YOUR EXPERT

IN ALTERNATIVE
FUELS
PRESENTS

Legal framework • Guidelines of the cement &

limeindustry • Calculation basis for alternative fuels
• Types of alternative fuels (biomass, waste-based
The most
fuels, solids/liquids) • Influences on the clinker
comprehensive
production process • Treatment technologies:
compendium
crushing, of
screening, classifying, removal of pollutants
alternative fuels
• Reception, dosing, storage, sampling techniques •
Flame control,
and raw burner technologies, fire protection •
materials
Impact
for theon CO2 emissions • Purchase management
cement
• Logistics • Quality control/quality management •
andorganization
Trials lime industry • Analysis procedures • Information
about origin, composition and availability • Chemical
and physical parameters, such as bulk density, flow
behavior and burning behavior • Specific influences
on the clinker production process • Economic and
technical conditions for treatment, storage and
dosage possibilities • Specific legal requirements
• Safety at work • Environmental aspects • Country-
specific information Legal framework • Guidelines
of the cement & limeindustry • Calculation basis for
alternative fuels • Types of alternative fuels (biomass,
waste-based fuels, solids/liquids) • Influences on the
clinker production process • Treatment technologies:
crushing, screening, classifying, removal of pollutants
• Reception, dosing, storage, sampling techniques •
Dammstraße 11a, 47119 Duisburg, Germany
Flame control,
Tel: +49 burner
(0) 203 34 65 16 – 25 technologies,
Fax: +49 (0) 203 34 fire
65 16 – 50 sales@lechtenberg-partner.de protection •
www.lechtenberg-partner.de

Impact on CO2 emissions • Purchase management

Alternative Fuels and Raw Materials Handbook

Content
Preface 5 Chapter: 4
Production of RDF 83
List of Abbreviations 17 4.1 Separation technologies – impurities 85
4.2 Screening technology 86
List of Chemical Formulae 23 4.2.1 Drum screens/trommel 86
4.2.2 Ballistic separation 90
4.2.3 Oscillating or vibrating screen 91
PART I 4.3 Air classification 93
4.4 Hard/rigid material classifier 95
Chapter: 1 4.5 Manual separation/hand picking 97
History and overview of alternative raw 4.6 Optical sorting systems 98
materials and fuels 27 4.7 Metal separation 100
1.1 Alternative raw materials 27
4.7.1 Separation of ferrous materials 100
1.1.1 Definition 27
4.7.2 Non-ferrous separation 101
1.1.2 History and utilisation of alternative raw
materials 28 4.8 Shredding 103
1.1.3 Types of alternative raw materials 28 4.8.1 Pre–shredding 103
1.1.4 Characteristics of alternative raw materials 30 4.8.2 Final shredding 107
1.1.5 Principles when using alternative raw materials 33 4.9 Pelletising 113
1.1.6 Utilisation of alternative raw materials 34 4.10 Drying technologies 117
1.1.7 Transport and storage of alternative raw
4.10.1 Solar drying 118
materials39
1.1.8 Conditioning and dosing of alternative raw 4.10.2 Belt dryers 120
materials39 4.10.3 Drum dryers 122
1.1.9 Quality assurance 41 4.10.4 Notes on dryer systems 124
1.1.10 Outlook 44 4.11 Examples of RDF production plants 125
1.2 Alternative fuels 45 4.12 Economic evaluation of RDF production plants 129
1.2.1 Definition 45
1.2.2 History of alternative fuels 46
Chapter: 5
1.2.3 Types of alternative fuels 50
Quality management for alternative fuels 133
1.2.4 Waste as raw material for alternative fuels 52
5.1 Environmentally relevant elements 133
1.2.5 Identification of wastes 53
5.2 Contaminant sources in alternative fuels 134
Chapter: 2 5.3 Investigation of alternative fuels – declaration
Waste evaluation 63 analysis 138
2.1 Defining waste generating sectors 65 5.4 Evaluation of waste and alternative fuels in an
2.2 Collecting the required information 66 RDF production plant 143
2.3 Quantification and characterisation of the mixed 5.5 Evaluation of AF in the cement/lime plant –
waste 67 sampling 147
2.4 Quantification of waste from generators 70 5.6 Sample preparation 149
2.5 Fuel-technical properties 72 5.7 Analysis of alternative fuels 152
2.6 Basic principles for the use of alternative fuels 73 5.7.1 Preliminary notes 152
5.7.2 Moisture 154
Chapter: 3 5.7.3 Volatiles and ash 156
Key issues for investments in RDF 5.7.4 Calorific value 156
production technologies and alternative
5.7.5 Chlorine 159
fuel usage 77
5.7.6 Sulphur 160
3.1 Basic economic considerations 77
5.7.7 Trace elements 161
3.2 Criteria influencing the production of
waste-derived fuels 80 5.8 Monitoring and reporting 163
Alternative Fuels and Raw Materials Handbook

