Environmental and economic aspects of production and utilization of RDF as alternative fuel in cement plants: A case study of Metro Vancouver Waste Management

Municipal solid waste (MSW) disposal and management is one of the most significant challenges faced by urban communities around the world. Municipal solid waste management (MSWM) over the years has utilized many sophisticated technologies and smart strategies. Municipalities worldwide have pursued numerous initiatives to reduce the environmental burden of the MSW treatment strategies. One of the most beneficial MSWM strategies is the thermal treatment or energy recovery to obtain cleaner renewable energy from waste. Among many waste-to-energy strategies, refuse-derived fuel (RDF) is a solid recovered fuel that can be used as a substitute for conventional fossil fuel. The scope of this study is to investigate the feasibility of RDF production with MSW generated in Metro Vancouver, for co-processing in two cement kilns in the region. This study investigates environmental impacts and benefits and economic costs and profits of RDF production. In addition, RDF utilization as an alternative fuel in cement kilns has been assessed. Cement manufacturing has been selected as one of the most environmentally challenged industries and as a potential destination for RDF to replace a portion of conventional fossil fuels with less energy-intensive fuel. A comprehensive environmental assessment is conducted using a life cycle assessment (LCA) approach. In addition, cost–benefit analysis (CBA) has been carried out to study the economic factors. This research confirmed that RDF production and use in cement kilns can be environmentally and economically viable solution for Metro Vancouver.     

Emissions study of co-firing waste carpet in a rotary kiln

Post-consumer carpet represents a high volume, high energy content waste stream. As a fuel for co-firing in cement kilns, waste carpet, like waste tires, has potential advantages. Technological challenges to be addressed include assessing potential emissions, in particular NO emissions (from nylon fiber carpets), and optimizing the carpet feed system. This paper addresses the former. Results of pilot-scale rotary kiln experiments demonstrate the potential for using post-consumer waste carpet as a fuel in cement kilns. Continuous feeding of shredded carpet fiber and ground carpet backing, at rates of up to 30% of total energy input, resulted in combustion without transient puffs and with almost no increase in CO and other products of incomplete combustion as compared to kiln firing natural gas only. NO emissions increased with carpet waste co-firing due to the nitrogen content of nylon fiber. In these experiments with shredded fiber and finely ground backing, carpet nitrogen conversion to NO ranged from 3 to 8%. Conversion increased with enhanced mixing of the carpet material and air during combustion. Carpet preparation and feeding method are controlling factors in fuel N conversion.     

An analysis of the use of life cycle assessment for waste co-incineration in cement kilns

Life cycle assessment, LCA, has become a key methodology to evaluate the environmental performance of products, services and processes and it is considered a powerful tool for decision makers. Waste treatment options are frequently evaluated using LCA methodologies in order to determine the option with the lowest environmental impact. Due to the approximate nature of LCA, where results are highly influenced by the assumptions made in the definition of the system, this methodology has certain non-negligible limitations. Because of that, the use of LCA to assess waste co-incineration in cement kilns is reviewed in this paper, with a special attention to those key inventory results highly dependent on the initial assumptions made. Therefore, the main focus of this paper is the life cycle inventory, LCI, of carbon emissions, primary energy and air emissions. When the focus is made on cement production, a tonne of cement is usually the functional unit. In this case, waste co-incineration has a non-significant role on CO₂ emissions from the cement kiln and an important energy efficiency loss can be deduced from the industry performance data, which is rarely taken into account by LCA practitioners. If cement kilns are considered as another waste treatment option, the functional unit is usually 1 t of waste to be treated. In this case, it has been observed that contradictory results may arise depending on the initial assumptions, generating high uncertainty in the results. Air emissions, as heavy metals, are quite relevant when assessing waste co-incineration, as the amount of pollutants in the input are increased. Constant transfer factors are mainly used for heavy metals, but it may not be the correct approach for mercury emissions.     

