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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.
WHAT IS SRF?
SRF is the name that is given to an alternative fuel that is widely used in the European Cement Industry and stands for Solid Recovered Fuel. SRF is a waste derived fuel which is made using household residual and commercial waste, therefore re-using valuable materials that would otherwise have been wasted. It looks like shredded paper and consists of paper, cardboard, wood, carpet, textiles and plastics. The material has been subject to a treatment process to remove biodegradable matter and produce a solid, clean and non-hazardous fuel. The fuel is manufactured to a tight specification by specialist companies so that it is suitable for use as a fuel in cement kilns.
Ash SRF contains up to 10% ash, which is not dissimilar to the coal mix that is currently being used in Indian cement plants.
As with coal, there are no residues remaining 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.
WHAT HAPPENS TO EMISSIONS WHEN USING SRF? There should be no change in emissions when substituting coal with SRF. The material is finely shredded 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 should have 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.
HOW CAN SRF BE USED? SRF is being successfully used in many cement kilns within Europe and can be adapted to many different process types. SRF is being used on the main burner on Lepol and preheater kilns and both the main burner and in the calciner in precalciner kilns. When used on the main burner in the kilns, it is usually burnt with another fuel such as coal which supports the use 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.
When SRF is used in the calciner, it can be transported into the kiln either by a pneumatic transport system or a mechanical transport system.
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 coal system i.e. the SRF is not mixed with the coal prior to injection into the kiln or calciner.
SRF APPLICATIONS
Used for energy recovery and it is generally used for the following thermal conversion processes: Co-combustion in coal fired boilers Co-incineration in cement kilns Co-gasification with coal or biomass.