Uses of alternative fuels and raw materials in the cement industry as sustainable waste management options

The proper use of alternative fuels and materials in the cement industry is essential for the planning and promotion of different methods that can decrease the environmental impacts, lower the consumption of energy and material resources, and reduce the economic costs of this industry. Because of the great potential for the cement industry to save energy and reduce greenhouse gas emissions (GHG), many new research advances associated with the promising approach of introducing waste materials as alternative fuels or sustainable raw materials into the cement manufacturing process have been developed in recent years. Therefore, the main objective of this paper is to provide a literature review of these approaches based on previously published research studies. The analysis is specially focused on the technical, economic, and environmental effects of the uses of five solid wastes, namely, municipal solid waste (MSW), meat and bone animal meal (MBM), sewage sludge (SS), biomass, and end-of-life tyres (ELT), in the cement industry.

[1]  Esther Cascarosa,et al.  Co-gasification of meat and bone meal with coal in a fluidised bed reactor , 2011 .

[2]  R. Font,et al.  Dioxin production during the thermal treatment of meat and bone meal residues. , 2005, Chemosphere.

[3]  S. Rapagnà,et al.  Steam gasification of almond shells in a fluidised bed reactor: the influence of temperature and particle size on product yield and distribution , 1997 .

[4]  R. Siddique Utilization of municipal solid waste (MSW) ash in cement and mortar , 2010 .

[5]  E. Kakaras,et al.  Meat and bone meal as secondary fuel in fluidized bed combustion , 2007 .

[6]  M. Nehdi,et al.  Carbon dioxide emissions and climate change: policy implications for the cement industry , 2005 .

[7]  Larry L. Baxter,et al.  Comprehensive study of biomass fly ash in concrete: Strength, microscopy, kinetics and durability , 2007 .

[8]  William T. Choate,et al.  Energy and Emission Reduction Opportunities for the Cement Industry , 2003 .

[9]  D. Huntzinger,et al.  A life-cycle assessment of Portland cement manufacturing: comparing the traditional process with alternative technologies , 2009 .

[10]  Michael S Kaylen An economic analysis of using alternative fuels in a mass burn boiler. , 2005, Bioresource technology.

[11]  Toshinori Kojima,et al.  Production of cement clinkers from municipal solid waste incineration (MSWI) fly ash. , 2007, Waste management.

[12]  J. Werther,et al.  Combustion of agricultural residues , 2000 .

[13]  J. E. Davison,et al.  CO2 Capture in the Cement Industry , 2009 .

[14]  Rafael Font,et al.  Interaction between pollutants produced in sewage sludge combustion and cement raw material. , 2007, Chemosphere.

[15]  Germán Ferreira,et al.  Characterisation and Environmental Analysis of Sewage Sludge as Secondary Fuel for Cement Manufacturing , 2012 .

[16]  Won-Jun Park,et al.  CO2 emission reduction by reuse of building material waste in the Japanese cement industry , 2014 .

[17]  Martin Schneider,et al.  Sustainable cement production—present and future , 2011 .

[18]  Eugeniusz Mokrzycki,et al.  Use of alternative fuels in the Polish cement industry , 2003 .

[19]  R. Font,et al.  Thermal decomposition of meat and bone meal , 2003 .

[20]  Esther Cascarosa,et al.  Meat and bone meal and coal co-gasification: Environmental advantages , 2012 .

[21]  R. Yan,et al.  Hydrogen-rich gas production by steam gasification of palm oil wastes over supported tri-metallic catalyst , 2009 .

[22]  Ni-Bin Chang,et al.  Solid waste management in European countries: a review of systems analysis techniques. , 2011, Journal of environmental management.

[23]  Lynn Price,et al.  Use of Alternative Fuels in Cement Manufacture: Analysis of Fuel Characteristics and Feasibility for Use in the Chinese Cement Sector , 2008 .

[24]  Wendell de Queiroz Lamas,et al.  Waste materials co-processing in cement industry: Ecological efficiency of waste reuse , 2013 .

[25]  J. Werther,et al.  Sewage sludge combustion , 1999 .

