMPTION PER TON OF CLINKER FROM JUNE - DEC. 2012
0.13
0.125
M. TON
0.12
0.115

JA N.

FEB.

MA RC

A PRIL

MA Y

M. TON

JUNE

JULY

A UG.

SEPT.

OCT.

NOV .

DEC.

0.1241

0.1249

0.1248

0.1211

0.1244

0.1243

0.1277

CONSUM PTION OF COAL PER TON OF CLINKER FOR THE YEAR 2013
0.135
0.13
M.TON

0.125
0.12
0.115
M.TON

JA N.

FEB.

MA RC

A PRIL

MA Y

JUNE

JULY

A UG.

SEPT.

OCT.

NOV .

DEC.

0.1263

0.1296

0.1281

0.1290

0.1312

0.1326

0.1265

0.1266

0.1225

0.1237

0.1225

0.1229

CONSUMPTION OF COAL PER TON OF CLINKER FROM JAN. - JULY 2014

0.135
0.13
M.TON
0.125
0.12
M.TON

JAN.

FEB.

MARC

APRIL

MAY

JUNE

JULY

0.1255

0.1244

0.1324

0.1283

0.1250

0.1252

0.1252

AUG.

SEPT.

OCT.

NOV.

DEC.

Alternative fuels

Alternative fuels
Such fuels as wood chips, sludge, used car tyres or even
house hold garbage .. etc.
The application of these fuels are becoming more and more
interesting. There is no doubt that in the future the cement
kiln will be used more and more as incineration plant for
disposal of hazardous waste.
In this regard, we are nowadays using carbon dust which is
available in Aluminium industry with reasonable Price ,
also full unit of used car tyres.

Carbon Dust Specifications

S.NO

SPECIFICATION

UNIT

YEAR-2013
CARBON
DUST
GRADE-I

YEAR-2014

CARBON
DUST
GRADEII

CARBON
DUST
GRADE-I

CARBON
DUST
GRADEII

Kcal / Kg

7562.26

3586.11

7534.07

4095.51

SULPHUR

1.69

1.07

1.48

1.30

ASH CONTENT

3.01

45.68

2.85

38.23

01

GROSS
CALORIFIC
VALUE

02

03

Alternative fuels

Alternative fuels
PERCENTAGE OF COAL AND ALTERNATE
FUEL FROM JUNE 2012 TO JULY 2014
100.00
95.00
90.00
85.00
80.00
75.00
70.00
65.00
60.00
55.00
50.00
45.00
40.00
35.00
30.00
25.00
20.00
15.00
10.00
5.00
-

94.90

91.45

92.40

COAL
ALTERNATE FUEL

5.10
2012

8.55
2013

7.60
2014

Energy cost
ENERGYCOSTINUSD/TONOFCLINKER
60.00
50.00
40.00
30.00

Series1

20.00
10.00
Series1

FUEL OIL

C OA L

C OA L + C A R B ON D UST

COA L + TYRES

COA L + CA RB ON DUST +
TYR E

51.70

13.67

13.30

13.16

12.79

Energy cost
ENERGYCOSTINUSD/TONOFCLINKER
15.00
14.00
13.00
Series1
12.00
11.00
10.00

Series1

COAL

COAL + CARBON
DUST

COAL + TYRES

COAL + CARBON
DUST + TYRE

13.67

13.30

13.16

12.79

Thank you very much

for your
kind attention!