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INTRODUCTION
The aim of this document is to answer some of the
basic questions relating to the potential use of
Solid Recovered Fuel (SRF) in the Indian
Cement Industry.
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WHAT IS SRF?
SRF is the name that is given to an alternative fuel thatis widely used in the European Cement Industry and
stands for Solid Recovered Fuel. SRF is a wastederived fuel which is made using household residualand commercial waste, therefore re-using valuablematerials that would otherwise have been wasted. Itlooks like shredded paper and consists of paper,
cardboard, wood, carpet, textiles and plastics. Thematerial has been subject to a treatment process toremove biodegradable matter and produce a solid,clean and non-hazardous fuel. The fuel ismanufactured to a tight specification by specialist
companies so that it is suitable for use as a fuel incement kilns.
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WHY IS SRF AN IDEAL FUEL?
SRF is an ideal fuel for the cement industry as it has similar
properties to some of the fuels that already used in the
cement industry. The size of SRF
normally around 20-30mm flat pieces of plastic or paper means that it burns
rapidly, releasing the heat into the cement manufacturing
process where it is needed. Using SRF will save valuable
fossil fuels such as coal, heavy fuel oil and gas. As the
components that make up SRF are carefully monitored, inmost cases the variability of parameters such as moisture,
ash and chloride will be lower than in fossil fuels such as
coal.
In addition, as compared to industrial waste, lack of supply isnever an issue given the large quantities of household
residual and commercial waste generated each day.
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HOW DOES THE CALORIFIC VALUE (CV) COMPARE TO
COAL?
Dependent upon the proportions of materials such as
paper and plastics, the CV of the SRF can be tailored bythe producer of the SRF to suit the requirements of the
cement manufacturer. However, a typical SRF would
have a net CV of between 18 and 20 MJ/tonne. Whilst
there are many different grades of coal available inIndia, it is understood that a typical CV of coal used in
the cement industry would be a blend of Indian and
International coal with a blended CV of around 17
MJ/tonne. Therefore it can be seen that, in terms of CV,
SRF could be substituted on a like-for-like basis with
coal.
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WHAT ARE THE OTHER PROPERTIES OF SRF?In relation to the cement manufacturing process, the following parameters have been
reviewed:
Moisture content SRF contains around 10-15% moisture. Clearly this is higher than in
pulverised fuel that is used in the cement manufacturing process. If fired in the mainburner in the kiln experience shows that it does not have a major impact as the SRF is
only a partial replacement of the coal, which is the principal fuel in the burning zone. If
SRF is used in the calciner almost no impact is observed, as the calciner vessel of the
pyro-processing line is ideal for lower grade fuels.
Chloride SRF can contain up to 2% chloride due to the plastics fraction in the fuel;
however, the SRF is designed to have a chloride content based upon the total chlorideinputs into the pyro-processing system up to a level where build-ups in the process can
be avoided. More typical levels of chloride in SRF are around 0.5 1%. A chloride balance
can be performed to identify the maximum level of chloride for a particular SRF addition
rate. Many manufacturers who are using high levels of chloride have installed volatiles
by-pass systems to remove chlorides.
Sulphur SRF contains almost no sulphur and therefore is particularly advantageous in
plants that have high levels of sulphur in the process as it will reduce the overall sulphurinput into the process.
Ash SRF contains up to 10% ash, which is not dissimilar to the coal mix that is currently
being used in Indian cement plants.
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ARE THERE ANY RESIDUES LEFT OVER WHEN USING
SRF?
As with coal, there are no residuesremaining from the use of SRF. All of the
ash is incorporated into the clinker. SRF
will be delivered wrapped in plastic bales;this plastic can be recycled locally in
India.
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WHAT HAPPENS TO EMISSIONS WHEN USING SRF?
There should be no change in emissions when
substituting coal with SRF. The material is finelyshredded and therefore burns rapidly in the
high temperature of the kiln ensuring complete
combustion of the material and therefore no
change in CO or VOCs. The use of SRF shouldhave no effect on NOx as the majority of NOx
produced in a kiln is thermal NOx. Due to the
low sulphur in SRF, no change in SO2
emissions will occur.
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HOW CAN SRF BE USED?
SRF is being successfully used in many cementkilns within Europe and can be adapted to many
different process types. SRF is being used onthe main burner on Lepol and preheater kilnsand both the main burner and in the calciner inprecalciner kilns. When used on the main
burner in the kilns, it is usually burnt withanother fuel such as coal which supports theuse of the SRF and maintains the flame shape.When used in the calciner it can be used with a
blend of other alternative fuels or on its own.
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WHAT KIND OF SYSTEM NEEDS TO BE INSTALLED TO USE SRF?
When SRF is used on the main burner in the kiln, it is necessary to
transport the fuel into the kiln via a pneumatic transport system.
When SRF is used in the calciner, it can be transported into the kiln
either by a pneumatic transport system or a mechanical transportsystem.
Firing SRF mid-kiln, using a technology called MIFLEX, is the better
solution for long dry and wet kilns. It has the added advantage to be
able to co-fire other bulk fuels like tires simultaneously.
The right solution, including the investment costs, will depend on the
existing process parameters, feed rates, plant lay-out etc.
No system is particularly complicated, with the most important item in
the system being the volume control, so that the fuel can be metered
in at the correct weight. The systems are independent of the coalsystem i.e. the SRF is not mixed with the coal prior to injection into
the kiln or calciner.
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WHY SHIP SRF FROM THE UK TO INDIA?
SRF is being produced in the UK for use in cement kilns and
there is a surplus of material. Due to the cost structure of
disposing of these materials in the UK, the fuel can be
produced at extremely low cost and therefore provides a
suitable alternative fuel for the cement manufacturing
process. From the Indian perspective, there is a shortage of
coal for the production of both power and cement which
means that expensive international coal needs to beimported into the country.
Therefore SRF represents a real opportunity for the cement
industry. Whilst the materials that make up SRF are available
in India, they are potentially more valuable to be recycled/re-
used elsewhere rather than used as a fuel for cement kilns.
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WHERE ELSE IS SRF BEING USED?
SRF is being extensively used throughout the United
Kingdom and Europe as a substitute fuel in cementkilns. SRF is widely transported between countries in
Europe where there is a surplus of material in one
country and a demand in another. All of the major
international companies such as Lafarge, Holcim,CEMEX, Italcementi and Heidelberg are using SRF in
Europe and SRF is taking over from other alternative
fuels such as tyre chips.
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WHAT ABOUT CO2 EMISSIONS AND CARBON CREDITS?
The use of alternative fuels in the cement industry savesfossil fuels that would have otherwise been burnt. WithinEurope, alternative fuels that have a biomass content
will have a proportion of their CO2 emissions classed ascarbon neutral when annual CO2 emissions arecalculated. SRF contains around 50% biomass andtherefore only 50% of the CO2 emissions from this fuelwould be counted in an emissions trading scheme.
Outside of Europe, alternative fuels projects whichdemonstrate a reduction in CO2 through the use ofbiomass may fall under the Clean DevelopmentMechanism (CDM) of the UNFCCC. Under this scheme,carbon credits (which could be sold on the open market)would be obtained upon implementation of the
alternative fuels scheme. This scheme would have to bereviewed on a case by case basis.
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SRF APPLICATIONS
Used for energy recovery and it is generallyused for the following thermal conversion
processes:
Co-combustion in coal fired boilers
Co-incineration in cement kilns
Co-gasification with coal or biomass.
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THANK YOU FOR YOUR TIME!
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