PMT-Zyklontechnik GmbH 1 Alternative fuel

ALTERNNATIVE FUELS IN THE

CEMENT-INDUSTRY

DI FRIEDRICH WILLITSCH
DR. GERNOT STURM
PMT-ZYKLONTECHNIK GMBH
KREMS, AUSTRIA

PROF. FRIEDRICH WURST

PROF. THEODOR PREY
UNIVERSITY OF VIENNA
PMT-Zyklontechnik GmbH 2 Alternative fuel

INDEX OF CONTENTS -
ALTERNATIVE FUELS IN THE CEMENT INDUSTRY
1 INTRODUCTION................................................................................................... 3

2 IMPORTANT FUELS IN THE CEMENT INDUSTRY ............................................ 5

3 PREPARATION AND CONDITIONING OF ALTERNATIVE FUELS ................... 7

3.1 WPP-OPERATION ................................................................................................. 8

3.2 TPP-OPERATION .................................................................................................. 8
3.3 PPP-OPERATION .................................................................................................. 9
3.4 MTP-OPERATION ............................................................................................... 10

4 STORAGE, DOSING AND FEEDING OF FUELS .............................................. 11

4.1 STORAGE ........................................................................................................... 11

4.2 DOSING AND FEEDING ......................................................................................... 12

5 BURNER CONCEPTION AND COMBUSTION.................................................. 15

6 CONTROL AND ANALYZING ............................................................................ 15

6 CONTROL AND ANALYZING............................................................................ 16

6.1 INITIAL CONTROL ................................................................................................ 16

6.2 INTERMEDIATE CONTROL ..................................................................................... 17
6.3 OVERVIEW OF ANALYZING AND LABORATORY APPARATUSES FOR QUALITY CONTROL
OF ALTERNATIVE FUELS:............................................................................................. 17

7 INFLUENCE ON EMISSION............................................................................... 20

7.1 EMISSION OF BALANCE COMPLIANT ELEMENTS ...................................................... 20

7.2 EMISSION OF NON NON BALANCED TRACE ELEMENTS – ORGANIC COMPOUNDS ........ 21

8 INFLUENCE OF ALTERNATIVE FUEL IN CLINKER PRODUCTION ............... 23

8.1 GENERAL ........................................................................................................... 23

8.2 LOW VOLATILE METALS ...................................................................................... 23
8.3 SEMI- LOW VOLATILE METHOD ............................................................................ 24
8.4 HIGH VOLATILE METALS ..................................................................................... 24
PMT-Zyklontechnik GmbH 3 Alternative fuel

ALTERNATIVE FUELS IN THE CEMENT INDUSTRY

1 INTRODUCTION
The production of Portland cement requires a high degree of thermal energy. Burning
of 1kg PZ-Clinker out of raw material components limestone and clay requires 1,75
MJ thermal energy in basic calculation.
This requirement is based on endothermal reactions of Decarbonisation of limestone
and dehydration of the Kaolinits (a value of approx. 2,20 MJ/kg) and exothermal
reaction of phase forming (C35, C23, C3A and C4AF (value approx. –0,45 MJ/kg).
The effective requirement of thermal energy is approx. 3.2-6 MJ/kg depending on the
process.

The dry-process value is split to approx. 50% for chemical reaction and approx. 50%
in radiation loss (approx. 10-12%) exhaust air (about 10%) exhaust gas (up to 20%)
and clinker (approx. 2%).

The heat recuperation is from the exhaust air through the drying of raw material,
coke, blast furnace slag, etc. The combustion efficiency can achieve 80%.

For production of serviceable PZ-Clinker, fuel has to be put in oxidizing atmosphere

to approx. 1450° C (sintering). Therefore a minimum temperature of some 1800°C at
3% Oxygen O2 content is required. Practically the exhaust gas temperature should
be at 2000° C .

At a secondary air temperature of lower than 800° C a calorific value of minimum of

13 MJ/kg fuel would be pertinent to the above mentioned case.. To secure a
continuously running operation the calorific value should not undergo the limit of 18
MJ/kg fuel.
At secondary combustion the calorific value could be below 10 MJ/kg.

