Dirk Lechtenberg Dr. Hansjorg Diller Alternative Fuels and Raw Materials Handbook for the Cement and Lime Industry MVW LECHTENBERG & PARTNER
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Dirk LechtenbergDr. Hansjorg Diller
Alternative Fuelsand Raw Materials
Handbookfor the Cement and Lime Industry
MVWLECHTENBERG & PARTNER
Content
Content
Preface 5
List of Abbreviations 17
List of Chemical Formulae 23
PARTI
Chapter: 1History and overview of alternative raw materials and fuels 271.1 Alternative raw materials 27
1.1.1 Definition 27
1.1.2 History and utilisation of alternative raw materials 28
1.1.3 Types of alternative raw materials 28
1.1.4 Characteristics of alternative raw materials 30
1.1.5 Principles when using alternative raw materials 33
1.1.6 Utilisation of alternative raw materials 34
1.1.7 Transport and storage of alternative raw materials 39
1.1.8 Conditioning and dosing of alternative raw materials 39
1.1.9 Quality assurance 41
1.1.10 Outlook 44
1.2 Alternative fuels 45
1.2.1 Definition 45
1.2.2 History of alternative fuels 46
1.2.3 Types of alternative fuels 50
1.2.4 Waste as raw material for alternative fuels 52
1.2.5 Identification of wastes 53
Chapter: 2Waste evaluation 632.1 Defining waste generating sectors 65
2.2 Collecting the required information 66
2.3 Quantification and characterisation of the mixed waste 67
Content
2.4 Quantification of waste from generators 70
2.5 Fuel-technical properties 72
2.6 Basic principles for the use of alternative fuels 73
Chapter: 3Key issues for investments in RDF production technologies andalternative fuel usage 773.1 Basic economic considerations 77
3.2 Criteria influencing the production of waste-derived fuels 80
Chapter: 4Production of RDF : 834.1 Separation technologies - impurities 85
4.2 Screening technology 86
4.2.1 Drum screens/trommel 86
4.2.2 Ballistic separation 90
4.2.3 Oscillating or vibrating screen 91
4.3 Air classification 93
4.4 Hard/rigid material classifier 95
4.5 Manual separation/hand picking 97
4.6 Optical sorting systems 98
4.7 Metal separation 100
4.7.1 Separation of ferrous materials 100
4.7.2 Non-ferrous separation 101
4.8 Shredding 103
4.8.1 Pre-shredding 103
4.8.2 Final shredding 107
4.9 Pelletising 113
4.10 Drying technologies 117
4.10.1 Solar drying 118
4.10.2 Belt dryers 120
4.10.3 Drum dryers 122
4.10.4 Notes on dryer systems 124
4.11 Examples of RDF production plants 125
4.12 Economic evaluation of RDF production plants 129
Chapter: 5Quality management for alternative fuels 1335.1 Environmentally relevant elements 133
5.2 Contaminant sources in alternative fuels 134
5.3 Investigation of alternative fuels-declaration analysis 138
Content
5.4 Evaluation of waste and alternative fuels in an RDF production plant .7: 143
5.5 Evaluation of AF in the cement/lime plant-sampling 147
5.6 Sample preparation 149
5.7 Analysis of alternative fuels 152
5.7.1 Preliminary notes 152
5.7.2 Moisture 154
5.7.3 Volatiles and ash 156
5.7.4 Calorific value 156
5.7.5 Chlorine 159
5.7.6 Sulphur 160
5.7.7 Trace elements 161
5.8 Monitoring and reporting 163
Chapter: 6Logistics and storage of RDF 1656.1 Basic principles 165
6.2 Transport, loading of alternative fuels 165
6.3 Truck reception 169
6.4 Reception systems for bulk solid materials 175
6.5 Storage of alternative fuels 176
6.5.1 Basic requirements 176
6.5.2 Homogenisation 177
6.5.3 Special section: Fire protection 178
6.5.4 Fire protection evaluation using the example of a storage facility 182
6.5.5 Verification of infrastructural fire protection 191
6.5.6 Explosion protection in secondary fuel storage facilities 194
6.6 Types of storage 195
6.6.1 Storage as bulk material in an enclosed facility 196
6.6.2 Storage in one or several silos 197
6.6.3 Moving floor storage 198
6.6.4 Storage in a deep bunker with discharge systems 200
6.6.5 Storage in a bunker with crane unloading 201
6.6.6 Storage in special storage boxes 203
Chapter: 7Dosing and feeding of alternative fuels 2077.1 Screening 207
7.2 Separation of impurities 212
7.3 Conveying technology 212
7.3.1 Pneumatic conveying 212
7.3.2 Mechanical conveying 217
Content
7.3.3 Pipe conveyors 220
7.4 Weighing 221
