WASTE FUELS COMBINED WITH FOSSIL FUELS
At the factory in Hinge, Denmark, liquid waste fuels from the pharmaceutical industry, mainly Novo Nordisk, are used in addition to coal. The liquid fuels primarily consist of water and solvents.
"We are planning on replacing the remaining coal with waste wood products, which are much better for the environment", Jesper Schmidt explains.
Another new invention still in the test stage is to put a plug at the end of the furnaces to prevent false air from entering. This solution should increase productivity without increasing energy consumption - thus reduce energy consumption per produced m3 of Leca.
Note: Leca UK has lightweight expanded clay aggregate imported from a range of factories including Denmark, Norway and Portugal and each factory is responsible for their own green credentials. Each factory has its own method of production depending on the use of the material.
Because the Kilns in the Leca factories run more or less all-year-round, the heat from the Kilns can be delivered to district heating systems to nearby cities all year, if the cities are within a certain radius of the factory. "In this way, Leca can become a supplier of two instead of one product" Jesper Schmidt says.
LECA LWA – PLASTIC CLAY AND COMMODITY REPLACEMENT
The production of Leca Lightweight Expanded Clay Aggregate usually takes place locally in the countries where the product is sold. In Denmark, the factory is located in Hinge, outside of Randers, where the clay deposits are optimal.
The factory has produced lightweight aggregates since 1953 and is good for approx. 500,000m3 - 600,000 m3 a year,equivalent to more than 180 billion lightweight aggregate clay pellets. The clay that is used to manufacture the aggregates is called plastic clay, and 1m3 of this can easily become 5m3 Leca® lightweight aggregate, when adding the right replacement products to the mixture.