Secondary fuels in cement production

(Source/Quelle: Cembureau, OneStone)

1 Co-processing of wastes

(Source/Quelle: Cembureau, OneStone)

(Source/Quelle: OneStone)

2 Cement burning process, temperatures, residence times

(Source/Quelle: OneStone)

(Source/Quelle: HeidelbergCement)

3 Fuels used at HeidelbergCement 2009

(Source/Quelle: HeidelbergCement)

(Source/Quelle: Lafarge)

4 RDF and fluff

(Source/Quelle: Lafarge)

(Source/Quelle: OneStone)

5 Benchmark for CO₂ emissions in the cement industry

(Source/Quelle: OneStone)

6 Alternative fuel usage rates

(Source/Quelle: OneStone)

7 Usage rate of CO₂-neutral biofuels

(Source/Quelle: OneStone)

(Source/Quelle: Holcim/GTZ)

8 Criteria for co-processing

(Source/Quelle: Holcim/GTZ)

(Source/Quelle: Holcim Deutschland)

9 Used tyre handling

(Source/Quelle: Holcim Deutschland)

(Source/Quelle: HeidelbergCement)

10 Waste oil disposal

(Source/Quelle: HeidelbergCement)

(Source/Quelle: Vecoplan)

11 Fuel handling with a disc screen

(Source/Quelle: Vecoplan)

(Source/Quelle: Aumund Group)

12 Truck delivery with a Samson feeder

(Source/Quelle: Aumund Group)

(Source/Quelle: HeidelbergCement)

13 Storage of alternative fuels

(Source/Quelle: HeidelbergCement)

(Source/Quelle: Pfister)

14 Multi-material dosing systems

(Source/Quelle: Pfister)

(Source/Quelle: HeidelbergCement)

15 Overview of costs for waste co-processing

(Source/Quelle: HeidelbergCement)

(Source/Quelle: HeidelbergCement, OneStone)

16 Amortisation periods for waste co-processing

(Source/Quelle: HeidelbergCement, OneStone)

(Source/Quelle: Oficeman)

17 The co-processing situation in Europe

(Source/Quelle: Oficeman)

(Source/Quelle: Geocycle)

18 AFR preparation plant in Belgium

(Source/Quelle: Geocycle)

(Source/Quelle: Consultic)

19 Plastics recycling in Germany

(Source/Quelle: Consultic)

(Source/Quelle: HeidelbergCement)

20 TOP co-processing locations of HeidelbergCement

(Source/Quelle: HeidelbergCement)

Alternative fuel handling in a cement plant

(Source/Quelle: HeidelbergCement)

21 Maastricht cement plant of ENCI

(Source/Quelle: HeidelbergCement)

(Source/Quelle: Holcim Deutschland)

22 Lägerdorf cement plant

(Source/Quelle: Holcim Deutschland)

(Source/Quelle: ACC, Geocycle)

23 Development of waste usage rates at ACC

(Source/Quelle: ACC, Geocycle)

(Source/Quelle: Fauji Cement)

24 Cement kiln at Fauji Cement

(Source/Quelle: Fauji Cement)

(Source/Quelle: HeidelbergCement)

25 Co-processing aims

(Source/Quelle: HeidelbergCement)

Summary: Alternative fuels have become a trend topic all over the world. This is partly due to the increase in price of conventional fuels and partly to the discussion about resource conservation and climate change. What contribution can the cement industry make? This report presents background facts and experience gained in the cement industry. Its purpose is not only to deal with the technological aspects but rather to explore the economic and ecological considerations. It particularly discusses the cost-effectiveness and ecological benefit of waste co-processing in cement plants and what developments are currently taking place.

1 Introduction

Western Europe is a world leader in the utilization of alternative fuels in the cement industry. The concept of “Co-Processing” was propagated as long ago as the beginning of the 1990s and within a few years was developed to the point of practical application in numerous cement plants [1, 2]. In contrast to separate refuse incineration and cement production, the utilization of alternative fuels instead of conventional fossil energy sources in the form of waste co-processing in the cement plant has proved to be an effective way of reducing the emission of such greenhouse gases as...