Energetic valorization of SRF in dedicated plants and cement kilns and guidelines for application in Greece and Cyprus

A debate is still open on issues of waste to energy methodologies aiming to answer to questions of particular relevance, such as whether the concept of SRF/RDF production can be applied directly to MSW through the Mechanical–Biological Treatment (MBT) process, when selective collection acts as a virtual pre-treatment of the same, or if the use of SRF/RDF as alternative fuel in cement kilns is the most sustainable solution. In this study, two scenarios were analyzed and compared: (a) the use of SRF in a new dedicated thermal plant for electricity production and (b) the use of SRF as an alternative fuel in an existing cement plant. The comparative assessment was based on principles of Sustainable Waste Management embracing technical and cost issues, environmental protection, industrial ecology and symbiosis. The application of SWOT analysis showed that the use of SRF in cement kilns is more sustainable compared to its use in a new dedicated plant for electricity production.     

A disaggregated emissions inventory for Taiwan with uses in hybrid input‐output life cycle analysis (IO‐LCA)

This paper reports on a life‐cycle analysis (LCA) of Taiwan's “agriculture and forestry”, “crude petroleum, coal and natural gas extraction” and “electricity generation” sectors, revealing for the first time Taiwan's CO₂ and CH₄ emissions inventories and matching Taiwan's input‐output sectors. Integrated hybrid input‐output life cycle analysis is used to disaggregate the electricity generation sector into nuclear, hydro, gas, oil and coal, and cogeneration. Results show that the fossil‐fuel‐related electricity sub‐sectors have higher CO₂ emissions intensity than the remaining sectors in the economy and that the “paddy rice” sector is Taiwan's most CH₄‐intensive sector, making rice cultivation an important source of CH₄ emissions. This work is vital to sound policy decisions concerning power generation, coal, and agriculture and forestry at the national level.     

Techno-Economic Study of CO2 Capture from an Existing Cement Plant Using MEA Scrubbing

Carbon dioxide is the major greenhouse gas responsible for global warming. Man-made CO₂ emissions contribute approximately 63% of greenhouse gases and the cement industry is responsible for approximately 5% of CO₂ emissions emitting nearly 900 kg of CO₂ per 1000 kg of cement. CO₂ from a cement plant was captured and purified to 98% using the monoethanolamine (MEA) based absorption process. The capture cost was $51 per tonne of CO₂ captured, representing approximately 90% of total cost. Steam was the main operating cost representing 39% of the total capture cost. Switching from coal to natural gas reduces CO₂ emissions by about 18%. At normal load, about 36 MW of waste heat is available for recovery to satisfy the parasitic heat requirements of MEA process; however, it is very difficult to recover.     

Life‐Cycle Assessment of Construction in a Developing Country

The construction industry plays a great role in a country's or an area's economy. Construction activities also have significant and increasing effects on the environment. Life‐cycle assessment (LCA) is one of the environmental management techniques that can be used to evaluate the environmental burdens of construction. The authors of this study applied the LCA approach and SimaPro 7.1 software within the framework of the International Organization of Standardization's (ISO) 14040 series of standards and analyzed the global warming potential (GWP) and acidification potential (AP) of the materials acquisition and construction phases of the Parand residential apartment complex located in the southwest part of Tehran province, Iran.     

Reject management from a Mechanical Biological Treatment plant in Bangkok, Thailand

The potential reuse of rejects from upstream and downstream process of Mechanical-Biological-Treatment (MBT) plant for the production refuse derived fuel (RDF) was investigated in the present study. Since, the rejects were characterized with the high calorific values of approximately 21 kJ/kg for upstream process and 29.5 kJ/kg for downstream process, both can be considered for RDF production. Further, heavy metal contents were also not exceeding the European standards for using it as RDF is additional benefit. But, RDF production from upstream process rejects showed maximum energy supply of 3.20 × 10⁶ MJ/d with less ash (11.8%), chlorine (0.6%) and sulfur (0.2%) contents than the downstream process rejects. Among the three potential RDF users surveyed, the cement industries showed positive interest to burn RDF in their cement kiln with the energy supply cost of <2.1 USD/GJ. Few technical, economical and safety barriers were also identified with the RDF end users and potential suggestions were discussed for thriving RDF market in Thailand.     

