Taiheiyo Cement Group’s Waste Utilization Technologies December 2019 @ Taiheiyo Engineering AT i oa |Taiheiyo Engineering Corporation TAIHEIYO ENGINEERING has gained extensive Know- how and advanced technology as part of the TAIHEIYO CEMENT GROUP and provides the consultancy, engineering services and special equipment necessary for the construction and operation of cement plants and cement related industries, Company Profile Company Name TAIHEIYO ENGINEERING CORPORATION Established April 1, 1976 ‘Address SA Building, Sth Floor, 2-17-12 Kiba, Koto-ku, ‘Tokyo 135-0042, Japan Capitalization Paid-in Capital: 490 million Japanese Yen Number of 177 as of March 2019 EmployeesUnique Characteristics of Taiheiyo Engineering Taiheiyo Engineering has the following four functions or characteristics, from Raw Material Quarry Development to Products Shipping, in one company. Cement Producer ~ Same viewpoint of the client a 3 : O Feasibility Study é Soy Manufacturing Ousdeie O Taiheiyo Chloride Bypass Supervision O TMP Burner O TCS System O O-SEPA O AVM (Vertical Roller Mill) O Taiheiyo Sewage Sludge Reactor and many more. © Plant Diagnosis ete. @ Taiheiyo Engineering1. Background (Environmental issue in Japan) @ Taiheiyo Engineering1. Scarcity of natural resources, insufficient landfill site - Increasing of waste in accordance with economical development and mass consuming society. - Difficulty to develop new landfill site - No more ocean disposal allowed 2. Hazardous waste - Dioxins from incinerator - Elution of hazardous heavy metals from landfill site - Increasing of waste electrical appliance 3. Global warming - Increasing energy consumption 4. Air and water pollution - More strict regulatory standards @ Taiheiyo EngineeringCement Rotary Kilns’ Unique Characteristics 1. High temperature in a Kiln can decompose almost all of toxic organic substances. 2. Primary raw material, limestone, is the most widely used neutralizing agent for hazardous materials. 3. Ash component of waste is effectively used as raw material, thereby no secondary waste is generated from the cement plant. 4. Trace elements such as heavy metals are safely captured in the cement clinker. 5. Production capacity of Kiln is very large compared to waste material usage. @ Taiheiyo EngineeringCement Rotary Kiln Raw meal - CaO/CaCO, Rotary Kiln - Flame: 1800 - 2000 deg-C - Material : 1450 deg-C > 15 min - Gas: > 900 deg-C - -_Raw meal: 700 deg-C Preheater ¢} = dry scrubber for acid gases and metals 6668 @ Taiheiyo Engineering2. Utilization of Various Wastes @ Taihelyo EngineeringWaste and By-products Used in the Cement Manufacturing Process te Grewst 2 ide wae Tt aw Material Preparation Process After preheating, the materials Limestone, iton wastes, etc, te pobatng the mates embed together died “=P aeburedin alan ooh aan ooled to form an intermediate product called ink, ease and by roduc sed t Raw materials Raw materials Blast furnace slag, coal ash, ‘Municipal waste incineration ash, fly polluted waste studge, ssh, sed cay sewage sige ‘nonferrous siag, Fuels raw Wesel wast past used tes, construction soll molding | vwoldips sup padiaio madi, sand, etc, | ‘ROF (municipal waste), recycled ol, 8OF Ea bass —_ ‘A small amount of gypsum {5 added to the dlnker and {ground in the finish mill to produce cement, Mineral components Slag powder, fly ash {CSR REPORT 2018: TAIHEIYO CEMENT CORPORATION} @ Taiheiyo EngineeringUtilization of wastes/by-products in Taiheiyo Cement (FY 2017) [ternative fuel Industrial Coal ash (including JIS fly ash) 2,009,314 1254 Blast furnace slag 1,192,701 744 By-product gypsum 537,339 Bae) ‘Unburned ash, dust emissions, dust 473,735, 29.6 Dirtand sludge 449,472 28.0 Construction soil 380,612 Bs Waste plastic * 161,459 10.1 Waste oil * 139,759 87 Wood chips * 110,807 69 Other 650,550 40.6 Sub-total 6,105,748 381.0 