scholarly journals Socio-environmental Impacts Associated with Burning Alternative Fuels in Clinker Kilns

2013 ◽  
Vol 3 (4) ◽  
pp. 479-482 ◽  
Author(s):  
F. B. Mainier ◽  
L. P. C. Monteiro ◽  
R. J. Mainier
Keyword(s):  
Environmental Impacts ◽  
Alternative Fuels ◽  
Lower Cost ◽  
Raw Materials ◽  
Agricultural Waste ◽  
Production Costs ◽  
Cement Clinker ◽  
Laboratory Studies ◽  
Environmental Care ◽  
Rotary Kilns

The pollutants found in emissions from cement plants depend on the processes used and the operation of the clinker kilns. Another crucial aspect concerns the characteristics of raw materials and fuels. The intensive use of fuels in rotary kilns of cement plants and the increasing fuel diversification, including fuels derived from coal and oil, from a multitude of industrial waste and from biomass, charcoal and agricultural waste (sugarcane bagasse, rice husk), is increasing the possibilities of combinations or mixtures of different fuels, known as blends. Thus, there are socio-environmental impacts associated with the burning of alternative fuels in clinker kilns. In view of the growing trend of entrepreneurs who want to target the waste produced in their unit and of the owners of the cement plants who want to reduce their production costs by burning a waste with lower cost than conventional fuels, it is necessary to warn that a minimum level of environmental care should be followed regarding these decisions. It is necessary to monitor the points of emission from cement kilns and in the wider area influenced by the plant, in order to improve environmental quality. Laboratory studies of burning vulcanised rubber contaminated with arsenic simulate the burning of used tires in cement clinker kilns producing SO2 and As2O3.

scholarly journals METHODS OF REPEATED USE OF CEMENT DUST

2019 ◽  
Author(s):  
М.Ш. Саламанова ◽  
С.А. Алиев ◽  
Р.С.-А. Муртазаева
Keyword(s):  
Portland Cement ◽  
Raw Materials ◽  
Cement Industry ◽  
Cement Clinker ◽  
Liquid Sodium ◽  
Portland Cement Clinker ◽  
Repeated Use ◽  
Electrostatic Precipitators ◽  
Rotary Kilns ◽  
Technogenic Raw Materials

В процессе обжига портландцементного клинкера в электрофильтрах вращающихся печей скапливается большое количество пыли, как клинкерной, так и аспирационной, поэтому рациональное использование этих продуктов, содержащих определенную долю полноценного сырьевого ресурса, является актуальной задачей индустрии цемента. В данной работе представлены результаты исследований цементной пыли, проведен энергодисперсионный и сравнительный анализ исследуемых порошков, а также приводится возможный способ утилизации цементной пыли для получения бесклинкерных цементов щелочной активации и бетонов на их основе. Разработанные рецептуры бесклинкерных вяжущих с применением отходов цементной промышленности и натриевого жидкостекольного затворителя позволят получать менее затратные, прочные и долговечные композиты, которые позволят частично заменять традиционный бетон на дорогом портландцементе. Работа выполнена в рамках исследований по реализации научного проекта 1848200001 Высококачественные бетоны с повышенными эксплуатационными свойствами на основе местного природного и техногенного сырья , получившего поддержку Российского фонда фундаментальных исследований (РФФИ). In the process of firing Portland cement clinker in electrostatic precipitators, in rotary kilns, a large amount of harmful substances, both clinker and aspiration, accumulates, therefore rational use of these products leads to certain shares of a fullfledged river resource, which are derived from industrial cement. It should be noted that the reuse of dust electrostatic precipitators is impossible. The basis for obtaining durable and more resourceefficient composites is based on modern technological methods that contribute to the improvement of technical and physicomechanical properties, with the integrated application of technogenic raw materials and liquid sodium binder. The developed clinkerfree binder formulations using the cement industry wastes and sodiumbased sludge glass will make it possible to produce less expensive, durable, and durable composites that will partially replace traditional concrete with expensive portland cement.

scholarly journals PRODUCTION AND USE OF BIOENERGY RESOURCES OF THE AGRICULTURAL SECTOR OF UKRAINE ON THE BASIS OF SUSTAINABILITY

2021 ◽  
pp. 80-87
Author(s):  
Svitlana Strapchuk
Keyword(s):  
Biomass Production ◽  
Alternative Energy ◽  
Alternative Fuels ◽  
Agricultural Sector ◽  
Raw Materials ◽  
Agricultural Waste ◽  
Energy Resource ◽  
Clean Energy ◽  
Biodiesel Production ◽  
Bioenergy Crops

