AFRHandbook Vol 1-2 Contents

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
of
crushing,
screening,
classifying, removal of pollutants
Reception,
dosing, storage, sampling techniques
alternative fuels
Flame
control,
burner technologies, fire protection
and raw
materials
Impact
CO2 emissions Purchase management
for theon
cement
Logistics Quality control/quality management
andorganization
lime industry Analysis procedures Information
Trials
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 Countryspecific 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
Solinger Strasse 19, D- 45481 Mlheim an der Ruhr, Germany
FlameTel: +49
control,
technologies,
fire
protection
(0) 208-94 16 87 0burner
Fax: +49 (0) 208-94
16 87 50 info@lechtenberg-partner.de
www.lechtenberg-partner.de
Impact on CO2 emissions Purchase management
Alternative Fuels and Raw Materials Handbook
Content
Preface 5
List of Abbreviations 17
List of Chemical Formulae 23
Chapter: 4
Production of RDF 83
4.1 Separation technologies impurities 85
4.2 Screening technology 86
4.2.1 Drum screens/trommel 86

4.2.2 Ballistic separation 90
PART I
Chapter: 1
History and overview of alternative raw
materials and fuels 27
1.1 Alternative raw materials 27
1.1.1 Definition 27
1.1.2 History and utilisation of alternative raw
materials
28
1.1.3 Types of alternative raw materials 28
1.1.4 Characteristics of alternative raw materials 30
1.1.5 Principles when using alternative raw materials 33
1.1.6 Utilisation of alternative raw materials 34
1.1.7 Transport and storage of alternative raw
materials39
1.1.8 Conditioning and dosing of alternative raw
materials39
1.1.9 Quality assurance 41
1.1.10 Outlook 44
1.2 Alternative fuels 45
1.2.1 Definition 45
1.2.2 History of alternative fuels 46
1.2.3 Types of alternative fuels 50
1.2.4 Waste as raw material for alternative fuels 52
1.2.5 Identification of wastes 53
Chapter: 2
Waste evaluation 63
2.1 Defining waste generating sectors 65
2.2 Collecting the required information 66
2.3 Quantification and characterisation of the mixed
waste 67
2.4 Quantification of waste from generators 70
2.5 Fuel-technical properties 72
2.6 Basic principles for the use of alternative fuels 73
Chapter: 3
Key issues for investments in RDF
production technologies and alternative
fuel usage 77
3.1 Basic economic considerations 77
3.2 Criteria influencing the production of
waste-derived fuels 80
4.2.3 Oscillating or vibrating screen 91
4.3 Air classification 93

4.4 Hard/rigid material classifier 95
4.5 Manual separation/hand picking 97

4.6 Optical sorting systems 98
4.7 Metal separation 100

4.7.1 Separation of ferrous materials 100
4.7.2 Non-ferrous separation 101
4.8 Shredding 103
4.8.1 Preshredding 103

4.8.2 Final shredding 107
4.9 Pelletising 113
4.10 Drying technologies 117
4.10.1 Solar drying 118
4.10.2 Belt dryers 120

4.10.3 Drum dryers 122
4.10.4 Notes on dryer systems 124
4.11 Examples of RDF production plants 125

4.12 Economic evaluation of RDF production plants 129
Chapter: 5
Quality management for alternative fuels 133
5.1 Environmentally relevant elements 133
5.2 Contaminant sources in alternative fuels 134

5.3 Investigation of alternative fuels declaration
analysis 138
5.4 Evaluation of waste and alternative fuels in an

RDF production plant 143
5.5 Evaluation of AF in the cement/lime plant
sampling 147
5.6 Sample preparation 149

5.7 Analysis of alternative fuels 152
5.7.1 Preliminary notes 152
5.7.2 Moisture 154

5.7.3 Volatiles and ash 156
5.7.4 Calorific value 156

5.7.5 Chlorine 159
5.7.6 Sulphur 160
5.7.7 Trace elements 161
5.8 Monitoring and reporting 163
Chapter: 6
Logistics and storage of RDF 165
6.1
6.2
6.3
6.4
6.5
Basic principles 165

