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Jun 03, 2018

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    INTRODUCTION

    The aim of this document is to answer some of the

    basic questions relating to the potential use of

    Solid Recovered Fuel (SRF) in the Indian

    Cement Industry.

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    WHAT IS SRF?

    SRF is the name that is given to an alternative fuel thatis widely used in the European Cement Industry and

    stands for Solid Recovered Fuel. SRF is a wastederived fuel which is made using household residualand commercial waste, therefore re-using valuablematerials that would otherwise have been wasted. Itlooks like shredded paper and consists of paper,

    cardboard, wood, carpet, textiles and plastics. Thematerial has been subject to a treatment process toremove biodegradable matter and produce a solid,clean and non-hazardous fuel. The fuel ismanufactured to a tight specification by specialist

    companies so that it is suitable for use as a fuel incement kilns.

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    WHY IS SRF AN IDEAL FUEL?

    SRF is an ideal fuel for the cement industry as it has similar

    properties to some of the fuels that already used in the

    cement industry. The size of SRF

    normally around 20-30mm flat pieces of plastic or paper means that it burns

    rapidly, releasing the heat into the cement manufacturing

    process where it is needed. Using SRF will save valuable

    fossil fuels such as coal, heavy fuel oil and gas. As the

    components that make up SRF are carefully monitored, inmost cases the variability of parameters such as moisture,

    ash and chloride will be lower than in fossil fuels such as

    coal.

    In addition, as compared to industrial waste, lack of supply isnever an issue given the large quantities of household

    residual and commercial waste generated each day.

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    HOW DOES THE CALORIFIC VALUE (CV) COMPARE TO

    COAL?

    Dependent upon the proportions of materials such as

    paper and plastics, the CV of the SRF can be tailored bythe producer of the SRF to suit the requirements of the

    cement manufacturer. However, a typical SRF would

    have a net CV of between 18 and 20 MJ/tonne. Whilst

    there are many different grades of coal available inIndia, it is understood that a typical CV of coal used in

    the cement industry would be a blend of Indian and

    International coal with a blended CV of around 17

    MJ/tonne. Therefore it can be seen that, in terms of CV,

    SRF could be substituted on a like-for-like basis with

    coal.

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    WHAT ARE THE OTHER PROPERTIES OF SRF?In relation to the cement manufacturing process, the following parameters have been

    reviewed:

    Moisture content SRF contains around 10-15% moisture. Clearly this is higher than in

    pulverised fuel that is used in the cement manufacturing process. If fired in the mainburner in the kiln experience shows that it does not have a major impact as the SRF is

    only a partial replacement of the coal, which is the principal fuel in the burning zone. If

    SRF is used in the calciner almost no impact is observed, as the calciner vessel of the

    pyro-processing line is ideal for lower grade fuels.

    Chloride SRF can contain up to 2% chloride due to the plastics fraction in the fuel;

    however, the SRF is designed to have a chloride content based upon the total chlorideinputs into the pyro-processing system up to a level where build-ups in the process can

    be avoided. More typical levels of chloride in SRF are around 0.5 1%. A chloride balance

    can be performed to identify the maximum level of chloride for a particular SRF addition

    rate. Many manufacturers who are using high levels of chloride have installed volatiles

    by-pass systems to remove chlorides.

    Sulphur SRF contains almost no sulphur and therefore is particularly advantageous in

    plants that have high levels of sulphur in the process as it will reduce the overall sulphurinput into the process.

    Ash SRF contains up to 10% ash, which is not dissimilar to the coal mix that is currently

    being used in Indian cement plants.

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    ARE THERE ANY RESIDUES LEFT OVER WHEN USING

    SRF?

    As with coal, there are no residuesremaining from the use of SRF. All of the

    ash is incorporated into the clinker. SRF

    will be delivered wrapped in plastic bales;this plastic can be recycled locally in

    India.

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    WHAT HAPPENS TO EMISSIONS WHEN USING SRF?