The article deals the analysis of production and consumption of bioenergy resources in agriculture. It is established that the assessment of resource potential is carried out with regard to the following energy trilemma: decarbonization, energy security and affordability, which significantly increases the interest in alternative fuels derived from renewable sources. In order to achieve sustainable development in the context of providing businesses with affordable and clean energy, national indicators relevant to the agricultural sector have been developed. Biomass production utilizes both land and human resourse to a greater extent than any other renewable energy technology, and can create sustainable supply chains. It has been proven that the use of biomass improves the supply and access to energy at the local and national levels, but also reduces waste disposal, provides an alternative use of biomass or fossil resources. It is noted that the main products of biomass processing are solid and liquid biofuels, biogas. Ukraine's energy strategy 2035 suggests an increase in the use of biomass in energy generation up to 11,5 %, and the main stimulus for growth is the use of green tariff. Biomass production requires the largest amount of land resources compared to other alternative sources. It limits the use of sown areas for food crops in favor of bioenergy crops. In particular, the raw materials for the production of bioethanol in Ukraine are sugar, starch crops and cellulose materials, which are converted into the final product by alcohol and sugar factories. Biodiesel production is not widespread enough, and more than 95 % of the gross harvest of rapeseed and soybeans used for its production in 2019 was exported. In the structure of solid biofuels, agricultural waste, in particular straw, stalks and husks, has the greatest potential for the use. Thus, biomass is an alternative energy resource that creates significant prospects for sustainable agriculture, but wholesale energy tariffs need to be revised to take into account external factors that consider insurance risks and increased environmental taxation, which is low in Ukraine.

scholarly journals STRUCTURE AND PROPERTIES OF CONNECTING ALKALINE ACTIVATION USING CEMENT DUST

2019 ◽  
Vol 46 (2) ◽  
pp. 148-157
Author(s):  
S. A. Aliev ◽  
R. S.-A. Murtazayevа ◽  
M. Sh. Salamanova
Keyword(s):  
Portland Cement ◽  
Raw Materials ◽  
Physicomechanical Properties ◽  
Cement Industry ◽  
Cement Clinker ◽  
Liquid Sodium ◽  
Electrostatic Precipitators ◽  
Rotary Kilns ◽  
Technogenic Raw Materials ◽  
Technological Methods

Objectives In the process of firing Portland cement clinker in electrostatic precipitators, in rotary kilns, a large amount of harmful substances, both clinker and aspiration, accumulates, therefore rational use of these products leads to certain shares of a full-fledged river resource, which are derived from industrial cement. It should be noted that the reuse of dust electrostatic precipitators is impossible.Method The basis for obtaining durable and more resource-efficient composites is based on modern technological methods that contribute to the improvement of technical and physicomechanical properties, with the integrated application of technogenic raw materials and liquid sodium binder.Result The basis for obtaining durable and more resource-efficient composites is based on modern technological methods that contribute to the improvement of technical and physicomechanical properties, with the integrated application of technogenic raw materials and liquid sodium binder.Conclusion The developed clinker-free binder formulations using the cement industry wastes and sodium-based sludge glass will make it possible to produce less expensive, durable, and durable composites that will partially replace traditional concrete with expensive portland cement. 

scholarly journals Parametric Studies of Cement Production Processes

2020 ◽  
Vol 2020 ◽  
pp. 1-17 ◽  
Author(s):  
John P. John
Keyword(s):  
Energy Consumption ◽  
Alternative Fuels ◽  
Cement Industry ◽  
Production Costs ◽  
Cement Clinker ◽  
Cement Production ◽  
Exhaust Gases ◽  
Industrial Sectors ◽  
Study Results ◽  
Parametric Studies

