NOx Reduction using RDF (refuse derived fuel) in cement industry

Abstract: Nitric oxide (NO) and nitrogen dioxide (NO2), jointly referred to as
NOx, are the principal nitrogen oxides present in the atmosphere. Increased
emissions of NOx have become a problem because of the negative impact that
these oxides have on the environment and on health. Examples of negative effects
are contribution to the formation of acid rain and photochemical smog.
Cement kilns generate high emissions of NOx. This is due to the special
process conditions prevailing in cement kilns: High gas temperatures, oxidizing
conditions and long residence times promote thermal NOx formation, and the
extensive use of nitrogen-containing fuels leads to fuel-NOx formation. In a
cement kiln, staged combustion may be employed by adding RDF to the kiln
exhaust gas, either at the kiln inlet or in the precalciner. Through this, a reducing
zone is generated, and reduction of the NOx formed in the primary burning zone,
occurs. Several techniques have been developed for NOx reduction efficiency such
as SNCR, SCR and reburning technology.
Reburning is NOx staged combustion control techniques that consume the
NOx formed in the primary zones. Reburning can be applied to any type of kiln,
provided the gas stream residence time is long enough to allow the reburn fuel to
burn completely. NOx reductions of 50% to 70% are possible. Reburning can be
used in combination with a number of other NOx control techniques. NOx
reburning is also called reburn, in-furnace NOx reduction, and staged fuel
injection.
From the view of the environmental protection against the usage of RDF
fuels, a great amount of effort has been exerted to find an effective method that is
only for pollutant reduction. NOx reduction using RDF as secondary fuel is useful
technique in cement industry. In this case reburning is a useful technology for
reducing nitric oxide through injection of a secondary hydrocarbon fuel. Several
technologies have been developed to reduce NOx efficiency such as SNCR, SCR
and reburning technology. Reburning process can be demonstrated as an effective
NOx reduction method which could achieve reduction of NOx. Using RDF
(municipal solid waste, plastic, tyres etc) as much economical process in poor
country like Pakistan as compared to other NOx reduction technology such as
SNCR and SCR etc and safe as well
The benefits of using reburning technology are:
  Solid waste ulilization
 NOx reduction
 Cheap energy to use

PROBLEM STATEMENT:
Pakistan has 29 cement plants with total installed capacity of 44 million tons. The
shortage of natural gas and increasing cost of oil and coal has adversely affected
cement production in the country. The cement entrepreneurs are exploring different
venues to supplement their fuel requirement and bringing down their cost of
production.One of the options for them is to use certain percentage of refuse as
fuel, as being practiced in other countries. A number of cement units have
approached federal and provincial Environmental Protection Agencies for issuance
of consent under the environmental laws for processing and use of Refuse Derived
Fuel (RDF). The RDF system should guarantee the minimum environmental
contamination during manufacturing processes and, at the end of their working life
and guarantee the elimination of waste through recycling method. All obligations
and responsibilities imposed by the Pakistan Environmental Protection Act, 1997
and rules and regulations made there under continue to apply and a proponent may
still be liable if harm arises from the use of RDF.

Effect of NOx on humans and environment

 Small levels of NOx can cause nausea, irritated eyes and/or nose, fluid
forming in lungs and shortness of breath
 Breathing in high levels of NOx can lead to: rapid, burning spasms; swelling
of throat; reduced oxygen intake; a larger buildup of fluids in lungs and/or
death

 NOx, plus other ground-level ozone, can cause other major respiratory
problems in high levels Helps form acid rain
 It hampers the growth of plants
 NOx can form with other pollutants to form toxic chemicals.
Litreture review on different fuels used in cement industry
Environmental and economic advantages associated with the use of RDF in
cement kilns
Mustafa Kara
TUBITAK MRC (Marmara Research Center) Materials Institute, Gebze, Kocaeli,
Turkey.