Environmental sustainability assessment of food waste valorization options

Food waste can be valorized through different technologies, such as anaerobic digestion, incineration, and animal feed production. In this study we analyzed the environmental performance of two food waste valorization scenarios from a company of the retail sector in Belgium, through exergy analysis, exergetic life cycle assessment (ELCA), and a traditional life cycle assessment (LCA). In scenario 1 all food waste was considered to be valorized in an anaerobic digestion (producing electricity, heat, digestate and sorting the packaging material to be used as fuel for cement industry), while in scenario 2 a bread fraction was valorized to produce animal feed and a non-bread fraction was valorized in an anaerobic digestion (producing the same products on scenario 1, but in lower amounts). Scenario 2 was 10% more efficient than scenario 1 in the exergy analysis. For the ELCA and the single score LCA, scenario 2 presented lower environmental impacts than scenario 1 (32% and 26% lower, respectively). These results were mainly due to the avoided products from traditional supply chain (animal feed produced from agricultural products) and lower exergy loss at the feed production plant. Nevertheless, the high dry matter content of the bread waste played an important role on these results, therefore it should be pointed out that valorizing food waste to animal feed seems to be a better option only for the fractions of food waste with low water content (as bread waste).     

Bioethanol from waste: Life cycle estimation of the greenhouse gas saving potential

This paper considers two alternative feedstocks for bioethanol production, both derived from household waste—Refuse Derived Fuel (RDF) and Biodegradable Municipal Waste (BMW). Life Cycle Assessment (LCA) has been carried out to estimate the GHG emissions from bioethanol using these two feedstocks. An integrated waste management system has been considered, taking into account recycling of materials and production of bioethanol in a combined gasification/bio-catalytic process. For the functional unit defined as the ‘total amount of waste treated in the integrated waste management system’, the best option is to produce bioethanol from RDF—this saves up to 196 kg CO₂ equiv. per tonne of MSW, compared to the current waste management practice in the UK.However, if the functional unit is defined as ‘MJ of fuel equiv.’ and bioethanol is compared with petrol on an equivalent energy basis, the results show that bioethanol from RDF offers no saving of GHG emissions compared to petrol. For example, for a typical biogenic carbon content in RDF of around 60%, the life cycle GHG emissions from bioethanol are 87 g CO₂ equiv./MJ while for petrol they are 85 g CO₂ equiv./MJ. On the other hand, bioethanol from BMW offers a significant GHG saving potential over petrol. For a biogenic carbon content of 95%, the life cycle GHG emissions from bioethanol are 6.1 g CO₂ equiv./MJ which represents a saving of 92.5% compared to petrol. In comparison, bioethanol from UK wheat saves 28% of GHG while that from Brazilian sugar cane – the best performing bioethanol with respect to GHG emissions – saves 70%. If the biogenic carbon of the BMW feedstock exceeds 97%, the bioethanol system becomes a carbon sequester. For instance, if waste paper with the biogenic carbon content of almost 100% and a calorific value of 18 MJ/kg is converted into bioethanol, a saving of 107% compared to petrol could be achieved. Compared to paper recycling, converting waste paper into bioethanol saves 460 kg CO₂ equiv./t waste paper or eight times more than recycling.     