The cement industry is one of the most intensive energy consumers in the industrial sectors. The energy consumption represents 40% to 60% of production cost. Additionally, the cement industry contributes around 5% to 8% of all man-made CO2 emissions. Physiochemical and thermochemical reactions involved in cement kilns are still not well understood because of their complexity. The reactions have a decisive influence on energy consumption, environmental degradation, and the cost of cement production. There are technical difficulties in achieving direct measurements of critical process variables in kiln systems. Furthermore, process simulation is used for design, development, analysis, and optimization of processes, when experimental tests are difficult to conduct. Moreover, there are several models for the purpose of studying the use of alternative fuels, cement clinker burning process, phase chemistry, and physical parameters. Nonetheless, most of them do not address real inefficiency taking place in the processes, equipment, and the overall system. This paper presents parametric study results of the four-stage preheater dry Rotary Kiln System (RKS) with a planetary cooler. The RKS at the Mbeya Cement Company (MCC) in Tanzania is used as a case study. The study investigated the effects of varying the RKS parameters against system behaviour, process operation, environment, and energy consumptions. Necessary data for the modelling of the RKS at the MCC plant were obtained either by daily operational measurements or laboratory analyses. The steady-state simulation model of the RKS was carried out through the Aspen Plus software. The simulation results were successfully validated using real operating data. Predictions from parametric studies suggest that monitoring and regulating exhaust gases could improve combustion efficiency, which, in turn, leads to conserving fuels and lowering production costs. Composition of exhaust gases also depends both on the type of fuel used and the amount of combustion air. The volume of exit flue gases depends on the amount of combustion air and infiltrating air in the RKS. The results obtained from the study suggest a potential of coal saving at a minimum of about ṁcoal=1263 kg·h−1, which approximates to 76,126 tons per year at the current kiln feed of 58,000 kg·h-1. Thus, this translates to a specific energy saving of about 1849.12 kJ·kgcl-1, with relatively higher clinker throughput. In this vein, process modelling provides effective, safe, and economical ways for assessing the performance of the RKS.

scholarly journals Effect of Selected Alternative Fuels and Raw Materials on the Cement Clinker Quality

2015 ◽  
Vol 10 (2) ◽  
pp. 81-92 ◽  
Author(s):  
Július Strigáč
Keyword(s):  
Sewage Sludge ◽  
Alternative Fuels ◽  
Raw Materials ◽  
Steel Slag ◽  
Raw Material ◽  
Cement Clinker ◽  
Paper Sludge ◽  
Fluidized Bed Combustion ◽  
Suitable Alternative ◽  
Blastfurnace Slag

Abstract The article deals with the study of the effects of alternative fuels and raw materials on the cement clinker quality. The clinker quality was expressed by the content of two principal minerals alite C3S and belite C2S. The additions of alternative fuels ashes and raw materials, in principle, always increased the belite content and conversely reduced the amount of alite. The alternative fuels with high ash content were used such as the meat-bone meal, sewage sludge from sewage treatment plants and paper sludge and the used alternative raw materials were metallurgical slags - granulated blastfurnace slag, air cooled blastfurnace slag and demetallized steel slag, fluidized bed combustion fly ash and waste glass. Meat-bone meal, sewage sludge from sewage treatment plants and paper sludge were evaluated as moderately suitable alternative fuels which can be added in the amounts of 2.8 wt. % addition of meat-bone meals ash, 3.64 wt. % addition of sewage sludge ash and 3.8 wt. % addition of paper sludge ash to the cement raw mixture. Demetallised steel slag is suitable for production of special sulphate resistant cement clinker for CEM I –SR cement with addition up to 5 wt. %. Granulated blastfurnace slag is a suitable alternative raw material with addition 4 wt. %. Air cooled blastfurnace slag is a suitable alternative raw material with addition 4.2 wt. %. Waste glass is not very appropriate alternative raw material with addition only 1.16 wt. %. Fluidized bed combustion fly ash appears not to be equally appropriate alternative raw material for cement clinker burning with less potential utilization in the cement industry and with addition 3.41 wt. %, which forms undesired anhydrite CaSO4 in the cement clinker.

scholarly journals MODELING A CLINKER FURNACE MONITORING SYSTEM

2020 ◽  
pp. 12-18
Author(s):  
В. В. Шухин ◽  
М. С. Насуханов ◽  
М. С. Бараев
Keyword(s):  
Control System ◽  
Energy Consumption ◽  
Raw Materials ◽  
Cement Clinker ◽  
Design Parameters ◽  
Rotary Kilns ◽  
Control And Management ◽  
Stationary Approximation ◽  
Hot Zone ◽  
Main Operating