Article history:
Received 10 January 2012
Received in revised form 15 June 2012
Accepted 21 June 2012

In this study, the potential use of RDF materials from wastes

leaving the isolation unit and not being recycled wastes as supplementary
fuel (instead of fossil fuels) in cement kilns is investigated.
RDF, which was produced in this study, was added to main fuel
(petroleum coke) in ratios of 0%, 8%, 12% and 15%. Chemical analysis
clearly reveals that Portland cement clinker is produced. Emission
measurements made at industrial scale rotary cement kiln are
available to cement industry’s data. It is shown that 9.50 USD/h CO2
emission saving in petroleum coke and 94 USD/h real saving will
be achieve by using RDF. It is believed that success achieved in this
study will be a good example for Kyoto agreement that Turkey has
just signed.
Results obtained in this study are given below:
 When 15% RDF is used as supplementary fuel together with petroleum coke
in cement production, it does not cause any disadvantages in the view of
clinker quality and stack gas emission values. When a calculation based on
thermal value which was obtained in rotary kiln in AKC， ANSA Co., an
acceptance like “6030.77 kg/h petroleum coke equivalent to 13,440 kg/h
RDF” is taken. If RDF value is taken as 15%, the rest is 85% petroleum coke
 and according to theacceptance above, this corresponds to 5126 kg/h
petroleum.
 The real financial saving is 629.04 USD/year. This calculation explains only
the saving which was obtained by using RDF in cement industry. Because of
the fact that RDF was obtained from waste, a saving in waste collection,
sorting, processing and storing will be supplied.
Emphasizing Advantages by using RDF
Reduction of Nox – emissions (Kyoto-target):
Cost reduction of clinker production due to using inexpensive fuel.

Preservation of resources – lower use of fossil non-renewable fuel.

Perspectives for pilot scale study of RDF in Istanbul, Turkey
Mustafa Kara a,*, Esin Gunay a, Yasemin Tabak a, S_enol Yıldız.

Article history:
Accepted 29 July 2009
Available online 25 August 2009
In this study, it has been investigated the potential use of RDF materials from
wastes leaving the isolation unit and not being recycled wastes as a supplementary
fuel (instead of fossil fuels) in cement kilns.
Results obtained in this study are given below:
 The use of RDF as an alternative fuel in cement production is an
economically viable option to reduce fuel costs and landfill disposal. Thus,
the amount of fossil fuel imported from abroad will be reduced.
 The use of alternative fuels in cement manufacturing is helping the cement
industry to reduce effects on the environment and to improve its overall
environmental performance. Alternative fuels provide a waste management
solution for the community and reduce the use of non-renewable resources,
without adverse environmental effects.
 RDF produces a more homogeneous fuel which burns more evenly at a
higher temperature thereby making combustion control easier.
 Emission measurements are not required during experimental studies since
the pilot rotary kiln is manufactured for experimental purposes; because of
the pilot scale rotary kiln has not dust suppression and cyclone units which
are present in industrial scale cement rotary kiln.
 In the light of these evidence obtained in pilot scale, a test of one-to-one
scale will be conducted at Cement Industry. Since emission control has
became more important because of environmental concerns.
Perspectives and limits for cement kilns as a destination for RDF
G. Genon a, E. Brizio b,*
a Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy
b A.R.P.A. Piemonte, Via Vecchia di Borgo 11, 12100 Cuneo, Italy
Accepted 21 October 2007
Available online 8 January 2008

This paper has shown that the use of RDF in cement kilns is a real technological
solution both for RDF producers, urged to find a useful final destination for the
produced material, and for cement plant operators, whose first objectives
are the economics of production, optimal energy allocation, and limiting
environmental impact..
 From the point of view of environmental performance different conclusions
can be drawn:
 The substitution of RDF for coal or coke has a positive effect on greenhouse
gas formation over traditional schemes.
 The formation of conventional gaseous pollutants is not a critical aspect the
generation of nitrogen oxides can probably decrease due to lower flame
temperatures or lower excess air.
 The presence in atmospheric emissions of chlorinated micro-pollutants is
not influenced by the presence of RDF in fuel, due to the high thermal
destruction capacity of the kiln. Compliance with common standards for this
type of pollutant is not difficult. The mass fluxes of micro-pollutants and
their origin are not yet completely defined and must be further examined.
 On the basis of all of these considerations, taking into account the
absolutely critical aspects of the RDF market in Italy and the high
contribution of the cement industry to carbon dioxide emissions, this option
must be considered in the planning of territorial systems. This is not
necessarily intended as a general solution, but as a useful aid for actual
environmental problems.

