Cement Manufacturers Association (CMA)

11 Additional facilities comprise a comprehensive CCTV system for close monitoring of critical locations, including pits, hoppers, and truck entry points. To preserve environmental quality, a deodorization system is in place to manage odors from waste materials. Additionally, a fire control system is operational to swiftly suppress potential fires near the storage pits. These facilities and equipment enhance the system’s efficiency and safety. IMPACT ASSESSMENT After utilizing the TDF into cement kiln, the following conclusions were drawn: • Using TDF up to 21% TSR won’t significantly affect production, heat consumption, or calciner residence time. • Non-volatile (Cr, Ni, V, Zn) and low volatile (Pb, Cd) heavy metals in TDF ash have minimal impact on clinker quality due to their low concentrations. • Zinc (Zn) content limits TDF to 30% due to its adverse impact on cement workability when clinker Zn concentration exceeds 500ppm in Kiln. • Higher ash (35.5%) and iron (18%) content can be managed by optimizing the raw mix composition. • Substituting natural gas with shredded tyres reduces nitrogen content in the calciner fuel mix. • Ash from TDF has limited potential to contribute to PM emissions as most is absorbed into clinker. • No significant influence on stack emissions regarding heavy metals. • Large tyre chips (>50mm) should not be used as TDF to avoid increased CO formation in oxygen-deficient regions of the kiln. • Modern cement kilns co-processing waste can meet emission levels of 0.1 ng TEQ/m3 for dioxins and furans when well managed. • The increased use of TDF with natural gas may introduce chlorine (0.022% Cl content) into the kiln system, requiring detailed investigation of the raw meal/kiln feed sample by chemical methods for plant operation impact. CONCLUSION In summary, the introduction of Tyre Derived Fuel (TDF) with a 23% Thermal Substitution Rate (TSR) has had minimal operational and clinker quality impacts, contributing to sustainability and waste management. The National Council for Cement and Building Materials (NCB), successfully provided consultancy services for a continuous fully automated feeding system for tyre chip storage, handling, and feeding into the calciner. It exemplifies the collaborative partnership between the cement plant and NCB, showcasing responsible industrial practices in cement production and effective waste disposal. The project reduced fossil fuel consumption, with the calciner and kiln now operating at reduced levels while achieving a TSR of approximately 23%.