The standard used fuels in cement industry are gas, furnace oil, miscellaneous coals
and pet-coke. The used raw meal mix can be mixed with ash in addition.
Due to common combustion of high valued fuel (flammability due to volatile
components) with low-valued alternative fuel, the required calorific values can be
PMT-Zyklontechnik GmbH 4 Alternative fuel

achieved. Depending on the type of alternative fuel used, a substitution up to 80%

can be achieved – in some case up to 100%.
Due to the use of alternative fuel in the clinker production the cement industry takes
some important disposal functions at the same high economical stakes.

The claim of waste industry about destroying of detrimental organic substances in

controlled processes as well as the avoidance of detrimental residue (ash, slag) due
to the storage of heavy metal in clinker components in the lowest, most innocuous
concentration will be fully covered.

Emphasizing Advantages by using Alternative Fuels:

1. Reduction of CO2- Emissions (Kyoto-target):

- Dumping of thermal utilizing waste the active greenhouse effect will occur
- By combustion in combustion plant additional CO2 emission occurs.
2. Cost reduction of PZ-Clinker production due to using inexpensive fuel.
3. Preservation of resources – lower use of fossil nonrenewable fuel
4. Reasonable secondary use of material
5. Residue free combustion – due to not existing ash, soil and sewage
6. No significant change of emissions
7. Hazardous substances will be destroyed due to the process – high temperature
level, long gas residue time, alcalic combustion material, counter flow principle
and oxidizing atmosphere
8. High thermal efficiency
9. Fulfillment of substantial dump disposal
10. High yielding ecological balance
PMT-Zyklontechnik GmbH 5 Alternative fuel

2 IMPORTANT FUELS IN THE CEMENT INDUSTRY

Alternative fuels consist mainly 3 components, their parts can occur differently.

- water – as moisture
- organic components
- mineral components – responsible for the ash content

The following schedule shows currently used and most conventional alternative fuels
in European Cement Industry.

Calorific values and significant

impurities of alternative fuels

significant calorific value

material contamination calorific value (MJ/kg) [kcal/kg]
Pb, Zn, CI according to the water according to the water
residual oil and solvent content to 34 content 8100
CI, Cd, Pb, Zn
contaminated wood and according to the according to the humidity according to the
process waste from wood contamination 11 to 18 humidity 2600 to 4300
Tyre, rubber waste Zn, S ca. 25 ca. 6000 to 7000
plastic waste Cc, Cd, Pb, Zn according to the blend to 29 6900
thermal fraction of domestic
waste CI, Cd, Cr, Hg humidity <10% -22 humidity < 10% 5300
Pb, Cd, Hg according to the humidity according to the
sewage sludge to 8 humidity 2000
animal meal Ph, Cl 12 to 16 3100 to 3800

In that schedule the possible contamination is shown by different elements, potential

moisture content and the calorific values.

The properties of the elements at feeding as combustion fuel in the kiln system has to
be evaluated depending on the level of contamination. The question is, which
transfer and in which form and value could that be done?

Typical properties of the elements:

Transfer principal into the Clinker-mineral-elements Aluminum, Silicium,
clinker Low volatile metals Calcium, Iron, Chrome,
sulfur Zinc, Lead, Nickel,
Arsenic,etc., Sulfur of the
Fuel
PMT-Zyklontechnik GmbH 6 Alternative fuel

General transfer into the Volatile metals (as long as Mercury, non incinerated
exhaust air used without additional organics, Sulfur of raw
filter) combustion gases meal
Transfer into filter dust and Semi volatile metals Thallium, Mercury
external circulation via raw (partly),Cadmium (partly)
meal. As long as periodical
release of circulation due
to additional grinding to the
cement
Absorption due to raw meal Halogene, Alkalis Chlorine, Natrium &
in the cooler upper part. Kalium, residuals are
Recuperation in the hot kiln conveyed with the clinker
area. Internal circulation.
Due to implementation of a
By-pass system it is
possible to discharge those
elements for external
disposal.

In some case it is possible to compare some analysis of the used combustion fuel to
the used alternative fuel and raw meal – which has a lot bigger mass flow (raw
meal/fuel = approximately 16:1) – to give a ballpark figure about reaction.
PMT-Zyklontechnik GmbH 7 Alternative fuel

3 PREPARATION AND CONDITIONING OF ALTERNATIVE

FUELS
For operation and combustion process some important criteria have to be deemed for
conditioning.
Production of even PZ-Clinker requires a constant and complete combustion of the
used fuel. The oxidation of C and H runs any quicker if the intimate mix of fuels and
the specific surface is larger - that means to assure- especially in the case of liquid
fuel where the spraying- in has to be as smooth as possible, vs. solid fuels on
intimate mixture with other fuels used at the same time - the biggest possible surface
due to perfect conditioning (low particle size).