THE CEMENT INDUSTRY IN EGYPT:

Challenges and innovative Cleaner Production solutions
Eng. Yasser Askar, M.Sc
Technical and Institution support Department Director
Egyptian Environmental Affairs Agency (EEAA)
Prof. Donald Huisingh
Institute for a Secure and Sustainable Environment
University of TN ,Knoxville, TN, USA

Knowledge Collaboration & Learning for Sustainable Innovation

ERSCP-EMSU conference, Delft, The Netherlands, October 25-29, 2010
In 2010, Egypt faced water and electricity scarcity. Political, social and
environmental factors
RE putting pressure on the cement industries to improve their energy, water
management and environmental performance.
Three main facts, cement industries must anticipate and consider:
1. Introduction of new environmental law and executive regulations;
2. Introduction of new energy tariffs on cement industry;
3. Introduction of new water tariffs and wastewater discharge regulations.
In addition to these changes, cement industries affiliated with International groups
are committed to report to their headcounts and follow their International
regulations in energy, water and sustainability activities.
There are several opportunities to introduce CP options in the cement industry in
Egypt. The starting point is following the basics of sustain production in the
cement industries:
1.. Expand in using alternative materials and fuels
2. Adding De-Nox units.
3. Guarantee smooth process and flow of materials
4. Continuously monitor emissions and processes;
5. Recover heat and minimize heat losses;
6. Set targets for energy and emissions reduction per ton of clinker produced.

THE USAGE OF REFUSE DERIVED FUEL FROM URBAN

SOLIDWASTE IN CEMENT INDUSTRY AS AN ALTERNATIVE
FUEL
TUBITAK MRC (Marmara Research Center) Material Institute
P.O. Box 21, Gebze, Kocaeli, TURKEY

(**)ISTAÇ, Istanbul Metropolitan Municipality Environmental

Protection and Waste Materials Valuation Industry and Trade Co.
Piyalepasa, Istanbul, TURKEY
6th IASME/WSEAS International Conference on HEAT TRANSFER, THERMAL
ENGINEERING and ENVIRONMENT (HTE'08)
Rhodes, Greece, August 20-22, 2008
Waste conversion systems, including both the mass burn and RDF technologies,
have the potential to provide as much as 3% of the nation's annual energy demand.
Furthermore, the recycling of inorganic such as ferrous metals, glass, and
aluminium would further reduce our total energy use by an additional 1%. While
these quantities may seem to be insignificant, remember that this potential energy
source is currently being disposed of as having no value, and disposal is itself
expensive. Beneficiation of RDF is given below.
• Cement production, using RDF as a supplemental fuel was an economically
viable option to reduce fuel costs and reduce landfill disposal. Although this will
depend on cost of capital, coal and landfill disposal prices.
• Produces beneficial effects on air emission and ash residue when used as a fuel.
• Produces a more homogeneous fuel which burns more evenly at a higher
temperature thereby making combustion control easier
• Has a higher calorific value content, lower ash and moisture content
• Allows recovery of saleable materials.
• Can be processed at one site and transported to other locations for combustion
• Can be stored for extended periods of time.
• Allows flexibility in selecting materials to be recovered
• Can be burned in a wide range of existing boilers, fluidized bed combustors,
gasifiers and cement kilns with no, or only minimal, modifications required.
• Can be used as a feedstock for anaerobic digesters
• Can be co-fired in existing boilers with other fuels such as coal, wood, or sewage
sludge.
• Achieves 50% greater power generating efficiencies than mass burn power plants
when blends of RDF and coal are co-fired.

Objective
1. Influence of molar flowrate on reburning fuel

Using 5% , 10% ,15% etc molar ratio of reburning fuel

Increasing molar ratio of reburning fuel leads to enlargement of
temperature range in which the NOx reduction is more intense
2. Influence of air excess ratio
NOx reduction is directly propotional to fuel rich condition
.increasing air excess ratio NOx will be reduced
We are using optimum air excess ratio it may be stichometric or
slightly above
3. Influence of temperature
 By increasing temperature nox reduction will increase
In reburning process in some temperature ranges donot effect
concentration of CH ion to find optimum temperature for maximum
nox removal efficiency
4. Influence of residence time
Residence time means reaction time in reburning zone
Longer then residence time amount of nox reduction become constant
, reburning fuel residence time varies with molar flow rate
5. Design PFR model for reburning process. It will involve reactor
volume ,reactor flow rate , and residence time