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Alternative Fuels Substitution in Cement Industries for Improved Energy Efficiency and Sustainability

Author

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  • 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)

  • Ekua Afrakoma Armoo

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

  • Komi Agboka

    (West African Service Center for Climate Change and Adaptive Land Use (WASCAL), University of Lomé, Lomé 01BP1515, Togo)

  • Mani Kongnine Damgou

    (Department of Physics, University of Lomé, Lomé 01BP1515, Togo)

Abstract

The conventional energy source in cement industries is fossil fuels, mainly coal, which has a high environmental footprint. On average, energy expenditures account for 40% of the overall production costs per ton of cement. Reducing both the environmental impact and economic expenditure involves incorporating alternative energy sources (fuels) such as biomass, solid-derived fuel (SDF), refuse-derived fuel (RDF) etc. However, within cement plants, the substitution of conventional fossil fuels with alternative fuels poses several challenges due to the difficulty in incorporating additional fuel-saving techniques. Typically, an additional 3000 MJ of electricity per ton of clinker is required. One of the most effective solutions to this is thermal optimization through co-processing and pre-processing, which makes it possible to implement additional fossil-fuel-saving techniques. In developing nations such as Togo, waste-management systems rely on co-processing in cement factories through a waste-to-energy relationship. Also, there are some old cement plants with low-efficiency, multi-stage preheaters without pre-calciners, reciprocating huge coolers, low-efficiency motors etc., which still operate and need to be made environmentally sustainable. However, compared to modern kilns which can have up to 95% of energy recovery from waste, an old suspension preheater kiln can recover only up to 60% of its heat energy depending on the cooler type, and due to the lack of a bypass and combustion chamber (pre-calciner). This research paper evaluated the performance of a cement plant incorporating AF and presents the procedures and recommendations to optimize AF substitution in cement plants. To achieve this, a comparative performance study was carried out by assessing the alternative fuel characteristics and the equipment performance before and after the incorporation of the alternative fuel. Data were collected on the optimum substitution ratio, pre-processing and co-processing performance, raw-meal design and economic analysis. Results indicated that the cost to be covered per ton of waste input is €10.9 for solid-derived fuel (SDF), €15 for refuse-derived fuel (RDF), and that the co-processing cost optimization for the cement plant could have a cost saving of up to 7.81€/GJ. In conclusion, it is recommended that appropriate kiln and alternative-fuel models be created for forecasting production based on various AF.

Suggested Citation

  • Essossinam Beguedou & Satyanarayana Narra & Ekua Afrakoma Armoo & Komi Agboka & Mani Kongnine Damgou, 2023. "Alternative Fuels Substitution in Cement Industries for Improved Energy Efficiency and Sustainability," Energies, MDPI, vol. 16(8), pages 1-29, April.
    • Handle: RePEc:gam:jeners:v:16:y:2023:i:8:p:3533-:d:1127308
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    References listed on IDEAS

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    Cited by:

    1. Ahmed M. Nassef, 2023. "Improving CO 2 Absorption Using Artificial Intelligence and Modern Optimization for a Sustainable Environment," Sustainability, MDPI, vol. 15(12), pages 1-22, June.
    2. Ekua Afrakoma Armoo & Mutala Mohammed & Satyanarayana Narra & Essossinam Beguedou & Francis Boateng Agyenim & Francis Kemausuor, 2024. "Achieving Techno-Economic Feasibility for Hybrid Renewable Energy Systems through the Production of Energy and Alternative Fuels," Energies, MDPI, vol. 17(3), pages 1-21, February.
    3. Jorge Arroyo & Christian Pillajo & Jorge Barrio & Pedro Compais & Valter Domingos Tavares, 2024. "Deep Learning Techniques for Enhanced Flame Monitoring in Cement Rotary Kilns Using Petcoke and Refuse-Derived Fuel (RDF)," Sustainability, MDPI, vol. 16(16), pages 1-25, August.
    4. Kubilay Kaptan & Sandra Cunha & José Aguiar, 2024. "A Review: Construction and Demolition Waste as a Novel Source for CO 2 Reduction in Portland Cement Production for Concrete," Sustainability, MDPI, vol. 16(2), pages 1-50, January.
    5. Ekua Afrakoma Armoo & Satyanarayana Narra & Mutala Mohammed & Belinda Boahemaa & Essossinam Beguedou & Francis Kemausuor & Francis Boateng Agyenim, 2024. "Hybrid Waste-to-Energy Solutions within a Circular Economy Framework Directed towards Sustainable Urban Waste Management in Ghana," Sustainability, MDPI, vol. 16(12), pages 1-25, June.

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