Further significant points for the conditioning process especially for consistent
alternative fuels are:

1. even particle distribution

2. as even as high calorific value
3. Free of affecting contents like metals, glass, minerals
4. low moisture

This technical combustion requirements regard special preparation conditions for

consistent alternative fuels, which are given due the different components.
Especially it is to take care about separation of non-burning fuels as metals, glass,
mineral fraction etc.
It is pertinent to check up on organic contamination, because a rottenness process
can occur - potentially in combination with moisture, which can cause a reaction of
bacteria and nucleus. Another criterion for the conditioning plant is the regarded
hygienic and security condition for the operating personnel.
A very important point of the conditioning is the relation between economic efficiency
and reasonable combustion particle size. Frankly, lowering the particle size causes
an increase of
conditioning costs. The most favorable particle size for combustion depends on the
alternative fuel dosing, dosing bulk and scope of application for processing. Either
depending on the mode of operation. It should be determined in common to the
burning technology.
PMT-Zyklontechnik GmbH 8 Alternative fuel

PMT-Zyklontechnik GmbH has come to know how to meet and match the
requirements for conditioning of alternative fuels in cement industry, developed
according to the type of fuel the required technology and equipment. The
conditioning functionality at all operation is running mechanically and under ruled
hygienic conditions .

3.1 WPP-OPERATION
In WPP- operation (Wood-preparation-Process) contaminated wood is separated of
affecting contents and crushed -. depending on the scope of application in clinker
processing in accordance to the particle size (primary- and secondary combustion).
For using at primary conveying, a particle size of 6mm has shown as optimal size for
combustion.

3.2 TPP-OPERATION
The TPP-operation (Tire-Preparation-Process) is designed for crushing of plastic,
tires and plastic-like materials and plastic, as for separation of whole tires and the
gravimetric dosing
of that material to the kiln system too.

Preparation Plant for Tyres

The Process: storage bin for
shredded tyres

The plant provides photosensor

Tyre separation line

following functions: 5 steps

• Intermediate storage and scan conveyor

output storage box
conveying of tyres Metering conveyor
for complete
tyres
balance
dust binder

• Scanning and separation

of non suitable tyres

• Dosing of tyres and rubber Double flap

system with
pieces Pneumatic flaps
Rotary kiln
PMT-Zyklontechnik GmbH 9 Alternative fuel

3.3 PPP-OPERATION
The PPP-operation (Plastic-Preparation-Process)
This processing is to prepare of all types of plastic, textiles, paper, composite
materials, etc. contaminated with metal, glass, and minerals – mechanically fully
separated and prepared to fuel.

Preparation of plastic and substance

Flow sheet – alternative fuel plant
mixture
Pre-crushing

Separation of storage
lighter fraction

Fragmentation
of lighter
fraction

Fine crusching of hard

plastics
dosing and

after feeding to the

burner
before

For the use in primary combustion, the particle size of 10 mm edge length has shown
to be optimal for higher dosing rates
Combustion of bigger sized plastic material performs at entrance into the high
temperature area of the flame a ball-shaped profile instantly, due to the material
structure. (decreasing of surface). The reason is to avoid a too fast burn-off -
jeopardy of burning out at the clinker bed – creating of reducing condition).
The best and most economical solution to produce particles with a size of about
10mm is the use of high speed crushers. Disturbance variables have to be avoided.
Pmt-Zyklontechnik GmbH has developed a special processing for this purpose.
PMT-Zyklontechnik GmbH 10 Alternative fuel

3.4 MTP-OPERATION
The MTP-operation (Mechanical-Thermal-Process)
is a patented process for separation of high energy components (plastic, paper,
textiles, organic material etc.) moisture and highly affecting components as metals,
glass and mineral materials.

Alternative Fuel Preparation

Domestic Waste Preparation

Mechanical Thermical
Preparation

That process provides stable operation with the above mentioned material, additional
some increase of bacteria and nucleus is prevented. Either no emission loss in this
process. The thermal fraction is used in the PPP-process. The process was tested in
order to research and develop all pertinent measuring concerning affecting emission
and vitiation.

This type of process provided fuels containing a calorific value of more than 20 MJ/kg .