[26]  Neven Duić,et al.  Reducing the CO2 emissions in Croatian cement industry , 2013 .

[27]  Tao Li,et al.  Effect of moisture content in sewage sludge on air gasification , 2010 .

[28]  Helena Lopes,et al.  Particulate and PCDD/F emissions from coal co-firing with solid biofuels in a bubbling fluidised bed reactor , 2009 .

[29]  Arnaud Mercier,et al.  Prospective on the energy efficiency and CO 2 emissions in the EU cement industry , 2011 .

[30]  Eugeniusz Mokrzycki,et al.  Alternative fuels for the cement industry , 2003 .

[31]  S. Chakritthakul,et al.  Co-firing of eucalyptus bark and rubberwood sawdust in a swirling fluidized-bed combustor using an axial flow swirler. , 2011, Bioresource technology.

[32]  Guillaume Habert,et al.  Cement Production Technology Improvement Compared to Factor 4 Objectives , 2010 .

[33]  Mahyuddin Ramli,et al.  The implementation of wood waste ash as a partial cement replacement material in the production of structural grade concrete and mortar: An overview , 2011 .

[34]  Md. Rafiqul Islam,et al.  A review on kiln system modeling , 2011 .

[35]  A. N. Bratsev,et al.  On efficiency of plasma gasification of wood residues. , 2011 .

[36]  Kåre Helge Karstensen,et al.  Test burn with PCB-oil in a local cement kiln in Sri Lanka. , 2010, Chemosphere.

[37]  Kåre Helge Karstensen,et al.  Formation, release and control of dioxins in cement kilns. , 2008, Chemosphere.

[38]  Neven Duić,et al.  The application of CFD modelling to support the reduction of CO2 emissions in cement industry , 2012 .

[39]  Rahman Saidur,et al.  A review on emission analysis in cement industries , 2011 .

[40]  A. Mountouris,et al.  Plasma gasification of sewage sludge: Process development and energy optimization , 2008 .

[41]  Peter Arendt Jensen,et al.  Pretreatment of straw for power production by pyrolysis and char wash , 2001 .

[42]  Germán Ferreira,et al.  Estimation of the energy content of the residual fraction refused by MBT plants: a case study in Zaragoza's MBT plant. , 2012 .

[43]  Maria Chiara Bignozzi,et al.  Tyre rubber waste recycling in self-compacting concrete , 2006 .

[44]  Duncan Herfort,et al.  Sustainable Development and Climate Change Initiatives , 2008 .

[45]  Ernst Worrell,et al.  CO2 Emission Trends in the Cement Industry: An International Comparison , 2002 .

[46]  Oliver Lindqvist,et al.  Fly ash characteristics in co-combustion of wood with coal, oil or peat , 1999 .

[47]  Isabel Cabrita,et al.  Co-combustion of coal and meat and bone meal , 2005 .

[48]  Lynn Price,et al.  Potential Energy Savings and CO2 Emissions Reduction of China's Cement Industry , 2012 .

[49]  Marta Schuhmacher,et al.  Partial replacement of fossil fuel in a cement plant: risk assessment for the population living in the neighborhood. , 2010, The Science of the total environment.

[50]  Wang Tao,et al.  STUDY ON FIRED BRICKS WITH REPLACING CLAY BY FLY ASH IN HIGH VOLUME RATIO , 2005 .

[51]  J. A. Conesa,et al.  Pyrolysis kinetics of almond shells and olive stones considering their organic fractions , 1997 .

[52]  Fernando Pelisser,et al.  Concrete made with recycled tire rubber: Effect of alkaline activation and silica fume addition , 2011 .

[53]  Somnuk Tangtermsirikul,et al.  Properties of cement made by partially replacing cement raw materials with municipal solid waste ashes and calcium carbide waste , 2004 .

[54]  S. Tsimas,et al.  USE OF CONSTRUCTION AND DEMOLITION WASTES AS RAW MATERIALS IN CEMENT CLINKER PRODUCTION , 2006 .

[55]  Anastasia Zabaniotou,et al.  Utilization of sewage sludge in EU application of old and new methods--A review , 2008 .

[56]  Ernst Worrell,et al.  Emission Reduction of Greenhouse Gases from the Cement Industry , 2003 .

