Cement Manufacturers Association

10 Derived Fuel (WDF) and initiating their suitable use in cement manufacturing. Data based development on the availability and characterization of combustible waste, waste derived fuels and evaluation of international best practices and technology for waste management and utilization and their adaptation for Indian Cement Plants will additionally be helpful. Indian Cement Industry has a lot of potential to utilize alternate fuels in cement manufacturing with benefits in terms of conservation of natural resources and prevention of environmental hazards including mitigation of Greenhouse Gas Emission, hence serving the goal of sustainable growth and development in India. Industrial and mineral wastes from mineral processing industries, such as chemicals, metallurgy, petrochemical, power, paper and pulp accounts for more than 200 MT out of which more than 6MT are hazardous and can be used alternatively in cement kilns. Today, many cement plants are exploring to collect all the municipal waste of the area, processing it and use it as an alternate fuel. Keeping in view all these, long ago KHD rolled down equipment to use alternate fuels of varying degrees and one such example is of combustion chamber. KHD Combustion chamber is specially designed to burn materials which are coarse and lumpy in nature as well as difficult to ignite. The Calciner process is ruled by a classical dilemma, that temperature and oxygen levels need to be reduced to the maximum to increase production at reduced heat consumption and emission levels while a complete burn-out is still required to avoid CO-triggered failures. Adding to difficulty, increasingly more often secondary fuels of lumpy size and sometimes problematic combustion properties are fired, which must be given sufficient retention time to burn out and must be kept clear from the brick lining until they are not fully burnt. An optimized flow pattern of gas-meal-fuel suspension within the vessel is necessary to accomplish, without creating excessive calciner dimensions. The Calciner design is based on requirements of creation of subsequent zones with dedicated functions for controlled process of NOx reduction, staged combustion and mixing zone for reliable final oxidization on CO- remains. KHD Pyrorotor® is a unique rotary combustion reactor that sustainably co-processes waste materials. Within the range of modular solutions from KHD for co-processing of alternative fuels in clinker production process. The Pyrorotor® covers the demands for highest TSR rates of least pre- processed AF. Due to its high temperature process and longer residence time, it is suitable for nearly all types of coarse solid fuels. For burning fuels tertiary air is used as combustion air (Fig 3). Pyrojet ® Kiln Burner Pyroclon ® Calciner Pyrocion ® R with Pyroincinerator Pyrocion ® R with Comb. Chamber Pyrocion ® R with Pyroroter ® Pre-processing demand Usable particle size Waste oil / Animal meal / Sewage sludge      Biomass max. 2 x 1 x 1 mm (3D) max. 5 x 5 x 2 mm (3D) max. 20 x 20 x 5 mm (3D) max. 40 x 40 x 10 mm (3D) max. 100 x 100 x15 mm (3D) Plastics max. 2 x 1 x 1 mm (3D) max. 5 x 5 x 2 mm (3D) max. 20 x 20 x 5 mm (3D) max. 40 x 40 x 10 mm (3D) max. 300 x 100 x 100 mm (3D) RDF/Fluff max. 10 x 10 mm (2D) max. 30 x 30 mm (2D) max. 70 x 70 mm (2D) max. 100 x 100 mm (2D) max. 300 x 300 mm (2D) Tire Chips X max. 40 x 40 x 25 mm (3D) max. 50 x 50 x 25 mm (3D) max. 70 x 70 x 25 mm (3D) max. 300 x 300 x 25 mm (3D) Whole Tires X X X X  Figure 3 KHD Modular solutions for co-processing waste fuels