    There should be no change in emissions when

    substituting coal with SRF. The material is finelyshredded and therefore burns rapidly in the

    high temperature of the kiln ensuring complete

    combustion of the material and therefore no

    change in CO or VOCs. The use of SRF shouldhave no effect on NOx as the majority of NOx

    produced in a kiln is thermal NOx. Due to the

    low sulphur in SRF, no change in SO2

    emissions will occur.

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    HOW CAN SRF BE USED?

    SRF is being successfully used in many cementkilns within Europe and can be adapted to many

    different process types. SRF is being used onthe main burner on Lepol and preheater kilnsand both the main burner and in the calciner inprecalciner kilns. When used on the main

    burner in the kilns, it is usually burnt withanother fuel such as coal which supports theuse of the SRF and maintains the flame shape.When used in the calciner it can be used with a

    blend of other alternative fuels or on its own.

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    WHAT KIND OF SYSTEM NEEDS TO BE INSTALLED TO USE SRF?

    When SRF is used on the main burner in the kiln, it is necessary to

    transport the fuel into the kiln via a pneumatic transport system.

    When SRF is used in the calciner, it can be transported into the kiln

    either by a pneumatic transport system or a mechanical transportsystem.

    Firing SRF mid-kiln, using a technology called MIFLEX, is the better

    solution for long dry and wet kilns. It has the added advantage to be

    able to co-fire other bulk fuels like tires simultaneously.

    The right solution, including the investment costs, will depend on the

    existing process parameters, feed rates, plant lay-out etc.

    No system is particularly complicated, with the most important item in

    the system being the volume control, so that the fuel can be metered

    in at the correct weight. The systems are independent of the coalsystem i.e. the SRF is not mixed with the coal prior to injection into

    the kiln or calciner.

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    WHY SHIP SRF FROM THE UK TO INDIA?

    SRF is being produced in the UK for use in cement kilns and

    there is a surplus of material. Due to the cost structure of

    disposing of these materials in the UK, the fuel can be

    produced at extremely low cost and therefore provides a

    suitable alternative fuel for the cement manufacturing

    process. From the Indian perspective, there is a shortage of

    coal for the production of both power and cement which

    means that expensive international coal needs to beimported into the country.

    Therefore SRF represents a real opportunity for the cement

    industry. Whilst the materials that make up SRF are available

    in India, they are potentially more valuable to be recycled/re-

    used elsewhere rather than used as a fuel for cement kilns.

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    WHERE ELSE IS SRF BEING USED?

    SRF is being extensively used throughout the United

    Kingdom and Europe as a substitute fuel in cementkilns. SRF is widely transported between countries in

    Europe where there is a surplus of material in one

    country and a demand in another. All of the major

    international companies such as Lafarge, Holcim,CEMEX, Italcementi and Heidelberg are using SRF in

    Europe and SRF is taking over from other alternative

    fuels such as tyre chips.

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    WHAT ABOUT CO2 EMISSIONS AND CARBON CREDITS?

    The use of alternative fuels in the cement industry savesfossil fuels that would have otherwise been burnt. WithinEurope, alternative fuels that have a biomass content

    will have a proportion of their CO2 emissions classed ascarbon neutral when annual CO2 emissions arecalculated. SRF contains around 50% biomass andtherefore only 50% of the CO2 emissions from this fuelwould be counted in an emissions trading scheme.

    Outside of Europe, alternative fuels projects whichdemonstrate a reduction in CO2 through the use ofbiomass may fall under the Clean DevelopmentMechanism (CDM) of the UNFCCC. Under this scheme,carbon credits (which could be sold on the open market)would be obtained upon implementation of the

    alternative fuels scheme. This scheme would have to bereviewed on a case by case basis.

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    SRF APPLICATIONS

    Used for energy recovery and it is generallyused for the following thermal conversion

    processes:

    Co-combustion in coal fired boilers

    Co-incineration in cement kilns

    Co-gasification with coal or biomass.

    http://www.betalabservices.com/renewable-carbon/municipal-solid-waste.htmlhttp://www.betalabservices.com/renewable-carbon/municipal-solid-waste.html
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    THANK YOU FOR YOUR TIME!