Alternative fuels solutions for cement production processes
Alternative fuels and co-processing solutions with fast ROI
Adopting alternative fuel co-processing in cement plant operations provides several important advantages, such as reducing energy costs and fossil fuels consumption
In some regions, it contributes to mitigating local waste management challenges by reducing the amount of household waste that otherwise needs to be disposed of in the community. Here, local authorities often offer subsidies for waste processing, bringing added economic benefits to the cement plant operations.
With cement production processes consuming such a large amount of energy, the opportunity is clear for cement plant operators to introduce alternative fuels co-processing to their combustion and production processes.
What is co-processing?
Co-processing in cement production operations refers to the use of alternative fuels in both combustion and production processes. In terms of combustion, it involves substituting primary fuels, such as coal, petroleum and gas, with waste. This typically consists of combustible municipal waste or refuse-derived fuels (RDF), biomass, and non-hazardous industrial and commercial waste.
The second element of co-processing involves substituting part of the natural raw materials used in the production process with ash residue from the combustion process.
Achieving an attractive return on your investments in alternative fuels co-processing requires comprehensive planning. It is important you work with an experienced partner who understands the processes and technologies required to create a viable solution for your operations.
There are many factors to consider when planning for alternative fuels co-processing. Before it can be used as an energy source, for example, the materials comprising your alternative fuels require homogenisation. Alternative fuels are often received from different suppliers, which means the characteristics change from charge to charge. Factors such as humidity and density also affect the process.
For alternative fuels, we can help with everything from consultancy and upgrades to helping you design an entirely new plant with the latest co-processing technology, systems and infrastructure.
We offer advisory services to determine your plant’s pyroprocessing capabilities and assess the process impact. Here, we evaluate aspects such as quality, chemistry, corrosion and emissions, and we help you plan fuel preparation and handling prior to delivery at the plant.
Our structured approach is designed to help you efficiently implement a scalable, sustainable and fully compliant alternative fuels solution while minimising risks and reducing uncertainty.
Solutions for all alternative fuels demands
Our full range of solutions and technologies cover receiving, handling and storing alternative fuels, as well as systems for combustion and emissions mitigation.
These include the FLSmidth® HOTDISC® combustion device, which is a highly effective technology for substituting calciner fuel with coarse alternative fuels and for feeding waste materials into the kiln system. Another example is the FLSmidth® JETFLEX® burner, which is ideal for smaller solids as well as liquid alternative fuels.