Waste Preparation Plant Material Typical analysis of preparated domestic

and Gas Flow waste
Heat Suck off air Domestic
Exhaust air
exchanger waste
Waste heat fresh
Dryer off gas (polluted)
air Average
limiting value taken per 1
Precrushing Element unit (Government) month
Sieve- and As [mg/kg] 15 <2
To central Gas Heated fresh air dryer drum
burner Sb [mg/kg] 20 <2
cleaning
Pb [mg/kg] 500 118
Crushing Cd [mg/kg] 27 3,5
Conveying Cr [mg/kg] 300 226
Separator air + TF
exhaust air Harmful mat. Co [mg/kg] 100 8,7
Special separation Ni [mg/kg] 200 86
separator Fine crushing Hg [mg/kg] 2 0,63
Dosing to TI [mg/kg] 10 0,055
burner of hard TF
Fine V [mg/kg] 100 18,5
Dosing to grinding Sorting
Zn [mg/kg] 1000 700
precalciner Sn [mg/kg] 70 48
Thermal Fract. Humidity [%] 8
storage CL [%] 2 0,85
Glass and inert mat.Fe- Metal NonFe- Problematic Material
Metal HU [J/g] 17.955
PMT-Zyklontechnik GmbH 11 Alternative fuel

4 STORAGE, DOSING AND FEEDING OF FUELS

4.1 STORAGE
The storage condition for alternative fuels depends on the type of materials.
Generally it is to take care on emissions, technical and hygienic demands.
The following examples for storage should be deemed on the conditioning site.
A Initial storage
B Intermediate storage
C Finished product storage

4.1.1 INITIAL STORAGE

A storage can be out- or inside, it depends on the delivered material. Due to logistic
reasons for initial storage the area is commonly set-up directly to the conditioning
plant, but depending on the type of material and preparation.
The material is supplied by truck or by railroad.

Material mix with strong contaminations (substantial biologic content) and high
moisture (up to 40%) is mainly stored in special designed containers due to hygienic
rules and regulations.

Animal meal has to be conditioned in absolutely closed systems. It is supplied in

containers - the material can be conveyed either pneumatically or by mechanical
equipment to the storage.

Liquid and slag alternative fuels (waste oil, solvent and sewage sludge) are stored in
special containers. You have to elaborate special security guide lines (explosion safe,
etc.)

Problems of storage
1. Organic content
- Odour
- Bacteria/ growth of mould
- Development of heat
- Solidification
2. Humidity
3. Jamming
4. Voluminously – big storage space
5. Not a nice sight
6. Contamination
PMT-Zyklontechnik GmbH 12 Alternative fuel

4.1.2 INTERMEDIATE STORAGE

Intermediate storage is implemented in the conditioning plant, this is to check the
quality of alternative fuels after preparation process for further processing.

The intermediate storage normally is done by using some separated containers

(depending on the capacity of the conditioning plant), but regarding

1 sufficient space between each conditioning step

2 storage capacity, until the labor results are set.

If the quality check gives negative results the material is hold back for the feeding to
combustion. Depending on the rate of contamination, the manager in charge has to
decide about further use.

4.1.3 FINISHED MATERIAL STORAGE

In the finished material (product) storage, the alternative fuels which are ready for
burning, are stored. To avoid natural influence – such as humidity, moisture, even
rain, etc., the material has to be covered, or to be protected preferably in some
warehouse. The capacity should be calculated according to the combustion capacity
and the planned shut down period.

4.2 DOSING AND FEEDING

Most important points of dosage and
discharge
1. Material mixture and plastic – voluminously (ρ 200kg/m3)
2. Desagglomeration
3. Piping guidance
4. Abrasive material - material choice
5. Dosage accuracy
6. Constant dosage
7. Different density of the separate components - difficult
discharge
8. Loading of the conveying air (kg/Am3 air)
9. Conveying air temperature (animal meal)

The dosing of solid alternative fuels requires materials without property of jamming
content during the feeding and dosing operation. In this case moisture is the
significant role.
PMT-Zyklontechnik GmbH 13 Alternative fuel

Always keep a close look to design and construction of the feeding equipment. At
pneumatic feeding it has to be assured that the conveying air capacity is as low as
possible. (cooling the flame shape, NOx). Furthermore the wiring to the burner is very
important as well as abrasion property of the conveyed materials has to be
controlled.
Where to burn Alternative Fuels in a
Cement Plant
At At
At main
main burner
burner or
or
At kiln
kiln entrance
entrance
Precalciner
Precalciner
• Whole tyres • Contaminated
Tyres and Rubber wood
Wood Preparation
Preparation • Shredded tyres
• Waste wood