Chapter: 6 8.6.1 Influence of trace elements on cement

properties – strength and setting260
Logistics and storage of RDF 165
8.6.2 Leaching of trace elements in fresh cement
6.1 Basic principles 165
paste and hardened concrete261
6.2 Transport, loading of alternative fuels 165
8.7 Impact on fan capacities 263
6.3 Truck reception 169 8.7.1 Calculation basics 263
6.4 Reception systems for bulk solid materials 175 8.7.2 Example of a substitution scenario 265
6.5 Storage of alternative fuels 176 8.8 Specific energy consumption 266
6.5.1 Basic requirements 176 8.9 Remarks on quality control of the cement
6.5.2 Homogenisation 177 production process when using alternative fuels 267
6.5.3 Special section: Fire protection 178 8.10 Emissions 269
6.5.4 Fire protection evaluation using the example 8.11 CO2 reduction with alternative fuels 273
of a storage facility182
8.11.1 Basics 273
6.5.5 Verification of infrastructural fire protection 191
8.11.2 Biomass content and emission factors of
6.5.6 Explosion protection in secondary fuel storage alternative fuels274
facilities 194 8.11.3 Determination of biogenic content – mass
6.6 Types of storage 195 balance275
6.6.1 Storage as bulk material in an enclosed 8.11.4 Determination of biogenic content – manual
facility196 sorting, selective dissolution, 14C method276
6.6.2 Storage in one or several silos 197 8.11.5 Fossil CO2 savings in the cement and lime
6.6.3 Moving floor storage 198 industry277
6.6.4 Storage in a deep bunker with discharge
systems200 Chapter: 9
6.6.5 Storage in a bunker with crane unloading 201 Contracting alternative fuels 287
6.6.6 Storage in special storage boxes 203 9.1 Structure for waste sourcing and AFR units 287
9.2 Price evaluation and contracting 289
Chapter: 7 9.3 Contract structure 291
Dosing and feeding of alternative fuels 207 9.4 Bonus/malus regulations 291
7.1 Screening 207
7.2 Separation of impurities 212 Chapter: 10
7.3 Conveying technology 212 Emission limits and permitting issues 293
7.3.1 Pneumatic conveying 212 10.1 Monitoring of emissions 295
7.3.2 Mechanical conveying 217 10.2 Monitoring of safe combustion 296
7.3.3 Pipe conveyors 220 10.3 Permitting issues 298
7.4 Weighing 221 10.4 Applying for a permit 298
7.4.1 Fundamentals 221 10.5 Trial permit – organisation of trials 302
7.4.2 Weigh feeders 222 10.6 Public discussions – stakeholders 305
7.4.3 Differential weigh feeders 222
7.4.4 Rotor weigh feeder 223 Chapter: 11
7.4.5 Screw weigh feeder 224 Current developments of the use of
7.5 Feeding points for alternative fuels 225 alternative fuels 309
7.5.1 Basic considerations 225 11.1 Oxy-fuel technology 309
7.5.2 Main burner 227 11.2 Ultra fine milling of alternative fuels 312
7.5.3 Kiln inlet 236 11.3 Thermal technologies 314
7.5.4 Dosing of alternative fuels in the calciner 237 11.4 Pyrolysis of high-calorific residues 318
11.4.1 Fundamentals of pyrolysis technology 318
Chapter: 8 11.4.2 Applications 319
Influences on clinker and lime 11.4.3 Hydrothermal carbonisation 321
production 239
8.1 Ash composition 239 Annex I
8.2 Sulphur, chlorine, alkalis 244 Questionnaire for data collection landfill
8.3 Influence on lime production 250 site 323
8.4 Refractories 251 1. General information on landfill site 323
8.5 Grain size of fuels 254 2. General information on the current situation 324
8.6 Environmentally relevant trace elements 256 3. Waste input 326
Alternative Fuels and Raw Materials Handbook

Annex II Fact Sheet:

Quality management – Examples of Alternative fuel and raw material (AFR)
excerpts of process instructions for the review “Poultry litter” 369
processing plant 327 1 Classification according to European Waste
Catalogue EWC 369
Annex II a 1.1 AFR description 369
Process instructions for the processing plant 328 1.2 AFR pictures 370
2 AFR source and composition 371
Annex II b
2.1 Source 371
Work instructions for sampling waste input and
RDF 338 2.2 Quantity and availability 371
2.3 Flow chart of AFR production 373
Annex II c 2.4 AFR composition 374
Operational procedures for maintenance and r 2.5 AFR analysis 374
epairs 343 2.6 AFR ash composition 375

Annex II d 3 Harmful substances and hazardous

characteristics 375
Specification for the acceptance of municipal
mixed wastes (MMW) 346 4 Collection, recycling and disposal of the AFR 376
4.1 Collection and transport 376
Annex II e 4.2 Recycling, current use and disposal 377
Company Safety Instructions RDF 349 4.3 Use as alternative fuels in a cement plant 377
4.3.1 Economic value of the waste in a cement
plant377

