Utilization of alternative fuels and raw materials in the cement production is already a standard process in many countries around the world. For example, in Austria, already 90% of the fuels used in cement industry are so-called “alternative fuels”. This is among the highest co-processing rates in the world.
However, to implement such system satisfactory in your cement plant is nevertheless a challenge. It requires to consider lots of different information for the engineering and financial planning. These include knowledge about the fuel raw materials properties, the necessary treatment of the alternative fuels and raw materials before firing (i.e. the pre-processing), the limits and modifications of existing pyro unit, the clinker production process (i.e. the co-processing), etc. The fuel supply has to be secured, proper quality control established, etc.
The conditions for the co-processing of waste differ a lot from country from country. For example, some countries might have established a waste collection and separation system already, others might not. The legal requirements are different from country to country.
There is no standard solution applicable for all cement plants. In order to implement a co-processing system meeting the requirements of the cement production, a project based on the local requirements has to be developed.
Co-processing project with IBBL
The typical procedure to implement co-processing in your plant with IBBL is presented in following six steps:
- Waste mapping
The first step is to evaluate the sources of the alternative fuels; i.e. the quantities, availability, physical properties and chemical composition, collecting system and conditions, etc. This information is the essential basis for the design of the pre-processing and the co-processing system.
- Site investigation
The team of experts evaluate the conditions at the existing plant. This includes to evaluate available space for the equipment installation, evaluate existing machinery for abilities of co-firing, limitations, etc.
- Basic engineering
Basic engineering combines process calculations, conceptual design, project schedule and estimation of project costs. Basic engineering can be extended to full feasibility study including also detailed analysis of operational costs. Basic engineering delivers a developed project ready for approval by the Client.
Based on the approved basic engineering, next step is tendering of equipment supply, construction and erection. The tendering process is managed by IBBL. Tenders are prepared, offers compared and negotiated in order to secure implementation of the project targets.
- Engineering and equipment supply
The detail design of the project is done, the equipment manufactured.
IBBL manages and monitors the project. This includes, e.g. follow-up on time schedule, drawings review and manufacturing inspection.
- Plant construction and operation
Installation of the supplied equipment, modification of the existing system and the commissioning are carried out. IBBL manages site, supervises the activities on site (erection and commissioning) and supports the Client during establishing proper operation.
For additional details, please see Download » IBBL services for alternative fuels and raw materials.