Waste Oil • Waste Oil

Preparation • Sewage sludge

Domestic Waste • Domestic

Precalciner Preparation Waste

Main burner
• Industr.
Plastics Plastic Waste
Preparation • Preseparated
Kiln entrance Plastics
riser duct
Animal Meal
• Animal Meal
Conditioning

4.2.1 DOSAGE AND FEEDING OF OLD TIRES AND WOOD

The dosage of tires and contaminated wood is done by weigh-belt feeder with an
exactitude of +- 1% of the determined dosing value - the value is shown on the
terminal of the clinker rotary kiln. Pertinent parameters to control are temperature and
the Carbon-monoxide CO-value of the combustion gas.

The feeding is commonly done with belt conveyors and weigh-belt feeder. The feed
to the kiln entrance happens with double pendulum flaps or special designed
dampers, to avoid fate air into the kiln system.

4.2.2 DOSAGE AND FEEDING OF PLASTIC, PAPER, TEXTILES AND MATERIAL MIX
Plastic, Paper and textiles are conveyed to the main burner either mixed or separated
(primary combustion), or to the secondary combustion.

An Advantage is, that the material is conveyed from an intermediate bin over a
weigh-belt feeder and rotary gate, by using compressed air, to the burner. This
system is simple designed and simple to maintain. At designing you have to be
aware to keep the requirement for compressed air as low as possible.

The operation of combustion is controlled as same by using conventional fuel with

conventional exhaust air components.
PMT-Zyklontechnik GmbH 14 Alternative fuel

Flow sheet – dosing and feeding to the

burner

prereservoir

Metering conveyor
scale

dosing reservoir

Rotary valve

To the burner
fan

4.2.3 DOSAGE AND FEEDING OF ANIMAL MEAL

By using Animal Meal it is absolutely important to use fully closed systems to avoid
emissions and to keep maintenance tasks as low.
As you can see from the image below, the animal meal gives “pressure equality”- that
means that the pressure can be adjusted in the dosing box in proportion to the
feeding pressure. The conveying air is cooled down to 10° C. This system is due to
the possibility to adjust pressure rate low in maintenance.

Flow sheet – dosing and feeding to the

burner

4.2.4 DOSING AND FEEDING OF LIQUID AND SLUDGE-LIKE ALTERNATIVE FUELS

This materials, prepared in the storage tank (e.g. mixed, heated), are conveyed by a
dosing pump to the main burner. Safety guidelines have be insured.
 PMT-Zyklontechnik GmbH 15 Alternative fuel

5 BURNER CONCEPTION AND COMBUSTION

A most modern Multifuel- Burner has to meet specific requirements for controlling the
temperature of the rotary kiln and has to guarantee a maximum of possibilities for
several operating conditions.
Generally the firing has to run trouble-free, has to be operated simply and must be
able to produce good clinker qualities even by using several Alternative Fuels.

This Multifuel- Burner is designed like a conventional burner, but has additional
channels for Alternative Fuel and some other nozzle system.

To incinerate Alternative Fuel as well, the Alternative Fuel has to be spread as well.
Due to the “Pneumo Swirl” the Alternative Fuel comes to rotation, in order to reduce
the burn-out zone.
The Alternative Fuel is provided centrally through a tube to the burner nozzle. The
particles come into rotation due to tangentially aimed air jets – right before leaving
the burner.

The images below show the principle of a most modern Multifuel- Burner.

Secondary fuel
inlet
Primary air
inlet
Flexible swirl setting
device for primary air
Swirl setting
6 device
with scale
(patent no.: 0642645)

Primary air
damper
Outer jacket tube

Flexible swirl
device

Nozzle outstream
system Pneumo swirl effect
for secondary fuel

Primary air
Burner nozzle section view
Coal (Petcoke)
Refractory
Solid waste Primary air
Secondary
fuel
Diesel oil gun
Coal

Waste oil gun Oil gun

(Waste Oil gun)
PMT-Zyklontechnik GmbH 16 Alternative fuel

CONTROL AND ANALYZING

6.1 INITIAL CONTROL
Initial Control of Alternative Fuels is the very first step in using Alternative Fuels in
order to

- achieve and guarantee legal emission limits at burning

- avoid clinker affecting vitiations as for instance Chlorine or Heavy Metals
- maintain preparation costs of Alternative Fuels as economically as well,
even for elimination of non specific material

In order to share an effective Initial Control, first it is pertinent to elaborate Alternative

Fuel specifications. The elaboration of that specification has to be based on internal
and external terms and conditions.