Household ‘Water treatment plant sewage sludge and ash 363,993 27 Municipal incinerator ash 133,965 84 Municipal waste, etc. 21,585 13 Sub-total 519,544 324 Total 6,625,292 434 Raw material-related 6,050,228 3775 Fucl-related * 575,067 35.9 {Suse CSR REPORT 2018; TAIMEIVO CEMENT CORPORATION] @ Taiheiyo EngineeringTrends in Use of Waste and By-products per Production (kg/t-cement) 500 450 430.1 427.9 a nie 4134 400 350 300 267.3 250 200 150 100 50 0 2000 2013 2014 2015 2016 2017 (FY) {CSR REPORT 2018: TAIHEIYO CEMENT CORPORATION} @ Taiheiyo Engineering i3. Example of Various Waste Utilization @ Taiheiyo EngineeringExamples of Alternative Fuels and Raw Materials (AFR) UtilizationUsed Tires @ Taiheiyo EngineeringWaste Plastics ‘@ Taihelyo Engineering 15Flow Diagram for Waste Plastics Secondary Shredder Primary rs Shredder Caleiner Burner: 2.5t/h Type of Waste Plastics Material Type Note Formed PE Sheet Bridged PE Sheet-tolled solid Rae PET, PE, phenol Rolled PET, PE rolled @ Taiheiyo EngineeringWaste Oil 1-@ Biondi ent by waste an @ Taiheiyo Engineering elRDF (“Pachinko” machine Wasted “Pachinko” machines are processed into RDF after erushing ind kneading. @ Taihelyo EngineeringSewage Sludge @ Taiheiyo EngineeringLatest Sewage Sludge Utilization in Japan Generated volume (thousand DS ton) 23500 2.000 1.300 1,900 300 Recycle rate Approx.29% ° * o i 18 (Fiscal year) *DS:Dry Solid [ Source: Ministry of Land Infrastructure and Transport Government of Japan J @ Taiheiyo Engineering. Taiheiyo Sewage Sludge Reactor System *by Hot meal Sewage Sludge Treatment Capacity: 150t/d Water content of Production from Reactor: <5.0% Preheater Steam Sludge Feeding Raw Sludge System GB Bowell ws Giclondned @ Taiheiyo EngineeringMunicipal Waste Incineration Ash High chloride content Adverse effect to product quality =>Prevent smooth operation Se Conny Pontiac mean Water seal ce ny | Containing metallic foreign object "| prevent smooth kiln operation i | @ Taiheiyo EngineeringAsh Washing System (Treatment of High Chloride Fly Ash) = \Confidential (incineration Ash Treatment Plant ) Fly Ash Washing System Bottom Ash Treatment System (ee Taiheiyo EngineeringAsh Washing System (Treatment of High Chloride Fly Ash) Bottom Ash Treatmt at Kumagaya Plant: Pera eked 2019.11.28) To Kiln Ca Magnetic separator Bottom ash ‘Screen and Crusher. And then, Sorted ash is treated at Kiln process. 10 2019 OTAIMEIYO CEMENT @ Taiheiyo EngineeringAsh Washing System (Treatment of High Chloride Fly Ash) Fly Ash Washing at Kumagaya Plant Water-washing & Desalination process ~ Chlorine content in Fly Ash is eliminated through water-washing & desalination process. ~ Desalinated Fly Ash slurry is dehydrated and treated at Kiln process. TAIHEIYO CEMENT w. ing water Desalinated cake , Dp | To Kiln rm Dissolution tank Transportation device To Waste-water treatment process ci 2019 TAIHEIVO CEMENT @ Taiheiyo EngineeringCera el estas at Kumagaya Pian Waste-water treatment system Harmful components (Suspended Solids, Heavy metals etc.) in filtrate is removed. = Waste water is controlled and discharged under waste water standard. Regulating tank. ae: ‘Sludge thickener Po Pa Je} a efit tank i$ To Kiln «| ‘Shudge tank Discharged water Discharging tank 2 20190 TAIMEIYO CEMENT. ‘@ Taiheiyo EngineeringBagged domestic waste can be directly put into this system. This eliminated municipal incinerator Taiheiyo Cement utilized 100% of 15,000t per annum I waste generated from Hidaka city, whose population is 64,000. @ Taiheiyo Engineering4. Countermeasures for more AFR Utilization @ Taihelyo Engineering ackground: Development of Countermeasures Social requirement - Environmental protection - Resource saving - Sustainable society | More waste (AFR) utiliz: Company’s requirement Cost reduction Contribution to local societies "4 ition nie uo Increase of hazardous component (Chlorine, Sulphur) ~e- asures are requir ri vo Taiheiyo Chlorine Bypass System TCS craiheiyo Coating Sotutiom System @ Taihelyo EngineeringCoating condition in relation to Chlorine and SO; in hot meal 35 3.0 25 20 us NS hese coating 10 Cl content of meal [i] acceptable coating 0s no coating 00 00 05 «10 «15 020k ‘80, content of meal [%] @ Taiheiyo EngineeringOperation Difficulties caused by Waste (AFR) Utilization Some of AFRs contain high chlorine and/or sulfur components. = Coating trouble at preheater and Kiln inlet may occur. 