Transport, loading of alternative fuels 165
Truck reception 169
Reception systems for bulk solid materials 175
Storage of alternative fuels 176
6.5.1 Basic requirements 176

6.5.2 Homogenisation 177
6.5.3 Special section: Fire protection 178
6.5.4 Fire protection evaluation using the example
of astorage facility182
6.5.5 Verification of infrastructural fire protection 191
6.5.6 Explosion protection in secondary fuel storage
facilities 194
6.6 Types of storage 195
6.6.1 Storage as bulk material in an enclosed

facility196
6.6.2 Storage in one or several silos 197
6.6.3 Moving floor storage 198
6.6.4 Storage in adeep bunker with discharge
systems200
6.6.5 Storage in abunker with crane unloading 201
6.6.6 Storage in special storage boxes 203
Chapter: 7
Dosing and feeding of alternative fuels 207
7.1 Screening 207
7.2 Separation of impurities 212
7.3 Conveying technology 212
7.3.1 Pneumatic conveying 212
7.3.2 Mechanical conveying 217
7.3.3 Pipe conveyors 220
7.4 Weighing 221
7.4.1 Fundamentals 221

7.4.2 Weigh feeders 222
7.4.3 Differential weigh feeders 222
7.4.4 Rotor weigh feeder 223
7.4.5 Screw weigh feeder 224
7.5 Feeding points for alternative fuels 225

7.5.1
7.5.2
7.5.3
7.5.4
Basic considerations 225

Main burner 227
Kiln inlet 236
Dosing of alternative fuels in the calciner 237
Chapter: 8
Influences on clinker and lime
production 239
8.1 Ash composition 239
8.2 Sulphur, chlorine, alkalis 244
8.3 Influence on lime production 250
8.4 Refractories 251
8.5 Grain size of fuels 254
8.6 Environmentally relevant trace elements 256
8.6.1 Influence of trace elements on cement

properties strength and setting260
8.6.2 Leaching of trace elements in fresh cement
paste and hardened concrete261
8.7 Impact on fan capacities 263
8.7.1 Calculation basics 263

8.7.2 Example of asubstitution scenario 265
8.8 Specific energy consumption 266

8.9 Remarks on quality control of the cement
production process when using alternative fuels 267
8.10 Emissions 269
8.11 CO2 reduction with alternative fuels 273
8.11.1 Basics 273

8.11.2 Biomass content and emission factors of
alternative fuels274
8.11.3 Determination of biogenic content mass
balance275
8.11.4 Determination of biogenic content manual
sorting, selective dissolution, 14C method276
8.11.5 Fossil CO2 savings in the cement and lime
industry277
Chapter: 9
Contracting alternative fuels 287
9.1
9.2
9.3
9.4
Structure for waste sourcing and AFR units 287

Price evaluation and contracting 289
Contract structure 291
Bonus/malus regulations 291
Chapter: 10
Emission limits and permitting issues 293
10.1 Monitoring of emissions 295
10.2 Monitoring of safe combustion 296
10.3 Permitting issues 298
10.4 Applying for apermit 298
10.5 Trial permit organisation of trials 302
10.6 Public discussions stakeholders 305
Chapter: 11
Current developments of the use of
alternative fuels 309
11.1 Oxy-fuel technology 309
11.2 Ultra fine milling of alternative fuels 312
11.3 Thermal technologies 314
11.4 Pyrolysis of high-calorific residues 318
11.4.1 Fundamentals of pyrolysis technology 318