External Guideline:
Enacted regulations from proper authority due to laws and some other regulation.

Internal Guideline:
Guideline for production and Quality Management according to quality management
of clinker or respectively of cement, especially for instance chlorine restriction, or
maybe guidelines by lobby.
That specification is specifically nationwide and can vary.

Tasks of Initial Control:

At receiving of the material on site, random samples are taken to check
homogenization of material.
Mode and method of control as well as the number of random samples, the bulk in
total to be analyzed, depend on the kind of fuel.
Those controls are generally to be committed and ruled with the proper authority
mutually.

Type of Control System:

visual testing - based on the operators level of experience

chemical analysis
physical condition analysis
PMT-Zyklontechnik GmbH 17 Alternative fuel

The samples are provided to the internal laboratory, while samples are held back for
processing.
If the analysis show all criteria will be fulfilled, the held-back samples are forwarded
to the bulk storage – either spaciously or by allocation.

If all criteria will not be fulfilled, all material will go back to the supplier who has to
take all expenses for hauling.

6.2 INTERMEDIATE CONTROL

The finally prepared material as Alternative Fuel is provided to an intermediate
transfer storage, where all is checked for approval – itemized every 30 ton.
In the laboratory quality criteria are checked and approved for further use as
Alternative Fuel.
In case of diverting results depending on impurity the person in charge has to take
decision about further forwarding – either external waste or new preparation.

6.3 OVERVIEW OF ANALYZING AND LABORATORY APPARATUSES

FOR QUALITY CONTROL OF ALTERNATIVE FUELS:

The checkup of the Alternative Fuel properties within the scope of Quality Control
Criteria you find beside some physical parameters, such as moisture content, calorific
value and granulometric distribution and some other connoting elements approved by
cement industry.
In order to fit all requests as well, the following equipment is absolutely pertinent:

- Drying closet (105°C) to dry the samples

- Checker or groomed divider (various width of gaps) to create
representative sub-samples.
- Laboratory jaw crusher to prepare the finished material starting at 1 µm up
to 10 µm maximum sized granules
- Vibratory disc mill for sample grinding to the degree of fineness of analysis
- Ultra-centrifugal ball mill: to crush all organic material as plastic, animal
meal, wood (freeze grinding process)
- Apparatus for sampling of flue-gas, for sampling of clean gas to evaluate
the chlorine and fluorine content in clinker- rotay kiln waste gas
PMT-Zyklontechnik GmbH 18 Alternative fuel

Exploration Method:

- classic and chemical exploration method as Sadoexploration,

nitrohydrochloric acid.
- Device to provide molten pearls, forward samples into a glass-matrix
(Lithiumtetraborate) with X- ray fluorescence analysis
- Molding die to process briquettes out of pulverized material for X- ray
fluorescence analysis
- Microwave- Exploration equipment for hard decomposing material, acidic
decomposition, especially concerning heavy metals and all cations.
- Bomb- Exploration for all volatile anions.

6.3.1 CHEMICAL ANALYSIS METHOD:

- Various drying closets (40 – 250°C) to prepare samples and determine
moisture content
- High output muffle furnace (500 – 1100°C) for incineration of organic
samples and determination of ignition loss
- Analytical balance
- Device for providing clean water to analyze trace elements by the use of
ICP
- Analyzer – mainly to support both – classic and wet-chemical methods
- PH – Ionic meter, pH value, fluorine, chlorine,
- Titroprocessor for chlorine
- Photometric apparatus to determine all methods photometrically, even for
Manganese, Chrome, etc.
- CS – Analyzer for sulphur and carbon (TOC an carbon Dioxide)
- X- Ray Fluorescenic Analyzer for wide spread range of heavy metals, but
so called Light-elements – starting at Hydrogen up to Oxygen. All
elements, especially heavy metals within the range of 10 ppm and below
sub- quantitatively.
- ICP Plasma 400 for most of all cations within a range of trace elements up
to as much as approx. 1 ppm, but Thallium an Tin at limits of detection of
approx. 10 ppm.