Utilization of cement kiln dust (CKD) in cement mortar and concrete—an overview

Solid waste management is one of the major environmental concerns around the world. Cement kiln dust (KKD), also known as by-pass dust, is a by-product of cement manufacturing. The environmental concerns related to Portland cement production, emission and disposal of CKD is becoming progressively significant. CKD is fine-grained, particulate material chiefly composed of oxidized, anhydrous, micron-sized particles collected from electrostatic precipitators during the high temperature production of clinker. Cement kiln dust so generated is partly reused in cement plant and landfilled. The beneficial uses of CKD are in highway uses, soil stabilization, use in cement mortar/concrete, CLSM, etc.Studies have shown that CKD could be used in making paste/mortar/concrete. This paper presents an overview of some of the research published on the use of CKD in cement paste/mortar/concrete. Effect of CKD on the cement paste/mortar/concrete properties like compressive strength, tensile strength properties (splitting tensile strength, flexural strength and toughness), durability (Freeze–thaw), hydration, setting time, sorptivity, electrical conductivity are presented. Use of CKD in making controlled low-strength materials (CLSM), asphalt concrete, as soil stabilizer, and leachate analysis are also discussed in this paper.     

Life cycle modelling of fossil fuel power generation with post-combustion CO2 capture

Due to its compatibility with the current energy infrastructures and the potential to reduce CO₂ emissions significantly, CO₂ capture and geological storage is recognised as one of the main options in the portfolio of greenhouse gas mitigation technologies being developed worldwide. The CO₂ capture technologies offer a number of alternatives, which involve different energy consumption rates and subsequent environmental impacts. While the main objective of this technology is to minimise the atmospheric greenhouse gas emissions, it is also important to ensure that CO₂ capture and storage does not aggravate other environmental concerns. This requires a holistic and system-wide environmental assessment rather than focusing on the greenhouse gases only. Life Cycle Assessment meets this criteria as it not only tracks energy and non-energy-related greenhouse gas releases but also tracks various other environmental releases, such as solid wastes, toxic substances and common air pollutants, as well as the consumption of other resources, such as water, minerals and land use. This paper presents the principles of the CO₂ capture and storage LCA model developed at Imperial College and uses the pulverised coal post-combustion capture example to demonstrate the methodology in detail. At first, the LCA models developed for the coal combustion system and the chemical absorption CO₂ capture system are presented together with examples of relevant model applications. Next, the two models are applied to a plant with post-combustion CO₂ capture, in order to compare the life cycle environmental performance of systems with and without CO₂ capture. The LCA results for the alternative post-combustion CO₂ capture methods (including MEA, K⁺/PZ, and KS-1) have shown that, compared to plants without capture, the alternative CO₂ capture methods can achieve approximately 80% reduction in global warming potential without a significant increase in other life cycle impact categories. The results have also shown that, of all the solvent options modelled, KS-1 performed the best in most impact categories.     

The use of petroleum coke as fuel in a 10 kWth chemical-looping combustor

Tests were made in a 10 kW_th chemical-looping combustor with a petroleum coke as the solid fuel and the oxygen carrier ilmenite, an iron titanium oxide. The fuel reactor is fluidized by steam and the oxygen carrier reacts with the volatiles released as well as the gasification intermediates CO and H₂. A constant fuel flow corresponding to a thermal power of 5.8 kW was introduced into the fuel reactor and a total of 11 h of operation was reached. The effects of particle circulation and carbon stripper operation on solid fuel conversion, conversion of gas from the fuel reactor and CO₂ capture were investigated. The actual CO₂ capture ranged between 60% and 75% while the solid fuel conversion was in the range of 66–78%. The low values of solid fuel conversion reflect loss of char due to low efficiency of the fuel reactor cyclone. The incomplete conversion of the gas from the fuel reactor is expressed as oxygen demand. The oxygen demand corresponds to the fraction of oxygen lacking to achieve full gas conversion and was typically 25%, due to presence of CH₄, CO and H₂ from the fuel reactor. Typical ratios of CH₄, CO and H₂ over the total gaseous carbon from the fuel reactor are respectively 5, 10 and 25%. Low loss of non-combustible fines from the system indicates very low attrition of the oxygen carrier.     

