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Cement manufacturing using alternative fuels: Enhanced productivity and environmental compliance via oxygen enrichment

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  • Tsiliyannis, C.A.

Abstract

Use of alternative fuels (AF) in cement manufacturing is rising worldwide due to environmental benefits and associated subsidies, e.g. CO2 tradeable rights. Ιncreased kiln fluegas volumes from AFs imply lower clinker production, lower residence times in the air-pollution–control-system and removal efficiencies and elevated offgas pollutant emissions. Ever-present variations in AF composition, particularly if refuse derived, intensify operational uncertainty. A rigorous method is presented for quantifying the benefits of oxygen enrichment (OXE) in cement manufacturing, based on fundamental principles (mass and enthalpy balances). It employs a novel multidimensional formulation enabling simultaneous consideration of any number and types of AFs, isolating the invariant part of combustion stoichiometry from the OXE-dependent part and from the uncertain AF composition and flowrates. It was shown that OXE implies higher clinker production and lower fluegas and offgas volumes, while emissions are not impaired or even ameliorate, e.g. NOx emissions. Explicit formulae for clinker and offgas rates are presented, encompassing inner circuiting, direct or compound operation, fluegas bypass and heat integration of clinker cooler with secondary/tertiary air. The potency of the method and the significant benefits of OXE in cement manufacturing are demonstrated in a case study of an actual dry process clinker facility.

Suggested Citation

  • Tsiliyannis, C.A., 2016. "Cement manufacturing using alternative fuels: Enhanced productivity and environmental compliance via oxygen enrichment," Energy, Elsevier, vol. 113(C), pages 1202-1218.
    • Handle: RePEc:eee:energy:v:113:y:2016:i:c:p:1202-1218
    DOI: 10.1016/j.energy.2016.07.082
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    References listed on IDEAS

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    1. Worrell, Ernst & Martin, Nathan & Price, Lynn, 2000. "Potentials for energy efficiency improvement in the US cement industry," Energy, Elsevier, vol. 25(12), pages 1189-1214.
    2. Mokrzycki, Eugeniusz & Uliasz-Bochenczyk, Alicja & Sarna, Mieczyslaw, 2003. "Use of alternative fuels in the Polish cement industry," Applied Energy, Elsevier, vol. 74(1-2), pages 101-111, January.
    3. Zabaniotou, A. & Theofilou, C., 2008. "Green energy at cement kiln in Cyprus--Use of sewage sludge as a conventional fuel substitute," Renewable and Sustainable Energy Reviews, Elsevier, vol. 12(2), pages 531-541, February.
    4. Mokrzycki, Eugeniusz & Uliasz- Bochenczyk, Alicja, 2003. "Alternative fuels for the cement industry," Applied Energy, Elsevier, vol. 74(1-2), pages 95-100, January.
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    Cited by:

    1. Herrera, Bernardo & Amell, Andrés & Chejne, Farid & Cacua, Karen & Manrique, Raiza & Henao, Wilson & Vallejo, Gabriel, 2017. "Use of thermal energy and analysis of barriers to the implementation of thermal efficiency measures in cement production: Exploratory study in Colombia," Energy, Elsevier, vol. 140(P1), pages 1047-1058.
    2. Tsiligiannis, Aristeides & Tsiliyannis, Christos, 2020. "Oil refinery sludge and renewable fuel blends as energy sources for the cement industry," Renewable Energy, Elsevier, vol. 157(C), pages 55-70.
    3. Tsiligiannis, Aristeides & Tsiliyannis, Christos, 2019. "Renewable energy in cement manufacturing: A quantitative assessment of energy and environmental efficiency of food residue biofuels," Renewable and Sustainable Energy Reviews, Elsevier, vol. 107(C), pages 568-586.

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