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INCREASING the USE of ALTERNATIVE FUELS at CEMENT PLANTS: INTERNATIONAL BEST PRACTICE © 2017 International Finance Corporation All Rights Reserved

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INCREASING the USE of ALTERNATIVE FUELS at CEMENT PLANTS: INTERNATIONAL BEST PRACTICE © 2017 International Finance Corporation All Rights Reserved INCREASING THE USE OF ALTERNATIVE FUELS AT CEMENT PLANTS: INTERNATIONAL BEST PRACTICE © 2017 International Finance Corporation All rights reserved. 2121 Pennsylvania Avenue, N.W. Washington, D.C. 20433 ifc.org The material in this work is copyrighted. Copying and/or transmitting portions or all of this work without permission may be a violation of applicable law. IFC does not guarantee the accuracy, reliability or completeness of the content included in this work, or for the conclusions or judgments described herein, and accepts no responsibility or liability for any omissions or errors (including, without limitation, typographical errors and technical errors) in the content whatsoever or for reliance thereon. Cover Image: Sofies AS TABLE OF CONTENTS ABBREVIATIONS ........................................................................vi ACKNOWLEDGMENTS .................................................................. vii ABSTRACT ............................................................................ vii FOREWORD ..........................................................................viii 1 OVERVIEW OF THE USE OF ALTERNATIVE FUELS IN THE CEMENT INDUSTRY ..................... 1 1.1 Worldwide Use of Alternative Fuels in the Cement Industry ......................................... 1 1.2 Fuel Preparation ....................................................................... 2 1.2.1 Hazardous Waste .................................................................. 2 1.2.2 Non-hazardous Industrial and Commercial Wastes ........................................... 6 1.2.3 Municipal Waste .................................................................. 7 1.2.4 Biomass ........................................................................ 8 1.2.5 Other Unclassified Alternative Fuels .................................................... 11 1.3 Review of Pretreatment Technologies ........................................................ 12 1.3.1 Mixing in Liquid Phase ............................................................. 13 1.3.2 Mechanical Treatment ............................................................. 17 1.3.3 Bio-mechanical Treatment ........................................................... 20 1.3.4 Other Pretreatment Techniques ....................................................... 21 2 COMPREHENSIVE INFORMATION BY ALTERNATIVE FUEL TYPE ............................... 24 2.1 Hazardous Spent Solvents ............................................................... 24 2.2 Waste Oil and Industrial Oil .............................................................. 25 2.3 Wastewater .......................................................................... 26 2.4 Used Tires and Rubber Waste ............................................................. 27 2.5 Industrial Sludge ...................................................................... 28 2.6 Non-hazardous Industrial Waste ........................................................... 29 2.7 Municipal Solid Waste .................................................................. 31 2.8 Municipal Sewage Sludge ................................................................ 32 2.9 Construction and Demolition Waste ........................................................ 33 2.10 Biomass and Green Wastes .............................................................. 34 2.11 Animal Meal ........................................................................ 35 Increasing the Use of Alternative Fuels at Cement Plants: International Best Practice i 3 KEY SUCCESS FACTORS FOR ALTERNATIVE FUEL PROJECTS .................................. 37 3.1 Success Criteria for Alternative Fuel Projects ................................................... 37 4 FOUR CASE STUDIES OF ALTERNATIVE FUEL USE ........................................... 38 4.1 Municipal Solid Waste .................................................................. 38 4.1.1 Composition of Municipal Solid Waste .................................................. 38 4.1.2 Quality of Refuse-derived Fuel ........................................................ 39 4.1.3 Preparation of Municipal Solid Waste ................................................... 39 4.1.4 Business Models .................................................................. 42 4.1.5 Conditions for an Alternative Fuel Project Using Municipal Solid Waste ........................... 43 4.2 Sewage Sludge ....................................................................... 44 4.2.1 Description of Municipal Sewage Sludge ................................................. 