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Alternative Fuel Substitution Improvements in Low NO x In-Line Calciners

Author

Listed:
  • Essossinam Beguedou

    (Department of Waste and Resource Management, University of Rostock, 18059 Rostock, Germany)

  • Satyanarayana Narra

    (Department of Waste and Resource Management, University of Rostock, 18059 Rostock, Germany
    German Biomass Research Centre gGmbH, 04347 Leipzig, Germany)

  • Komi Agboka

    (West African Service Center for Climate Change and Adaptive Land Use (WASCAL), University of Lomé, Lomé P.O. Box 1515, Togo)

  • Damgou Mani Kongnine

    (Faculty of Sciences, Department of Physique, Centre d’Excellence Regional pour la Maîtrise de l’Electricité (CERME), University of Lomé, Lomé P.O. Box 1515, Togo)

  • Ekua Afrakoma Armoo

    (Department of Waste and Resource Management, University of Rostock, 18059 Rostock, Germany)

Abstract

The process of making cement clinker uses a lot of energy and produces a lot of pollution. Currently, cement companies use a combination of traditional fossil fuels and alternative fuels (AF-Fuels) to lower their energy consumption and environmental footprint by improving the pyro-system. In a calciner, AF-Fuels can reach a thermal substitution rate (TSR) of up to 80–100%. However, a kiln burner can only achieve a TSR of 50–60%. High TSR values have been provided by improvements in multi-channel burners, proper AF-Fuel feeding point setups, and various AF pre-combustion methods. Significant modeling of the calciner burner and system has also improved TSRs. However, the cement industry has encountered operational problems such as kiln coating build-up, reduced flame temperatures, higher specific heat consumption, and incomplete combustion. There is growing interest in waste substitution, a promising source of AF-Fuel that needs to be integrated into the current cement plant design to solve the calciner operational problems of the cement industry. This study discusses the latest developments and different experimental and modeling studies performed on the direct burning/co-firing of AF-Fuel in the cement industry as well as the incorporation of gasification in cement manufacturing. Based on this, a technically and environmentally improved solution is proposed. The characteristics of both approaches towards pre-calciner function and optimization are critically assessed. The many in-line cement calciner integration technologies and their various configurations for the long-term problems of cement plants are discussed. This project report also focuses on the necessity of creating appropriate calciner models for forecasting calciner production based on various AF-Fuels and their feeding positions in the calciner.

Suggested Citation

  • Essossinam Beguedou & Satyanarayana Narra & Komi Agboka & Damgou Mani Kongnine & Ekua Afrakoma Armoo, 2023. "Alternative Fuel Substitution Improvements in Low NO x In-Line Calciners," Clean Technol., MDPI, vol. 5(2), pages 1-31, June.
    • Handle: RePEc:gam:jcltec:v:5:y:2023:i:2:p:36-743:d:1161872
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    References listed on IDEAS

    as
    1. Li, Xiaoguang & Zeng, Lingyan & Zhang, Ning & Zhang, Xin & Song, Minhang & Chen, Zhichao & Li, Zhengqi, 2022. "Effects of the gas/particle flow and combustion characteristics on water-wall temperature and energy conversion in a supercritical down-fired boiler at different secondary-air distributions," Energy, Elsevier, vol. 238(PC).
    2. Rikard Edland & Fredrik Normann & Thomas Allgurén & Christian Fredriksson & Klas Andersson, 2019. "Scaling of Pulverized-Fuel Jet Flames That Apply Large Amounts of Excess Air—Implications for NO x Formation," Energies, MDPI, vol. 12(14), pages 1-18, July.
    3. Yanfei Yao & Songxiong Ding & Yanxin Chen, 2020. "Modeling of the Thermal Efficiency of a Whole Cement Clinker Calcination System and Its Application on a 5000 MT/D Production Line," Energies, MDPI, vol. 13(20), pages 1-16, October.
    4. Sharma, Prateek & Sheth, Pratik N. & Mohapatra, B.N., 2023. "Co-processing of petcoke and producer gas obtained from RDF gasification in a white cement plant: A techno-economic analysis," Energy, Elsevier, vol. 265(C).
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