[57]  Chakib Bouallou,et al.  Study of an innovative gas-liquid contactor for CO2 absorption , 2011 .

[58]  Ron Zevenhoven,et al.  CEMENT MANUFACTURING USING ALTERNATIVE FUELS AND THE ADVANTAGES OF PROCESS MODELLING , 2004 .

[59]  V. Valančienė Utilization of Meat and Bone Meal Bottom Ash in Ceramics , 2011 .

[60]  Xianwei Ma,et al.  Reuse of water purification sludge as raw material in cement production , 2010 .

[61]  Juan Carlos Ciscar,et al.  Energy consumption and CO2 emissions from the world cement industry , 2003 .

[62]  P. Pipilikaki,et al.  Use of tire derived fuel in clinker burning , 2005 .

[63]  S. Maschio,et al.  Fly and bottom ashes from biomass combustion as cement replacing components in mortars production: rheological behaviour of the pastes and materials compression strength. , 2011, Chemosphere.

[64]  A. Gupta,et al.  Hydrogen and syngas production from sewage sludge via steam gasification , 2010 .

[65]  M. Dehestani,et al.  Mechanical properties of concrete containing a high volume of tire-rubber particles. , 2008, Waste management.

[66]  Germán Ferreira,et al.  Study of the environmental performance of end-of-life tyre recycling through a simplified mathematical approach , 2012 .

[67]  Hendrik G. van Oss,et al.  Cement Manufacture and the Environment Part II: Environmental Challenges and Opportunities , 2003 .

[68]  Leandro dos Santos Coelho,et al.  Alternative fuels mixture in cement industry kilns employing Particle Swarm Optimization algorithm , 2008 .

[69]  Germán Ferreira,et al.  Environmental Implications of the Valorisation of the Residual Fraction Refused by Mbt Plants , 2012 .

[70]  Graziella Bernardo,et al.  The use of oil well-derived drilling waste and electric arc furnace slag as alternative raw materials in clinker production , 2007 .

[71]  E. Gartner Industrially interesting approaches to “low-CO2” cements ☆ , 2004 .

[72]  Johan Rootzén,et al.  Reducing Carbon Dioxide Emissions from the EU Power and Industry Sectors - An assessment of key technologies and measures , 2012 .

[73]  Gordana Stefanović,et al.  CO2 reduction options in cement industry: The Novi Popovac case , 2010 .

[74]  A. Zabaniotou,et al.  Green energy at cement kiln in Cyprus—Use of sewage sludge as a conventional fuel substitute , 2008 .

[75]  S Galvagno,et al.  Steam gasification of tyre waste, poplar, and refuse-derived fuel: a comparative analysis. , 2009, Waste management.

[76]  Patrick Sharrock,et al.  Physical and chemical characterisation of crude meat and bone meal combustion residue: "waste or raw material?". , 2005, Journal of hazardous materials.

[77]  C. Nielsen Utilisation of straw and similar agricultural residues , 1995 .

[78]  Ana Jiménez,et al.  Olive stone an attractive source of bioactive and valuable compounds. , 2008, Bioresource technology.

[79]  Ioannis K. Kookos,et al.  Classical and alternative fuel mix optimization in cement production using mathematical programming , 2011 .

[80]  M. Cyr,et al.  Low risk meat and bone meal (MBM) bottom ash in mortars as sand replacement , 2006 .

[81]  Rahman Saidur,et al.  A critical review on energy use and savings in the cement industries , 2011 .

[82]  M. F. Gazulla,et al.  Ceramic wastes as alternative raw materials for Portland cement clinker production , 2008 .

[83]  D. Bentz,et al.  Effects of the incorporation of Municipal Solid Waste Incineration fly ash in cement pastes and mortars: I. Experimental study , 2002 .

[84]  L. Catalan,et al.  Characterization and evaluation of fly-ash from co-combustion of lignite and wood pellets for use as cement admixture , 2010 .

[85]  M. Bazilian,et al.  Possibilities of reducing CO2 emissions from energy-intensive industries by the increased use of forest-derived fuels in Ireland. , 2009 .