7.4.1 Fundamentals 221
7.4.2 Weigh feeders 222
7.4.3 Differential weigh feeders 222
7.4.4 Rotor weigh feeder 223
7.4.5 Screw weigh feeder 224
7.5 Feeding points for alternative fuels 225
7.5.1 Basic considerations 225
7.5.2 Main burner 227
7.5.3 Kiln inlet 236
7.5.4 Dosing of alternative fuels in the calciner 237
Chapter: 8Influences on clinker and lime production 2398.1 Ash composition 239
8.2 Sulphur, chlorine, alkalis 244
8.3 Influence on lime production 250
8.4 Refractories 251
8.5 Grain size of fuels 254
8.6 Environmentally relevant trace elements 256
8.6.1 Influence of trace elements on cement properties - strengthand setting 260
8.6.2 Leaching of trace elements in fresh cement paste and hardenedconcrete 261
8.7 Impact on fan capacities 263
8.7.1 Calculation basics _ 263
8.7.2 Example of a substitution scenario 265
8.8 Specific energy consumption 2668.9 Remarks on quality control of the cement production process when using
alternative fuels 267
8.10 Emissions 269
8.11 CO2 reduction with alternative fuels 273
8.11.1 Basics 273
8.11.2 Biomass content and emission factors of alternative fuels 274
8.11.3 Determination of biogenic content - mass balance 275
8.11.4 Determination of biogenic content - manual sorting, selective dissolution,14C method 276
8.11.5 Fossil CO2 savings in the cement and lime industry 277
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Content
Chapter: 9Contracting alternative fuels 2879.1 Structure for waste sourcing and AFR units 287
9.2 Price evaluation and contracting 289
9.3 Contract structure 291
9.4 Bonus/malus regulations 291
Chapter: 10Emission limits and permitting issues 29310.1 Monitoring of emissions 295
10.2 Monitoring of safe combustion 296
10.3 Permitting issues 298
10.4 Applying for a permit 298
10.5 Trial permit-organisation of trials 302
10.6 Public discussions - stakeholders 305
Chapter: 11Current developments of the use of alternative fuels 30911.1 Oxy-fuel technology 309
11.2 Ultra fine milling of alternative fuels 312
11.3 Thermal technologies 314
11.4 Pyrolysis of high-calorific residues 318
11.4.1 Fundamentals of pyrolysis technology 318
11.4.2 Applications 319
11.4.3 Hydrothermal carbonisation 321
Annex IQuestionnaire for data collection landfill site 3231. General information on landfill site 323
2. General information on the current situation 324
3. Waste input 326
Annex IIQuality management - Examples of excerpts of process instructionsfor the processing plant 327
Annex II aProcess instructions for the processing plant 328
Annex II bWork instructions for sampling waste input and RDF 338
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Content
Annex II cOperational procedures for maintenance and repairs 343
Annex II dSpecification for the acceptance of municipal mixed wastes (MMW) 346
Annex II eCompany Safety Instructions RDF 349
PART II
Fact Sheet:Alternative fuel and raw material (AFR) review "Olive residues" 3531 Classification according to EWC European Waste Catalogue 353
1.1 AFR description 353
1.2 AFR pictures 354
2 AFR source and composition 354
2.1 Source 354
2.2 Quantity and availability 356
2.3 Flow chart of AFR production 358
2.4 AFR composition 358
2.5 AFR analysis 359
2.6 AFR ash composition 360
3 Harmful substances and hazardous characteristics 361
4 Collection, recycling and disposal of the AFR 361
4.1 Collection and transport 361
4.2 Recycling, current use and disposal 361
4.3 Use as alternative fuel in a cement or lime plant 362
4.3.1 Economic value of the waste in a cement or lime plant 362
4.3.2 AFR pre-processing 363
4.3.3 Storage at the plant site 364
4.3.4 Dosing and feeding systems 364
4.3.5 Quality influence on clinker and lime 365
5 Recommendations 367
6 References 367
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Content
Fact Sheet:Alternative fuel and raw material (AFR) review "Poultry litter" 3691 Classification according to European Waste Catalogue EWC 369
1.1 AFR description 369
1.2 AFR pictures 370
2 AFR source and composition 371
2.1 Source 371
2.2 Quantity and availability 371
2.3 Flow chart of AFR production 373
2.4 AFR composition 374
2.5 AFR analysis 374
2.6 AFR ash composition 375