11.4.2 Applications 319
11.4.3 Hydrothermal carbonisation 321
Annex I
Questionnaire for data collection landfill
site 323
1. General information on landfill site 323
2. General information on the current situation 324
3. Waste input 326
Annex II
Quality management Examples of
excerpts of process instructions for the
processing plant 327
Annex II a
Process instructions for the processing plant 328
Annex II b
Work instructions for sampling waste input and
RDF 338
Fact Sheet:
Alternative fuel and raw material (AFR)
review Poultry litter 369
1 Classification according to European Waste
Catalogue EWC 369
Annex II c
Operational procedures for maintenance and r
epairs 343
Annex II d
Specification for the acceptance of municipal
mixed wastes (MMW) 346
1 Classification according to EWC European

Waste Catalogue 353
AFR description 353
AFR pictures 354
AFR source and composition 354
2.1 Source 354

2.2
Quantity and availability 356
2.4
AFR composition 358
2.3
2.5
2.6
4.2
Collection and transport 376

Recycling, current use and disposal 377
Use as alternative fuels in a cement plant 377
AFR analysis 359
AFR ash composition 360

4.3 Use as alternative fuel in acement or lime

plant362
4.3.1 Economic value of the waste in acement 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
4.3.5 Quality influence on clinker and lime
365
5 Recommendations 367
6 References 367
378
4.3.3 Storage in the plant site
378
378
4.3.5 Quality influence on clinker
379
6 References 379
Fact Sheet:
review Scrap tyres 381
Catalogue EWC 381
Flow chart of AFR production 358
3 Harmful substances and hazardous

characteristics 361
4 Collection, recycling and disposal of the AFR 361
4.1
2.1 Source 371

2.2 Quantity and availability 371
2.3 Flow chart of AFR production 373
2.4 AFR composition 374
2.5 AFR analysis 374
2.6 AFR ash composition 375
4.3.1 Economic value of the waste in a cement

plant377
Fact Sheet:
review Olive residues 353
4.1
4.2
4.3
PART II
1.2
AFR description 369

AFR pictures 370

characteristics 375
Annex II e
Company Safety Instructions RDF 349
1.1
1.1
1.2
1.1
1.2
AFR description 381

AFR pictures 382

2.1 Source 383
2.6 Thermal properties 389

characteristics 389
4.1
4.2
4.3

Use as alternative fuels in a cement plant 391
4.3.1 Economic value of the AFR in a cement

plant391
392
392
393

395
4.3.1 Economic value of the waste in acement

plant431
6 References 396
432
Fact Sheet:
review Sewage sludge 399
432
433
433
catalogue EWC 399
1.1
1.2
AFR description 399

AFR picture 400
2.1 Source 400


characteristics 407
4 Collection, recycling and disposal 408
4.1
4.2
4.3

Use as alternative fuel in acement plant 410
4.3.1 Economic value of the AFR in acement

plant411
412
415
416
417
6 References 418
Fact Sheet:
review Straw 423
1 Classification according to European waste
Catalogue EWC 423
1.1
1.2
AFR description 423

AFR pictures 424
2.1 Source 424


characteristics 428
4.1
4.2
4.3

Use as alternative fuels in acement plant 431
6 References 436
Fact Sheet:
review Used oils 439
Catalogue EWC 439
1.1
1.2
AFR description 440

AFR pictures 440
2.1 Source 441


characteristics 447
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
452
453
453
4.3.5 Quality influence on products
453
6 References 455
Clinker Formulae 457

Bibliography 459
Table of Figures 475
Table of Pictures 479
Table of Tables 485
Advertisement Index 489
Index 495
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:
crushing,
screening,
classifying, removal of pollutants
compendium
of
Reception,
dosing, storage, sampling techniques
alternative fuels
Flame control, burner technologies, fire protection
and raw
Impact
onmaterials
CO2 emissions Purchase management
for the cement
Logistics
Quality control/quality management
Trials
andorganization
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 Countryspecific 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
Solinger Strasse 19, D- 45481 Mlheim an der Ruhr, Germany
FlameTel: +49
control,
technologies,
fire
protection
(0) 208-94 16 87 0burner
Fax: +49 (0) 208-94
16 87 50 info@lechtenberg-partner.de
www.lechtenberg-partner.de
Impact on CO2 emissions Purchase management
Content
Preface 5
List of Abbreviations 21
List of Chemical Formulae 33
Fact Sheet:
review Agriculture films