Comparison of energy produced from waste by removing its different components: A case study of the waste landfill in Tehran

In developing and populated cities such as Tehran, a massive amount of municipal solid waste (MSW), both wet and dry, is transferred to landfills daily. Combustion is one of the most common methods of using mixed waste energy from the past to the present. The Dulong formula is widely used to calculate the energy released from MSW combustion. According to the constituent components of Tehran MSW, removing food waste leads to an increase in energy potential, which will be a suitable condition for energy production. In this work, the energy derived from the combustion of mixed and separated dry MSW generated in Tehran was calculated using the experimental Dulong formula and tables in Integrated Solid Waste Management (Tchobanoglous et al. 1993, McGraw‐Hill). The Dulong formula indicates that the use of Tehran mixed MSW (without separating materials for recycling) as a fuel source yields 8,966.40 KJ/kg while the use of Tchobanoglous et al. (1993) tables can generate 8,236 kJ/kg. By removing food waste and recyclable materials, the potential of energy production changes to 22,047 kJ/kg using the Dulong formula and 16,207 kJ/kg and the Tchobanoglous et al. (1993) tables. It indicates increase by 1.46 times and 46%, respectively. Regarding the 200‐ton capacity of the Tehran waste incinerator, the Dulong formula indicated generation of 4,409 MJ/day energy, and the Tchobanoglous et al. table presents 3,241 MJ/day. Therefore, considering that Tehran generates more than 4,000 tons of reject waste daily, it can easily be converted to energy rather than landfilled. This can alleviate the problem of buying land and construction of landfills and leachate generation.     

The environmental life cycle assessment of agricultural sector in Thailand: EIO‐LCA approach

Agriculture is one of the major sectors in Thailand, with more than half of the population employed in agriculture‐related occupations. This study evaluated energy consumption and greenhouse gas (GHG) emissions of the Thai agricultural sector by applying the economic input–output life cycle assessment (EIO‐LCA) approach. The model evaluates the entire agricultural sector supply chain. Based on one million Thai baht (approximately $27,800 U.S. dollars) final demand of the rice paddy sector, the carbon dioxide (CO₂) emissions from the electricity sector are responsible for 27% (1,246 kilograms [kg] CO₂) of the total CO₂ emissions, whereas the emissions from paddy activities associated with the fertilizers and pesticides sector account for 16% (760 kg CO₂) and 11% (513 kg CO₂), respectively. The top three largest GHG emissions from the total agricultural sector supply chain are associated with the oil palm, the coffee and tea, and the fruit sectors. The government should promote and encourage sustainable agriculture by reducing the use of fertilizers and pesticides and by utilizing energy‐saving technologies.     

Life cycle assessment of natural gas combined cycle power plant with post-combustion carbon capture,transport and storage

Hybrid life cycle assessment has been used to assess the environmental impacts of natural gas combined cycle (NGCC) electricity generation with carbon dioxide capture and storage (CCS). The CCS chain modeled in this study consists of carbon dioxide (CO₂) capture from flue gas using monoethanolamine (MEA), pipeline transport and storage in a saline aquifer.Results show that the sequestration of 90% CO₂ from the flue gas results in avoiding 70% of CO₂ emissions to the atmosphere per kWh and reduces global warming potential (GWP) by 64%. Calculation of other environmental impacts shows the trade-offs: an increase of 43% in acidification, 35% in eutrophication, and 120–170% in various toxicity impacts. Given the assumptions employed in this analysis, emissions of MEA and formaldehyde during capture process and generation of reclaimer wastes contributes to various toxicity potentials and cause many-fold increase in the on-site direct freshwater ecotoxicity and terrestrial ecotoxicity impacts. NO_x from fuel combustion is still the dominant contributor to most direct impacts, other than toxicity potentials and GWP. It is found that the direct emission of MEA contribute little to human toxicity (HT < 1%), however it makes 16% of terrestrial ecotoxicity impact. Hazardous reclaimer waste causes significant freshwater and marine ecotoxicity impacts. Most increases in impact are due to increased fuel requirements or increased investments and operating inputs.The reductions in GWP range from 58% to 68% for the worst-case to best-case CCS system. Acidification, eutrophication and toxicity potentials show an even large range of variation in the sensitivity analysis. Decreases in energy use and solvent degradation will significantly reduce the impact in all categories.     