PART II 4.3.2 AFR pre-processing 378

Fact Sheet:
Alternative fuel and raw material (AFR)
review “Olive residues” 353
1 Classification according to EWC European
Waste Catalogue 353
1.1 AFR description 353
1.2 AFR pictures 354
2 AFR source and composition 354
2.1 Source 354
2.2 Quantity and availability 356
2.3 Flow chart of AFR production 358
2.4 AFR composition 358
2.5 AFR analysis 359
2.6 AFR ash composition 360
3 Harmful substances and hazardous
characteristics 361
4 Collection, recycling and disposal of the AFR 361
4.1 Collection and transport 361
4.2 Recycling, current use and disposal 361
4.3 Use as alternative fuel in a cement or lime
plant362
4.3.1 Economic value of the waste in a cement or
lime plant 362
4.3.2 AFR pre-processing 363
4.3.3 Storage at the plant site 364
4.3.4 Dosing and feeding systems 364
4.3.3 Storage in the plant site 378
4.3.4 Dosing and feeding systems 378
4.3.5 Quality influence on clinker 379
5 Recommendations 379
6 References 379
Fact Sheet:
Alternative fuel and raw material (AFR)
review “Scrap tyres” 381
1 Classification according to European Waste
Catalogue EWC 381
1.1 AFR description 381
1.2 AFR pictures 382
2 AFR source and composition 383
2.1 Source 383
2.2 Quantity and availability 383
2.3 Flow chart of AFR production 385
2.4 AFR composition 386
2.5 AFR analysis 387
2.6 Thermal properties 389
3 Harmful substances and hazardous
characteristics 389
4 Collection, recycling and disposal of the AFR 390
4.1 Collection and transport 390
4.2 Recycling, current use and disposal 390
4.3 Use as alternative fuels in a cement plant 391
4.3.1 Economic value of the AFR in a cement
plant391

4.3.5 Quality influence on clinker and lime 365 4.3.2 AFR pre-processing 392
5 Recommendations 367 4.3.3 Storage at the plant site 392
6 References 367 4.3.4 Dosing and feeding systems 393
Alternative Fuels and Raw Materials Handbook

4.3.5 Quality influence on clinker 395 4.3.1 Economic value of the waste in a cement
5 Recommendations 395 plant431

6 References 396 4.3.2 AFR pre-processing 432

Fact Sheet:
Alternative fuel and raw material (AFR)
review ”Sewage sludge” 399
1 Classification according to European Waste
catalogue EWC 399
1.1 AFR description 399
1.2 AFR picture 400
2 AFR source and composition 400
2.1 Source 400
2.2 Quantity and availability 402
2.3 Flow chart of AFR production 403
2.4 AFR composition 404
2.5 AFR analysis 405
2.6 AFR ash composition 406
3 Harmful substances and hazardous
characteristics 407
4 Collection, recycling and disposal 408
4.1 Collection and transport 408
4.2 Recycling, current use and disposal 409
4.3 Use as alternative fuel in a cement plant 410
4.3.1 Economic value of the AFR in a cement
plant411
4.3.2 AFR pre-processing 412
4.3.3 Storage at the plant site 415
4.3.4 Dosing and feeding systems 416
4.3.5 Quality influence on clinker 417
5 Recommendations 418
6 References 418
4.3.3 Storage at the plant site 432
4.3.4 Dosing and feeding systems 433
4.3.5 Quality influence on clinker 433
5 Recommendations 435
6 References 436
Fact Sheet:
Alternative fuel and raw material (AFR)
review “Used oils” 439
1 Classification according to European Waste
Catalogue EWC 439
1.1 AFR description 440
1.2 AFR pictures 440
2 AFR source and composition 441
2.1 Source 441
2.2 Quantity and availability 442
2.3 Flow chart of AFR production 444
2.4 AFR composition 445
2.5 AFR analysis 445
2.6 AFR ash composition 447
3 Harmful substances and hazardous
characteristics 447
4 Collection, recycling and disposal of the AFR 448
4.1 Collection and transport 448
4.2 Recycling, current use and disposal 449
4.3 Use as alternative fuels in cement or lime
plants450
4.3.1 Economic value of the AFR in cement
or lime plants 451
4.3.2 AFR pre-processing 452
4.3.3 Storage at the plant site 453

Fact Sheet: 4.3.4 Dosing and feeding systems 453

Alternative fuel and raw material (AFR) 4.3.5 Quality influence on products 453
review “Straw” 423 5 Recommendations 454
1 Classification according to European waste 6 References 455
Catalogue EWC 423
1.1 AFR description 423 Clinker Formulae 457
1.2 AFR pictures 424
2 AFR source and composition 424 Bibliography 459
2.1 Source 424
2.2 Quantity and availability 425 Table of Figures 475
2.3 Flow chart of AFR production 425
2.4 AFR composition 426 Table of Pictures 479
2.5 AFR analysis 427
2.6 AFR ash composition 428 Table of Tables 485
3 Harmful substances and hazardous
characteristics 428 Advertisement Index 489
4 Collection, recycling and disposal of the AFR 429
4.1 Collection and transport 429 Index 495
4.2 Recycling, current use and disposal 430
4.3 Use as alternative fuels in a cement plant 431