6.3.2 PHYSICAL ANALYSIS METHOD:

- Calorific Meter Gauge to determine the gross calorific value and to
calculate the net calorific value automatically.
- Screen and various screen plates to determine particle distribution within
the coarse of feed to screen
PMT-Zyklontechnik GmbH 19 Alternative fuel

Primarily the following parameter of Alternative Fuels have to be analyzed:

- Moisture
- Incineration
- Lower calorific value
- Higher calorific value
- Chlorine
- Heavy metals as: Arsenic, Antimony, Lead, Cadmium, Cobalt, Nickel,
Mercury, Titan, Vanadium, Zinc and Tin
PMT-Zyklontechnik GmbH 20 Alternative fuel

7 INFLUENCE ON EMISSION
Analysis and evaluation off the influence by using Alternative Fuel on emission, on
one hand we have to deem and match with balanced elements, on the other hand to
consider organic trace elements within cleangas, which can result out of non- fully
thermal- oxidizing destruction, caused by charged compounds within the fuel as well
as created organic structures within the down cooling flue gas.

7.1 EMISSION OF BALANCE COMPLIANT ELEMENTS

Wide experience due to numerous measuring analysis have shown that metallic
elements -including arsenic, but Mercury – in its emitting concentration correlates to
the dustload of cleangas, where it comes to importance significantly.
Some direct influence of emitted concentration in flue gas due to Alternative Fuel can
not be verified – except and only Mercury.
The emission value is generally below the enacted emission as that is defined in
legal restraints or respectively defined by law nationwide.
Material- flow has to be considered for charges in secondary fuel as well as the load
via raw meal (by 10 times higher mass flow).

To give evidence to that verification we have to survey the Cadmium element which
is especially evaluated critically due to its volatility.
The charging into the rotarys from 50 – 70% by raw meal and approximately 30 –
50% by Alternative Fuel.

Discharging out of the system is nearly quantitatively to the separated dust (cyclone
dust and precipitator dust), the cleangas emission concentration shows with and
without Alternative Fuel less than 0,0001 mg/Nm³ at a cleangas dust content of less
than 0,2 mg/Nm³.

Thallium, which shows properties to be compared to Cadmium – concerning volatility

in thermal processing, is nearly not contained and therewith it is no emission on
relevant matter.
PMT-Zyklontechnik GmbH 21 Alternative fuel

Mercury in clinker processing is deemed as critical element due to its higher volatility.
Referring to measuring for evaluation and material flow analysis, we can conclude
that the transfer turns into the dust loaded rawgas to nearly 100%, which are split to
precipitator dust and to dedusted cleangas depending on temperature and process –
from 40 – 60%.
A higher given factor for limitation of Hg-charging into the kiln system for this element
at initial controlling, respectively the waste fraction containing higher Hg-content
without additional Hg-separation referring to cleangas, can be expelled from
Alternative Fuel segment.
Precise data of conditioned secondary fuel (high calorific value) shows emission
concentrations from 0,003 and 0,018 mg/Nm³ - corresponding to enacted emission
regulation.

Chlorine content of fuel is to be processed in the hot incineration zone – first to HCl
causes with alkalis an inner concentrating circle, which can be released partly due to
By-pass discharge.
The input value of Alternative Fuel gets some more important, regarding Chlorine
and the accumulation of chlorine in the precipitator dust can be measured.
Due to alkali atmosphere and processing parameters it is not very likely getting HCl
released to higher concentration in cleangas.
Emission concentration in bag precipitator dedusting is around 4mg HCL/Nm³, but
parts of that content of Chlorine occurs as Ammonium- or Alkalichloride.

7.2 EMISSION OF NON NON BALANCED TRACE ELEMENTS –

ORGANIC COMPOUNDS

Due to environment and emission especially chlorine organic compounds (such as

polychloride Dibenzodioxine and Dibenzofuranes,PCDD/F) as aromatic and
accordingly polyaromatic Hydocarbon (BTEX an PAH). That groups represent
basically and essentially products of reactions of organic residuals within cooled off
fluegas and especially at primary use of Alternative Fuel not to be seen as residuals
of thermal-oxidative non fully destroyed impurities contained in fuel.
PMT-Zyklontechnik GmbH 22 Alternative fuel

For formation of chlorine organic compounds while fluegas cooling off in clinker
process, the existing condition is pretty awkward, therefore it has to be calculated
with low concentration of emission in that substance group without doing some
specific extra lowering process.
That has been evaluated in numerous and voluminous test series with Alternative
Fuel.