Вращающиеся печи используются для преобразования кальцинированной сырьевой смеси в цементный клинкер. В этой статье рассматривается система контроля и управления клинкерной вращающейся печью посредством трехмерной модели для моделирования ключевых процессов, происходящих в твердом слое клинкерных печей. Эта система опирается на математическую модель, состоящую из пяти операционных уровней: три слоя для мониторинга состояния печи и два для ее системы управления. Изменение высоты слоя и образование расплава в горячей зоне внутри печи были учтены. Энергетический баланс (включая кондуктивный, конвективный и радиационный теплообмен) определялся на основе квазистационарного приближения. Численные эксперименты проводились с целью исследования влияния основных рабочих и проектных параметров на потребление энергии печи. Модель можно использовать для мониторинга температурного профиля внутри печи, для снижения потребления энергии на тонну клинкера. Модель и результаты, рассматриваемые в данной статье, обеспечивают настройку системы управления печи обжига клинкера. Rotary kilns are used to convert calcined raw materials into cement clinker. This article discusses a control and management system for a clinker rotary kiln through a 3D model to simulate key processes occurring in the solid bed of clinker kilns. This system is based on a mathematical model consisting of five operating levels: three layers for monitoring the state of the furnace and two for its control system. The change in the layer height and the formation of melt in the hot zone inside the furnace were taken into account. The energy balance (including conductive, convective and radiative heat transfer) was determined on the basis of a quasi-stationary approximation. Numerical experiments were carried out to investigate the influence of the main operating and design parameters on the energy consumption of the furnace. The model can be used to monitor the temperature profile inside the kiln to reduce energy consumption per tonne of clinker. The model and results discussed in this article provide tuning of the clinker kiln control system.

scholarly journals Sustainability Assessment of the Green Compost Production Chain from Agricultural Waste: A Case Study in Southern Italy

Agronomy ◽  
2020 ◽  
Vol 10 (2) ◽  
pp. 230 ◽  
Author(s):  
Maria Pergola ◽  
Alessandro Persiani ◽  
Vittoria Pastore ◽  
Assunta Maria Palese ◽  
Carmine D’Adamo ◽  
...  
Keyword(s):  
Environmental Impacts ◽  
Sustainability Assessment ◽  
Agricultural Waste ◽  
Production Costs ◽  
Raw Material ◽  
Organic Farms ◽  
Conventional Agriculture ◽  
Production Chain ◽  
Sustainable Solutions ◽  
Technology Process

Horticultural farms are faced with the problem of disposing of huge amounts of agricultural by-products whose management requires sustainable solutions. Composting means to recycle organic waste to make compost—a high agronomic value product—able to positively affect soil quality: A good occasion to switch definitively from a conventional agriculture to an organic one. Nevertheless, composting can have negative direct/indirect environmental impacts. The aim of this research was to assess the sustainability of a windrow composting system, able to treat agricultural green waste of different typology (“light” and “heavy” with dry matter below or above 10%, respectively). Environmental impacts, energy consumptions, and production costs of all composting stages were evaluated by Life Cycle Assessment. Results show that the production of 1 ton of compost caused CO2eq emissions ranging from 199 to 250 kg and required between 1500 and 2000 MJ of energy; costs ranged between 98 and 162 euro, nevertheless lesser than the commercial green compost. The raw material typology affected significantly the composting process making compost based on “heavy” materials the most sustainable. These findings underline the need to spread this low technology process, easy to apply, especially in organic farms, and to promote the agronomic use of compost.

SELISIH BIAYA PRODUKSI SEBAGAI ALAT PENGENDALIAN MANAJEMEN PT INDO PUSAKA BERAU

2019 ◽  
Vol 3 (02) ◽  
pp. 397
Author(s):  
SAFITRI NURHIDAYATI ◽  
RIZKI AMELYA SYAM
Keyword(s):  
Raw Materials ◽  
Field Research ◽  
Analytical Tool ◽  
Production Costs ◽  
Raw Material ◽  
Labor Costs ◽  
Material Costs ◽  
Library Research ◽  
The Difference ◽  
The Cost

This study aims to analyze whether the difference that occurs in the cost of raw materials, direct labor, and factory overhead costs between the standard costs and the actual costs in PLTU LATI is a difference that is favorable or unfavorable. Data collection techniques with field research and library research. The analytical tool used is the analysis of the difference in raw material costs, the difference in direct labor costs and the difference in factory overhead costs. The hypothesis in this study is that the difference allegedly occurs in the cost of raw materials, direct labor costs, and factory overhead costs at PT Indo Pusaka Berau Tanjung Redeb is a favorable difference. The results showed that the difference in the cost of producing MWh electricity at PT Indo Pusaka Berau Tanjung Redeb in 2018, namely the difference in the price of raw material costs Rp. 548,029.80, - is favorable, the difference in quantity of raw materials is Rp. 957,216,602, - is (favorable) , the difference in direct labor costs Rp 2,602,642,084, - is (unfavorable), and the difference in factory overhead costs Rp 8,807,051,422, - is (favorable) This shows that the difference in the overall production cost budget is favorable or profitable. This beneficial difference shows that the company is really able to reduce production costs optimally in 2018.  

