Co-processing technology by ATS-Group in Hon Chong cement plant, Vietnam helps improve thermal substitution rate during clinker production by up to 35 per cent.
Geocycle Vietnam, the industrial waste management solutions brand of Holcim Vietnam Ltd (HVL), invested $12 million in 2014 towards green manufacturing in Hon Chong cement plant, Vietnam. The objective was to perfect its manufacturing processes by using green technologies such as co-processing in cement kiln technology. The new technologies related to co-processing includes upgrading the calciner, building a waste storage, integrating an automatic crane system for the storage management as well as two feeding and dosing systems to take waste up to level 5 of the pre-heater with a closed belt conveyor; and these challenges successfully met by ATS Conveyors India (100 per cent subsidiary of ATS Group France), based in Pune.
The properties of the secondary fuels (hazardous and nonhazardous waste) have to be considered while working out a successful technical solution. It is well known that the properties of the secondary fuels are never constant and by their nature, are heterogeneous. This requires the use of equipment that is very flexible in operation. Walter material handling division of ATS Group is specialised in turnkey solution for alternative solid fuels has developed suitable equipment specifically for safe and reliable dosing and feeding of alternative fuels such as shredded tires, RDF, impregnated saw dust, shredded plastics, etc...
Covered storage with automatic grab crane system, extraction and dosing with metallic apron extractor with integral mass flow measurement, have proved successful everywhere for feeding alternative fuels in cement kilns.
These technologies together form an automatic system, operating under the control of the control centre room. Dual De-nitrification Furnace (DDF) upgrading makes the combustion of waste in the DDF better, thanks to the increase in waste retention time in the DDF at high temperature, over 1,000oC.
The new investment, again re-affirms HVL commitment towards sustainable development strategy - the core of its business, emphasis on balancing economic profits with social responsibility and constantly strives to minimise its impact on the environment. In terms of the environment aspect, the new system helps improve the thermal substitution rate during clinker production up to 35 per cent (compared with 26 per cent in 2013), therefore save fuels coming from non-renewable energy sources.Also, it contributes to minimise exposure of people to waste, so it is safer for employees.
Geocycle with co-processing technology provides a safe and secure method of waste management that destroys hazardous components of waste while capturing its energy and mineral content in the production of cement. The modern kiln in Hon Chong plant is ideal for co-processing waste. With temperatures of up to 1,450¦C, almost all waste types can be destroyed without any residual materials. This process takes place without affecting cement production.
Geocycle can receive various industrial waste types such as paper, plastics, rubber, pesticides, and oil, as well as agricultural wastes such as rice husks. Over almost a decade since the establishment in 2004, Geocycle Vietnam had partnered with customers to treat a total of almost 450,000 tonne of waste till the end of 2014.
As a long-term investor in Vietnam, HVL is committed to sustainable development. Together with this investment, for many years, HVL has invested in the cement manufacturing by using state-of-the-art technologies like waste heat recovery. Power plant operated since 2012 is one of the first in Vietnam to use waste heat from the production process to generate electrical energy for the plant. It offers enormous benefits for the economy, society and environment with considerably reducing both fossil fuel consumption and CO2 emissions.