44 4.2.2 Positioning of Cement Plants in the Municipal Sewage Sludge Segment ............................ 44 4.2.3 Quality of Municipal Sewage Sludge .................................................... 45 4.2.4 Preparation of Municipal Sewage Sludge ................................................. 45 4.2.5 Business Models .................................................................. 46 4.2.6 Extension to Industrial Sludge ........................................................ 46 4.3 Biomass ............................................................................ 47 4.3.1 Description of Biomass Waste ........................................................ 47 4.3.2 Positioning of Cement Plants in Biomass Source Collection .................................... 47 4.3.3 Quality of Biomass Alternative Fuels ................................................... 48 4.3.4 Preparation of Biomass Alternative Fuels ................................................. 49 4.3.5 Technical Considerations for Biomass Integration in the Cement Process ........................... 49 4.3.6 Main Steps to Implement a Pilot Project Based on Biomass Sources ............................... 49 4.4 Industrial Waste ...................................................................... 49 4.4.1 Non-hazardous Industrial Waste ...................................................... 50 4.4.2 Blending of Hazardous Industrial Waste ................................................. 53 APPENDIX 1: DETAILED INFORMATION BY ALTERNATIVE FUEL TYPE ............................. 56 APPENDIX 2: USE OF ALTERNATIVE FUELS IN CEMENT PRODUCTION: THE CASE OF POLAND ........ 77 ii Increasing the Use of Alternative Fuels at Cement Plants: International Best Practice LIST OF TABLES Table 1: Alternative Fuel Substitution Rates in Selected Countries and Regions ............................... 1 Table 2: Shares of Different Types of Waste Used as Alternative Fuels by Large International Cement Groups .................................................... 3 Table 3: Type of Municipal Sewage Plant Affects Quality ............................................. 45 Table 4: Quality Characteristics of Selected Biomass ................................................ 49 Increasing the Use of Alternative Fuels at Cement Plants: International Best Practice iii LIST OF FIGURES Figure 1: Breakdown of Alternative Fuels and Main Fuel Types in the EU-28 ................................ 3 Figure 2: Solvent Storage in Austria and Storage and Recirculation Pumps in the United States .................... 4 Figure 3: Oil Lagoons in the United Arab Emirates .................................................. 5 Figure 4: Storage and Injection Facility for Solid Wastes in Mexico ....................................... 7 Figure 5: Jumbo Trucks Used in the Cement Industry in the Philippines .................................... 9 Figure 6: Storage of Rice Husks for Off-season Use .................................................. 9 Figure 7: Decommissioned Seeds .............................................................. 10 Figure 8: Wood from Rubber Trees in Africa ..................................................... 10 Figure 9: Reception and Storage of Animal Meal in France and Japan .................................... 11 Figure 10: Wood Waste Sorting Table in New England and Grinding Unit in Singapore ........................ 12 Figure 11: Examples of Manufactured Items Based on Used Tires ....................................... 13 Figure 12: Solvent Mixing in Storage Tanks in France ............................................... 13 Figure 13: Pretreatment in Liquid Phase in the United States .......................................... 14 Figure 14: Pretreatment Line in Spain, with Milling at the Top of the Process ............................... 15 Figure 15: Physical-chemical Pretreatment Unit Scori at the Leuna Refinery in Germany ....................... 16 Figure 16: Schematic of the Fabrication Process, Mixing Tower in Belgium, and Closed-circuit Production Unit in Norway ............................................ 17 Figure 17: Example of Typical Solid Waste Before Pretreatment, in Austria ................................ 18 Figure 18: Examples of a Primary Mill and Cutting Table ............................................ 20 Figure 19: Manual Sorting Table, Trammel, and Air Separator ......................................... 20 Figure 20: Secondary Shredding Mill in Austria and Mexico ........................................... 20 Figure 21: Schematic Showing the Bio-mechanical Treatment Process on a Landfill Site ........................ 20 Figure 22: Classical Bio-mechanical Treatment Unit ................................................ 21 iv Increasing the Use of Alternative Fuels at Cement Plants: International Best Practice Figure 23: Schematic of the AK System Process ...................................................
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