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Alternative fuel production and its use in the cement industry

The reduction of energy consumption in cement production is achieved by means of using alternative fuels based on different types of organic containing waste.

There is a constant increase in the utilisation of wastes as secondary materials in the cement industry to replace natural raw materials and fuels. There are corresponding activities in many countries, often even with government support. Beyond the economic interests of cement works, this can also make a considerable contribution to conservation of resources and reduction of waste in line with the concept of 'Sustainable Development'. European legislators have supported this development with the Recycling and Wastes Act, in particular through the clear requirement for 'priority use of utilisable wastes or secondary raw materials for the manufacture of products'. Under these conditions there has been a fundamental change in waste management in recent years. Useful materials, some of which are also of interest to the cement industry, are being obtained increasingly from wastes. Almost 20% of the total fuel requirement of the West European cement industry is now covered by secondary fuels. Results for the last year indicate an increase in the usage of alternative fuels in the cement industry in POLAND of up to 6% (90 thousand tons), although these figures are still lower than those attained by cement industries in many countries in Europe and other parts of the world, where the quantity of energy obtained in this way accounts for a dozen or even a few dozen percent of the total. At the same time, the Ukrainian cement industry now only plans to use alternative fuel. It is estimated that in 2007, over 10% of thermal energy of several cement plants of the UKRAINE will be obtained from alternative fuels. Our objective for the next few years is to ensure that the share of energy obtained from alternative fuels rises to a dozen or so percent, with complete acceptance on the part of society. The benefits thus generated can be shared between the natural environment, society and the industry. The goal of lowering production costs is one of two main factors stimulating activities aimed at replacing the natural fuel used in the cement production process with alternative fuels obtained from combustible wastes. The second factor is environmental protection, since instead of undergoing potentially hazardous storage, wastes can be duly treated and rendered harmless in a useful way, with the total consumption of their energy. Cement kilns, in which combustion processes reach temperatures of up to 2,000 degrees Celsius, are one of the few industrial installations ensuring the effective and environmentally friendly combustion of alternative fuels. The main objectives of the project are the following: - the place of the cement industry in the strategy of sustainable development; - environmental compatibility and plant safety when using secondary materials such as alternative fuels in the cement plants; - the special features of using waste materials in cement plants; - logistic processes in sustainable waste management; - alternative fuels and quality assurance of Portland cements; - factors affecting emissions and ambient pollution; - alternative fuel logistic systems in cement production; - environment, society and economic aspects of using alternative fuels in the cement industry; - types of alternative fuels and the technology of its production; - analysis and monitoring of cement plants that use alternative fuels; - development of ecological standards and alternative fuel certification; - ecological system management and audit (ISO- International Standards Organisation 14001) of alternative fuels used in cement industry; - unification of EU Waste Directives with Ukrainian Standards (DSTU). Keywords: alternative fuels.
Acronym: 
AFP-CEMIND
Project ID: 
3 723
Start date: 
01-02-2006
Project Duration: 
65months
Project costs: 
500 000.00€
Technological Area: 
Waste incineration
Market Area: 
Manufacture of Building Materials

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.