The emission concentration of PCDD/F are not affected between 0,003 and 0,006
ngTE/Nm³ and in this case significantly lower than the limit of 0,1 ng TE/Nm³.
Due to exact analysis, analog assertions can be done also for polychloride Biphenyle
(PCB), Polycicle aromatic hydrocarbon (PAH) and some others.

Therewith the numerous doubt is disproved that substitution of regular fuel by

Alternative Fuel in primary use, especially organic emission compounds, leads to
significant overrun of limits.
PMT-Zyklontechnik GmbH 23 Alternative fuel

8 INFLUENCE OF ALTERNATIVE FUEL IN CLINKER

PRODUCTION
8.1 GENERAL
Alternative Fuels such as Plastic fraction potentially can contain minor traces of
metal.
As shown in the figure below all potential value of major impurities of Alternative Fuel
compared to standard fuels in Cement Industry.

Content of heavy metals and chlorine

from typical fuels

Content given in
mg/kg if not prepared
specifically Polnish domestic
mentioned hard coal German hard coal petrol coke plastic animal meal waste oil waste - MTA
normal average
Cd 0,005 0,15 1 0,005 2 to 8 8 13 3,3
Cl 600 25 12800 2100 to 7240 8.400 1,23
Cr 6,5 1 9 7,6
Hg 0 0,15 0,4 0,2 0,3 2 0,15
Tl 0,2 0,2
Zn 13,9 35 10 to 200 5 114 to 177 124 3.000 378

As shown in the chart above, the major impurities are mainly consisting of Heavy
Metal and Chlorine.
The influence in clinker production due to that major impurities is shown as follows:

8.2 LOW VOLATILE METALS

That include metals as chrome, copper, zinc, tin, lead, nickel, arsenic, antimony,
vanadium and titan.
That metals are sintered into the clinker where the embedding mainly is based upon
molecular level as for instance in calcium silicate and the calcium silicate is replaced
by a lead atom. That heavy metal traces which can be integrated in the clinker, are all
in all at very low value, so there will not be some change in clinker mineralogy
significantly.

Austria done tests and probes have shown in field tests for clinker properties with as
much as 40% Alternative Fuel (thermal fractions of industrial waste) before and while
feeding Alternative Fuel.
PMT-Zyklontechnik GmbH 24 Alternative fuel

Contents of Oxide and phases in clinker do not show substantial change as shown in
the chart.

40% fuels substitution through thermical

fraction from waste
Influences on the clinker
Content
Content on
on oxides
oxides and
and phases
phases in
in [mass-%]
[mass-%]

without plastic with plastic

66,25 66,42
70
59,1556,24
60
50
[mass %]

40
30
21,81 21,85 20,25
17,91
20
5,47 8,78 9,6 8,54 8,83
10 5,11
2,81 2,91 1,67 1,82 1,6 1,75
0
SiO2 Al2O3 Fe2O3 CaO MgO C3S C2S C3A C4AF CaO-
free

8.3 SEMI- LOW VOLATILE METHOD

Counting among such metals as: Thallium, Bismut, in several case Mercury and
Cadmium.
That metals occur in the phase of gas, thereof only lowest quantities of that metal can
be integrated in clinker, but condense (precipitate) at lower temperature in waste gas
and are nearly separated completely in the dust filter. In that case it is substantial to
assure not to proceed the filter dust on the whole to raw meal in order to avoid circles
of concentration.
To damp the circle, the filter dust is conveyed to the cement grinding, where metals in
cement are integrated, but in innocuous traces.

8.4 HIGH VOLATILE METALS

Alkalis react like halogen and occur gaseous. Due that case those can hardly getting
integrated into clinker. Alkali- Halogens are absorbed into the raw meal in the cooler
area of the kiln.
Even due this internal circulation some jeopardy of getting improved circles of Alkali
Halogens.
By implementation of a By-pass system exactly these elements can be discharged
and provided to some external dump.
PMT-Zyklontechnik GmbH 25 Alternative fuel

Closing this file we conclude that the use of Alternative Fuel will give no lack in
clinker mineralogy, but as known, up to now there are no affluent field test results.