1. Taiheiyo Chlorine Bypass System To prevent coating trouble by removing chloride contained in kiln exhaust gas 2. TCS (Taiheiyo Coating Solution) System To prevent coating by absorbing SO: gas and sulfur compound with dispersed raw meal at kiln end. ‘@® Taiheiyo EngineeringTypical Taiheiyo Chlorine Bypass System Flow To prevent coating at Kiln inlet caused by low melting point chloride substance Cyclone | ae --. ig To ID-fan outlet ete. [Probe Return to Pyro- Process For reducing dust amount i + ie L oe Fr Coarse Dust i Fine Dast ia | Filter ‘To Cement Mill Section For removing more chlorine @ Taihelyo EngineeringEquipment Installation of Taiheiyo Chlorine Bypass System Ceponte oe a jaihelyo Engineering ElSupply List (as of March 2019) ae pe ee a % = Japan NSP (RSP) 3800 100 2018 Ratio-up 6510.0 aa 1s Korea NSP (RSP) 5500 50 2017 as S aa Japan NSP (RSP) su 100 2017 Ratio-up 5010.0 7 39H 3 Korea NSP 000 50 2017 163453 (ra Korea ase. 700 10. 201s 1s a 1 Korea NSP 300 0 2s 2? Sa Japan sP 1363) 60. 2018 Ratiosup 30-56 38 8) Thailand NSP 10100 cy 2015 cy 3 4? Korea NSP 9100 50 204 1, ae a NSP (SF) 3000 100 2014 284766 Thailand NSP 5780 50. 2014 aT) cs sepa sp 4980 3816) 40 2014 Ratio-up 20-40 9 6 48 6H Sapam NSP, 340 4 2014 Ratio-up 2454 Oy | Japan sp 4000 (3340) 10 20 7 4 8 Malaysia NSP (RSP) 000 30 2013 meee a China NSP (SF) 2000 120 2013, 3 4 ee Japan NSP(C-SE) 700 4 2013, Ratlo-up 2448 aa Tanzania 1500 120 2013, 3 39 ee Japan NSP (RSP) 100 70 2012 Ratio-up 3.67.0 ae 7 Japan NSP (RSP) 2880 70 2012 Ratio-up 357.0 1 Japan NSP(CSP) 900 20 1993, ee sanscry0 EngineeringTCS (Taiheiyo Coating Solution) System Brick want Raw meal Mechanism of Sulfur Coating Lor kiln dust Concept of TCS System Low temperature Raw met Raw meal or kiln dust @ Taiheiyo Engineering apply List (as of March 2019) A 1100a 2018 Waste fuel *Under construction RSP 900 va 2014 White Cement Produet Process DoF 1000 ¥a 2014 White Cement Product Process DDF 1000 va 2014 White Cement Produet Process Dp 200va 2012 Cement Product Process of Using waste carbide pF Hey 2011 Greyand White RSP, 3.500 0d 2010 China Rsp 6,000 va 2009 Anti-coating for 100% burning of high-Sulfur Coal India DF ‘00 va 2009 Sudan DoF 420004 2008 Malaysia pr 3,600 ud 2008 India NSP 7008 2008 Anti-coating for 100% burning of high-Sulfur pet-eoke nia NSP. 70008 2008 Anti-oating for 100% burning of high Sulfur petcoke Brazil RSP 2500 va 2007 Anti-coating for 100% burning of high-Sulfur petcoke Sudan pF 4200 ua 2006 Anti-oating for 100% burning of high Sulfur petcoke India NSP r100 a 2005 Anti-coating for 100% burning of high-Sulfur petcoke India DF 500d 2005 Anti-coating for 100% burning of high Sulfur potcoke India DDF 900 va 2003 Anti coating for 100% burning of high Sulfur pet-coke India DDF 2,000 va 2003 Anti coating for 100% burning of high Sulfur pe-coke Japan sp 4.000 ua 2003 Anti coating for high Sulfur coming from waste as raw materia Japan sp 4.000 va 2003 Anti coating for high Sulfur from limestone and petroscoke, Japan MC 7,000 ua 12003 Anti coating for high Sulfur coming from waste as raw material and fuel Japan RSP 3,000 ua 2000 Anti coating for high Sulfur from limestone and petro-coke 'w laineryo engineeringThank You Taiheiyo Engineering Corporation http://www.taiheiyo-eng.co,ip overseas_sales@taiheiyo-eng.c