Catalogue EWC 37
1.1 AFR description 37

1.2 AFR pictures 39
2 AFR source and composition 39
2.1 Source 39
2.5 AFR analysis 44
3 Harmful substances and hazardous characteristics 45


4.2 Recycling, current use and disposal of the AFR 46
4.3 Use as alternative fuel in acement or lime plant 47
6 References 51
Fact Sheet:
review Bagasse

Catalogue EWC 55

1.2 AFR pictures 56
2.1 Source 56
2.5 AFR analysis 60


6 References 65
Fact Sheet:
review Bamboo

Catalogue EWC 69

1.2 AFR pictures 70
2.1 Source 71
2.5 AFR analysis 75

6 References 82
Fact Sheet:
review Calcium fluoride sludge

Catalogue EWC 85

1.2 AFR pictures 86
2.1 Source 86
2.4 AFR composition and analysis 93

4.3 Use as alternative raw material in
acement plant 96
6 References 99
Fact Sheet:
review Carpets and rugs

Catalogue EWC 103

1.2 AFR pictures 104

2.1 Source 105


plant 115
6 References 121
Fact Sheet:
review Coconut shells
Catalogue EWC
127

2.1 Source 129



plant 137

plant 154
6 References 156
Fact Sheet:
review Foams

Catalogue EWC 159
2.1 Source 161




plant 169
6 References 172
Fact Sheet:
review Glycerine from biodiesel
production
6 References 140

Catalogue EWC 175
Fact Sheet:
review Coffee bean husks

Catalogue EWC 143

2.1 Source 145



2.1 Source 176



plant 185
6 References 188
Fact Sheet:
review Labels

Catalogue EWC 191




plant 250
2.1 Source 193

6 References 254

4.3 Use as alternative fuel in a cement or lime
plant 199


6 References 202
Fact Sheet:
review Lime residues

Catalogue EWC 205

Fact Sheet:
review Municipal solid waste

Catalogue EWC 259
2.1 Source 260



plant 272
2.1 Source 207

6 References 280

4.3 Use as alternative raw material in a
cement or lime plant 227

Catalogue EWC 283

6 References 233
Fact Sheet:
review Meat and bone meal

Catalogue EWC 239

2.1 Source 240

Fact Sheet:
review Nappies

2.1 Source 284



plant 294
6 References 297
Fact Sheet:
review Oil mud drillings

Catalogue EWC 303

2.1 Source 304



cement plant 316
6 References 320
Fact Sheet:
review Packaging materials

Catalogue EWC 323

2.1 Source 325



plant 338
6 References 340
Fact Sheet:
review Paper fly ashes

Catalogue EWC 343

2.1 Source 344




cement plant 349
6 References 352
Fact Sheet:
review Plastics

Catalogue EWC 355

2.1 Source 359



plant 375
6 References 382
Fact Sheet:
review Power plant ashes

Catalogue EWC 385

2.1 Sources 387



4.3 Use as alternative raw material in cement
plants 396
6 References 402
Fact Sheet:
review Rice husk

Catalogue EWC 405

2.1 Source 407



plant 416
6 References 421
Fact Sheet:
review Roofing felt

Catalogue EWC 423

2.1 Source 425



4.3 Use as alternative fuel in acement plant 432
6 References 437
Fact Sheet:
review Spent cell linings
also known as Spent pot linings

