EcoCem expands alternative fuel production in Sulaymaniyah

In 2020, Eggersmann Anlagenbau implemented the Eggersmann FUEL process in the Ecocem waste treatment plant in Sulaymaniyah. Since then, municipal solid waste (MSW) has been processed there into refuse derived fuel (RDF) with a particularly high net calorific value in a biological-mechanical process. The RDF is used in regional cement production of the Gasin Cement Company and Bazian Cement Company. The operator has now decided to expand the plant.

A new chapter

The expansion of the plant includes a stationary Eggersmann TEUTON ZS 55 single shaft shredder and four lanes for biological drying with the CONVAERO system. The system is an essential component of the Eggersmann FUEL process for producing a medium-calorific and more sustainable RDF. The expansion of the plant is intended to enable a more flexible response to changes in the future. The plant is currently designed for 1,100 tonnes per day. "A particularly high-quality substitute fuel is being produced with the Eggersmann FUEL process in Sulaymaniyah, whose net calorific value can be precisely tailored to the customer’s needs over the adjusting of the drying period. This quality makes a noticeable economic difference. That convinces" summarizes Eugen Becker, Business Development Manager at Eggersmann.

Higher net calorific value for more sustainability 

The Eggersmann FUEL process is characterised by the utilisation of renewable organic material for thermal treatment. Specifically, it enables the conversion of biowaste – which is an obstacle to incineration – into a component of RDF. In many countries, MSW is still sent to landfill and thus pollutes the environment. The production of RDF from household and commercial waste normally only aims to mechanically separate the high-calorific fraction from the organic fraction by means of size reduction and separation. In the end, RDF is produced for industrial use, but often not with the desired residual moisture. The amounts of fines to be landfilled from the conventional process are significantly larger and still pollute the environment. Biological drying using the CONVAERO system means that the organic material itself contributes to a significant increase in fuel quantity and quality.

The CONVAERO system

The Eggersmann FUEL is made possible by biological drying in lanes using a CONVAERO membrane and BACKHUS CON turner. Since 2020, a BACKHUS CON 100 in Sulaymaniyah has been regularly turning 24 rows with a total capacity of 57,200 m3 of waste – with the expansion, a further 10,400 m3 will be added. While driving over the lanes, the 10 m wide rotor of the BACKHUS CON 100 mixes the material, ensuring an even drying process and an ideal distribution of the microorganisms. It winds up the CONVAERO membrane on the front of the lane and unwinds another behind it at the same time. As a result, the lane is virtually completely sealed, which significantly reduces emissions. The CONVAERO membrane is semi-permeable: rain is repelled while water can escape through evaporation. Odours are also retained. The lane itself has a ventilation system that further accelerates the process. It does not require any external heat supply and works solely with the natural warmth of the composting process. Within approx. 20 days, the water content can be reduced from around ~57% to ~20%. At the same time, an increase in calorific value from approx. 2,800 kJ/kg (670 kcal/kg) to over 14,000 kJ/kg (3350 kcal/kg) can be measured. After drying, the material can also be mechanically processed more efficiently: The carryover rate is reduced. By integrating the biomass into the fuel itself, the amount to be landfilled is significantly reduced and methane emissions at the landfill site are prevented.

A success story

Ecocem Environomental Solution Ltd. is part of the Faruk Investment Group (FIG) based in Sulaymaniyah. The group of companies has a broad base and is active in the construction industry as well as in other areas such as telecommunications, engineering industries and healthcare. It also produces cement for the region via the Gasin & Tasluja Cement Companies. Ecocem is therefore both a public waste disposal company and a fuel supplier for the cement works. The production of cement clinker in particular requires a constant supply of large quantities of fossil heavy fuel oil. However, the Faruk Group states that they were able to replace ~30% of the costintensive fuel by the much more favourable RDF. At the same time, the remaining landfill mass was reduced by 80 % thanks to the Eggersmann FUEL process. "The greatest possible substitution of conventional fuel and the greatest possible landfill reduction – these were the two goals that the Faruk Group wanted to achieve with our Eggersmann FUEL. We definitely achieved them both."

An important signal

The expansion in Sulaymaniyah is seen as a valuable signal at Eggersmann: "The planned expansion proves once again that such projects can be implemented economically anywhere in the world," explains Jan Gressmann from the Biological Waste Treatment Systems business unit at Eggersmann. He cannot understand why some Western countries still practice untreated landfilling of waste: "If the FARUK Group can successfully establish our process in Iraq, which has been weakened by war and the IS, then this should certainly not be a problem in North America, for example. Our process reduces production costs and makes a significant contribution to climate protection."