Pengaruh Penggunaan Batu Basalt Lampung dan Batubara dalam Bahan Baku terhadap Karakteristik Klinker

2020 ◽  
Vol 10 (1) ◽  
pp. 49
Author(s):  
Suharto Suharto ◽  
Muhammad Amin ◽  
Muhammad Al Muttaqii ◽  
Syafriadi Syafriadi ◽  
Kiki Nurwanti
Keyword(s):  
Experimental Study ◽  
Raw Materials ◽  
Coal Ash ◽  
Heating Time ◽  
Raw Material ◽  
Silica Sand ◽  
Cement Clinker ◽  
Duration Of Heating

Experimental study on the use of basalt stone originated from Lampung has been conducted to evaluate its potential for a partial substitute of raw material in production of cement clinker. The basalt stone contains minerals of anorthite, augite, and albite phases that are required for clinker formation. In this study, the main raw materials were 80% limestone, 10% silica sand, 9% clay and 1% iron sand. The raw material in these experiments were mixtures 90% or 80% of the main raw material and 10% or 20% of basalt stone. The effect of adding coal to raw materials was also studied to see the possibility of an increase in clinkerization temperature inside the raw material mixture, and at the same time to see the effect of coal ash on clinker composition. Clinker obtained from heating of raw materials at a temperature of 1100oC had LSF of 94.1% and 95.1% (heating time of 1 and 3 hours). If heating is carried out at 1200oC, the clinker had LSF of 97.7% and 98.0% (heating time of 2 and 3 hours, respectively). Depending on the temperature and duration of heating, the clinker mostly had SM in the range of 2.18-2.40% , and AM in the range of 0,78-1.80%. Characterization using XRD showed that the clinker consisted of larnite and gehlenite phases, and dominated by CaO.Batu basalt Lampung telah diuji potensinya sebagai pengganti sebagian bahan baku utama pembuatan klinker semen. Batu basalt tersebut memiliki mineral-mineral dalam fase anorthite, augite, dan albite yang diperlukan pada pembentukan klinker. Pada penelitian ini, bahan baku utama adalah batu kapur 80%, pasir silika 10%, tanah liat 9% dan pasir besi 1%. Campuran bahan baku klinker adalah 90% atau 80% bahan baku utama dan 10% atau 20% batu basalt. Efek penambahan batubara ke dalam bahan baku klinker juga dipelajari untuk melihat kemungkinan kenaikan temperatur klinkerisasi di dalam campuran bahan baku, dan sekaligus untuk melihat efek abu batubara terhadap komposisi klinker. Klinker hasil pemanasan bahan baku pada temperatur 1100oC memiliki LSF 94,1% dan 95,1% (lama pemanasan 1 dan 3 jam). Jika pemanasan dilakukan pada 1200oC, klinker memilik LSF 97,7% dan 98,00% (lama pemanasan 2 dan 3 jam). Tergantung pada temperatur dan lama pemanasan, klinker hasil percobaan ini umumnya memiliki SM 2,18-2,40%, dan AM antara 0,78-1,80%. Karakterisasi dengan XRD menunjukkan bahwa klinker terdiri dari fase larnite dan gehlenite, dan didominasi CaO.

Experimental Research on the Qualitative Characteristics of Iron Ores and Ferrous Waste That Can Be Used in Blast Furnace Mixt Injection Technology

2019 ◽  
Vol 70 (11) ◽  
pp. 3835-3842
Author(s):  
Mihai Dumitru Tudor ◽  
Mircea Hritac ◽  
Nicolae Constantin ◽  
Mihai Butu ◽  
Valeriu Rucai ◽  
...  
Keyword(s):  
Blast Furnace ◽  
Experimental Research ◽  
Raw Materials ◽  
Coal Dust ◽  
Production Costs ◽  
Iron Ores ◽  
Fine Grained ◽  
Experimental Laboratory ◽  
Injection Technology ◽  
Direct Use

Direct use of iron ores in blast furnaces, without prior sintering leads to a reduction in production costs and energy consumption [1,2]. Fine-grained iron ores and iron oxides from ferrous wastes can be used together with coal dust and limestone in mixed injection technology through the furnace tuyeres. In this paper are presented the results of experimental laboratory investigations for establishing the physic-chemical characteristics of fine materials (iron ore, limestone, pulverized coal) susceptible to be used for mixed injection in blast furnace. [1,4]. The results of the experimental research have shown that all the raw materials analyzed can be used for mixt injection in blast furnace.

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