Catalogue EWC 441

2.1 Source 442

2.3
2.4
2.5
2.6

AFR composition 454
AFR analysis 455


6 References 464
Fact Sheet:
review Spent solvents

Catalogue EWC 467

1.2 AFR picture 469
2.1 Sources 469



plant 484
6 References 489
Fact Sheet:
review Synthetic gypsum

Catalogue EWC 491

2.1 Source 493



4.3 Use as alternative raw material in cement
plants 504
6 References 509
Fact Sheet:
review Textiles

Catalogue EWC 515

2.1 Source 516



plant 523
6 References 526
Fact Sheet:
review Tobacco waste

Catalogue EWC 531

2.1 Source 532



6 References 543
Fact Sheet:
review Used wood
Catalogue EWC 547

2.1 Source 549

2.3
2.4
2.5
2.6

AFR composition 556
AFR analysis 557


plant 564
6 References 570
Table of Figures 573

Table of Pictures 578
Table of Tables 584
Advertisement Index
590

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YOUR EXPERT

Alternative Fuels and Raw Materials Handbook

4.2 Screening technology 86

4.2.1 Drum screens/trommel 86

1.2 Alternative fuels 45

4.2.3 Oscillating or vibrating screen 91

4.3 Air classification 93

4.5 Manual separation/hand picking 97

4.7 Metal separation 100

4.7.2 Non-ferrous separation 101

4.8 Shredding 103

4.8.1 Preshredding 103

4.9 Pelletising 113

4.10 Drying technologies 117

4.10.1 Solar drying 118

4.10.2 Belt dryers 120

4.10.4 Notes on dryer systems 124

4.11 Examples of RDF production plants 125

5.2 Contaminant sources in alternative fuels 134

5.4 Evaluation of waste and alternative fuels in an

5.6 Sample preparation 149

5.7.1 Preliminary notes 152

5.7.2 Moisture 154

5.7.4 Calorific value 156

5.7.6 Sulphur 160

5.7.7 Trace elements 161

5.8 Monitoring and reporting 163

Alternative Fuels and Raw Materials Handbook

Basic principles 165

6.5.1 Basic requirements 176

6.6 Types of storage 195

6.6.1 Storage as bulk material in an enclosed

7.4 Weighing 221

7.4.1 Fundamentals 221

7.5 Feeding points for alternative fuels 225

Basic considerations 225

8.6.1 Influence of trace elements on cement

8.7 Impact on fan capacities 263

8.7.1 Calculation basics 263

8.8 Specific energy consumption 266

8.11.1 Basics 273

Structure for waste sourcing and AFR units 287

11.4.1 Fundamentals of pyrolysis technology 318

Alternative Fuels and Raw Materials Handbook

1 Classification according to EWC European

AFR source and composition 354

2.1 Source 354

Quantity and availability 356

AFR composition 358

Collection and transport 376

AFR analysis 359

AFR ash composition 360

Collection and transport 361

4.3 Use as alternative fuel in acement or lime

4.3.3 Storage at the plant site

4.3.4 Dosing and feeding systems

4.3.5 Quality influence on clinker and lime

4.3.2 AFR pre-processing

4.3.3 Storage in the plant site

4.3.4 Dosing and feeding systems

4.3.5 Quality influence on clinker

Flow chart of AFR production 358

3 Harmful substances and hazardous

5.4 Evaluation of waste and alternative fuels in an

6.6.1 Storage as bulk material in an enclosed

8.6.1 Influence of trace elements on cement

1 Classification according to EWC European

4.3 Use as alternative fuel in acement or lime

3 Harmful substances and hazardous

4.3.1 Economic value of the waste in a cement

3 Harmful substances and hazardous

3 Harmful substances and hazardous

4.3.1 Economic value of the AFR in a cement

4.3.3 Storage at the plant site

4.3.4 Dosing and feeding systems

4.3.1 Economic value of the waste in acement

1 Classification according to European Waste

3 Harmful substances and hazardous

4.3.1 Economic value of the AFR in acement

3 Harmful substances and hazardous

3 Harmful substances and hazardous