Utilization of cement kiln dust (CKD) in cement mortar and concrete—an overview

Solid waste management is one of the major environmental concerns around the world. Cement kiln dust (KKD), also known as by-pass dust, is a by-product of cement manufacturing. The environmental concerns related to Portland cement production, emission and disposal of CKD is becoming progressively significant. CKD is fine-grained, particulate material chiefly composed of oxidized, anhydrous, micron-sized particles collected from electrostatic precipitators during the high temperature production of clinker. Cement kiln dust so generated is partly reused in cement plant and landfilled. The beneficial uses of CKD are in highway uses, soil stabilization, use in cement mortar/concrete, CLSM, etc.Studies have shown that CKD could be used in making paste/mortar/concrete. This paper presents an overview of some of the research published on the use of CKD in cement paste/mortar/concrete. Effect of CKD on the cement paste/mortar/concrete properties like compressive strength, tensile strength properties (splitting tensile strength, flexural strength and toughness), durability (Freeze–thaw), hydration, setting time, sorptivity, electrical conductivity are presented. Use of CKD in making controlled low-strength materials (CLSM), asphalt concrete, as soil stabilizer, and leachate analysis are also discussed in this paper.     

Biogas upgrading and utilization from ICEs towards stationary molten carbonate fuel cell systems

Biogas production from anaerobic digestion has increased rapidly in the last years, in many parts of the world, mainly due to its local scale disposition and to its potential on greenhouse gases (GHG) emissions mitigation. Biogas can be used as fuel for combined heat and power systems (CHP), in particular for internal combustion engines (ICEs). In recent investigations, fuel cells have been considered as alternative CHP systems. In the present article, two different energy conversion systems are compared: a 1.4 MW class MCFC system, running on pipeline natural gas, and an in situ ICE, running on biogas. In the first case, biogas is considered as a source fuel to obtain upgraded gas to be injected in the natural gas grid. In such scenario, the location of the fuel cell power plant is no longer strictly connected to the anaerobic digester site. Several energy balances are evaluated, considering different upgrading techniques and different biogas methane/carbon dioxide ratios.     

Microalgae‐based biodiesel production in open raceway ponds using coal thermal flue gas: A case of West Bengal,India

India is one of the most populous countries and is the third largest greenhouse gas–emitting nation. Energy security is a serious issue for India as it relies heavily on fossil fuel imports. Biodiesel production using microalgae as feedstock can address both of these issues. In this study, the technical feasibility of microalgae‐based biodiesel production is carried out for a coal thermal power plant (i.e., Budge Budge Thermal Station) in the state of West Bengal, India, using a generic methodology. An oleaginous microalgae species that is tolerant toward flue gas was identified (i.e., Nannochloropsis sp). A 75‐acre open raceway microalgae production plant was designed keeping the costs, energy demand, and CO₂ emissions low. The open raceway pond can use 38 tons of CO₂, produce 19 tons of algal biomass, and treat 9320 m³ of wastewater per acre annually.     

Experimental investigation into performance of integrated hotbox in 1-kW solid oxide fuel cell system

An experimental investigation is performed to evaluate the performance of an integrated hotbox in a 1-kW solid oxide fuel cell (SOFC) system fed by natural gas. The integrated hotbox comprises all the main balance of plant components of an SOFC system, i.e. afterburner, reformer, and heat exchanger, and it not only reduces the physical size of the system but also yields improved system efficiency. The experimental results show that under optimal operating conditions, the combined H₂ and CO content of the reformate gas is approximately 70%, while both anode and cathode in-gas temperatures are around approximately 750°C.