3 Harmful substances and hazardous characteristics 375
4 Collection, recycling and disposal of the AFR 376
4.1 Collection and transport 376
4.2 Recycling, current use and disposal 377
4.3 Use as alternative fuels in a cement plant 377
4.3.1 Economic value of the waste in a cement plant 377
4.3.2 AFR pre-processing 378
4.3.3 Storage in the plant site 378
4.3.4 Dosing and feeding systems 378
4.3.5 Quality influence on clinker 379
5 Recommendations 379
6 References 379
Fact Sheet:Alternative fuel and raw material (AFR) review "Scrap tyres" 3811 Classification according to European Waste Catalogue EWC 381
1.1 AFR description 381
1.2 AFR pictures 382
2 AFR source and composition 383
2.1 Source 383
2.2 Quantity and availability 383
2.3 Flow chart of AFR production 385
2.4 AFR composition 386
2.5 AFR analysis 387
2.6 Thermal properties 389
3 Harmful substances and hazardous characteristics 389
4 Collection, recycling and disposal of the AFR 390
4.1 Collection and transport 390
Content
4.2 Recycling, current use and disposal 390
4.3 Use as alternative fuels in a cement plant 391
4.3.1 Economic value of the AFR in a cement plant 391
4.3.2 AFR pre-processing 392
4.3.3 Storage at the plant site 392
4.3.4 Dosing and feeding systems 393
4.3.5 Quality influence on clinker 395
5 Recommendations 395
6 References 396
Fact Sheet:Alternative fuel and raw material (AFR) review "Sewage sludge" .... 399
1 Classification according to European Waste catalogue EWC 399
1.1 AFR description 399
1.2 AFR picture 400
2 AFR source and composition 400
2.1 Source 400
2.2 Quantity and availability 402
2.3 Flow chart of AFR production 403
2.4 AFR composition 404
2.5 AFR analysis 405
2.6 AFR ash composition 406
3 Harmful substances and hazardous characteristics 407
4 Collection, recycling and disposal 408
4.1 Collection and transport 408
4.2 Recycling, current use and disposal 409
4.3 Use as alternative fuel in a cement plant 410
4.3.1 Economic value of the AFR in a cement plant 411
4.3.2 AFR pre-processing 412
4.3.3 Storage at the plant site 415
4.3.4 Dosing and feeding systems 416
4.3.5 Quality influence on clinker 417
5 Recommendations 418
6 References 418
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Content
Fact Sheet:Alternative fuel and raw material (AFR) review "Straw" 4231 Classification according to European waste Catalogue EWC 423
1.1 AFR description 423
1.2 AFR pictures 424
2 AFR source and composition 424
2.1 Source 424
2.2 Quantity and availability 425
2.3 Flow chart of AFR production 425
2.4 AFR composition 426
2.5 AFR analysis 427
2.6 AFR ash composition 428
3 Harmful substances and hazardous characteristics 428
4 Collection, recycling and disposal of the AFR 429
4.1 Collection and transport 429
4.2 Recycling, current use and disposal 430
4.3 Use as alternative fuels in a cement plant 431
4.3.1 Economic value of the waste in a cement plant 431
4.3.2 AFR pre-processing 432
4.3.3 Storage at the plant site 432
4.3.4 Dosing and feeding systems 433
4.3.5 Quality influence on clinker 433
5 Recommendations 435
6 References 436
Fact Sheet:Alternative fuel and raw material (AFR) review "Used oils" 4391 Classification according to European Waste Catalogue EWC 439
1.1 AFR description 440
1.2 AFR pictures 440
2 AFR source and composition 441
2.1 Source 441
2.2 Quantity and availability 442
2.3 Flow chart of AFR production 444
2.4 AFR composition 445
2.5 AFR analysis 445
2.6 AFR ash composition 447
3 Harmful substances and hazardous characteristics ; 447
4 Collection, recycling and disposal of the AFR 448
4.1 Collection and transport 448
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Content
4.2 Recycling, current use and disposal 449
4.3 Use as alternative fuels in cement or lime plants 450
4.3.1 Economic value of the AFR in cement or lime plants 451
4.3.2 AFR pre-processing 452
4.3.3 Storage at the plant site 453
4.3.4 Dosing and feeding systems 453
4.3.5 Quality influence on products 4535 Recommendations 454
6 References 455
Clinker Formulae 457
Bibliography 459
Table of Figures 475
Table of Pictures 479
Table of Tables 485
Advertisement Index 489
Index 495
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