National Cement Company. P.S.C Dubai LOESCHE SYMPOSIUM:

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1 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 Düsseldorf,

2 National Cement Company P.S.C Dubai

3 Dubai City in year 1976

4 Dubai City Today

5 Today in the heart of Dubai City National Cement Co. P.S.C Dubai Works

6 National Cement Co. Works in brief Commissioned wet process in 1978 Converted to dry process in 1987

7 National Cement Co. Works in brief Current capacity 4000 tpd Original heat source was HFO Conversion to coal firing since 2012

8 Fuel price from 2004 to 2012 (USD/TON)

9 Consumption of fuel per ton of clinker

10 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

11 Selection A Strategic Decision Selection of the Coal grinding Company? For cost saving as result of conversion from HFO to pulverized coal

12 Concepts and Considerations Coal Grinding Plant Concepts and Considerations

13 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

14 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

15 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

16 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 45 downwards.) Gas velocity in ducts (min. 20m/sec.)

17 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.

18 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

19 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

20 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

21 Beginning in 2012

22 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

23 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%R90μm Drive Capacity: 600 kw Commissioned:2012

24 National Cement Co. Coal Mill Building

25 Share Vertical Mills for Coal Grinding Numbers represent the year 2007/08

26 LOESCHE Mill Flow-sheet

27 Pulverized Coal Dosing Dosing Unit DRW 4.12/2 DRW 4.12/2 Type Rotor weigh feeder Rotor weigh feeder Material Coal Dust Coal Dust Capacity 16,2 t/h 17,8 t/h Application Calciner Main Burner Commissioning Bulk Density 0,35 0,6 t/m 3 0,35 0,6 t/m 3 Distance of Feed Line 70m 123m

28 Raw coal specifications S.NO SPECIFICATIONS UNIT SPECIFICATION YEAR 2013 YEAR TOTAL MOISTURE % MAX INHERENT MOISTURE % MAX GROSS CALORIFIC VALUE Kcal/k g MIN SULPHUR % MAX ASH CONTENT % MAX VOLATILE MATTER % MAX

29 Coal price for the year 2012

30 Market prices for coal 2013 & 2014

31 Coal consumption COAL CONSUMPTION PER TON OF CLINKER FROM JUNE - DEC M. TON JAN. FEB. MARC APRIL MAY JUNE JULY AUG. SEPT. OCT. NOV. DEC. M. TON CONSUMPTION OF COAL PER TON OF CLINKER FOR THE YEAR M.TON JAN. FEB. MARC APRIL MAY JUNE JULY AUG. SEPT. OCT. NOV. DEC. M.TON CONSUMPTION OF COAL PER TON OF CLINKER FROM JAN. - JULY M.TON 0.12 JAN. FEB. MARC APRIL MAY JUNE JULY AUG. SEPT. OCT. NOV. DEC. M.TON

32 Alternative fuels

33 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.

34 Carbon Dust Specifications S.NO SPECIFICATION UNIT YEAR-2013 YEAR GROSS CALORIFIC VALUE CARBON DUST GRADE-I CARBON DUST GRADE- II CARBON DUST GRADE-I CARBON DUST GRADE- II Kcal / Kg SULPHUR % ASH CONTENT %

35 Alternative fuels

36 Alternative fuels PERCENTAGE OF COAL AND ALTERNATE FUEL FROM JUNE 2012 TO JULY % COAL ALTERNATE FUEL

37 Energy cost ENERGY COST IN USD/TON OF CLINKER Series FUEL OIL COAL COAL + CARBON DUST COAL + TYRES COAL + CARBON DUST + TYRE Series

38 Energy cost ENERGY COST IN USD/TON OF CLINKER Series COAL COAL + CARBON DUST COAL + TYRES COAL + CARBON DUST + TYRE Series

39

40 Thank you very much for your kind attention!

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