Paper9

Procedia Environmental Sciences 31 (2016) 309 – 317
1878-0296 © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of Tsinghua University/ Basel Convention Regional Centre for Asia and the Pacific
doi:10.1016/j.proenv.2016.02.041
Available online at www.sciencedirect.com
ScienceDirect
The Tenth International Conference on Waste Management and Technology (ICWMT)
Co-processing of industrial waste in cement kiln – a robust system
for material and energy recovery
Rahul Baidyaa
*, Sadhan Kumar Ghoshb
, Ulhas V. Parlikarc
a,b
Department of Mechanical Engineering, Jadavpur University, and International Society of Waste Management, Air and Water (ISWMAW),
Kolkata, India
c
Geocycle India, ACC Limited, Mumbai, India
Abstract
Waste management is a serious issue around the world. It is most prominent in the developing countries. Non–hazardous
industrial waste is another aspect at 100 million tons/year with coal ash accounting for 70 million ton/year in India. It is the
second highest waste stream ending up in landfill site. The quantity is projected to be increased at faster rate in coming years with
increasing industrialization. This industrial waste has characteristics of municipal solid waste with percentage of non-
biodegradable waste on the higher side. Co-processing of this waste for energy recovery and as an alternative raw material in
cement kiln can be an effective management methodology for this waste stream. This is being practiced sustainably in number of
countries but in India the process lacks proper implementation. The auxiliary technological requirement is less and the process is
highly economical and effective. This study specifically shows the effectiveness of the co-processing in cement plants in India, as
a way for an effective utilization of energy and recoverable raw materials locked in the industrial waste. The robustness of the co-
processing of industrial waste has been analyzed based on three cases studies in India. The findings revealed that it can be one of
the most effective industrial waste disposal techniques in India and in other developing countries considering other practices of
waste disposal methodology in terms of zero ash generation, emission, less auxiliary technology requirements, less set up cost,
etc. The robustness of the co-processing as a waste disposal technique was also revealed by the economic and environmental
statistical analysis. The study shows the sustainability of co-processing as an energy and material recovery process and addresses
the issues related to sustainable management of industrial wastes. Number of study is available in the literature but analysis based
on multiple case studies specific to Indian scenario is scarce.
© 2015 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of Tsinghua University/ Basel Convention Regional Centre for Asia and the Pacific.
Keywords: Co-processing; Cement kiln; Industrial waste; India; Sustainability.
*
Corresponding author. Tel.: +91-9883010828.
E-mail address: rahulbaidya.ju@gmail.com
© 2016 The Authors. Published by Elsevier B.V This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of Tsinghua University/ Basel Convention Regional Centre for Asia and the Pacific

310 Rahul Baidya et al. / Procedia Environmental Sciences 31 (2016) 309 – 317
1. Introduction
India is the second largest producer of cement in the world. Cement production is an energy intensive process.
The cement industry in India emitted 129.92 million tons of CO2, which is 32% of the total CO2 emissions from the
industry sector in 20071
. The production of cement is material and energy intensive and co-processing of waste-
derived materials represents a common strategy to reduce the cost and environmental impact2, 3, 4
. Coupled with
resource conservation and reduced carbon emissions, co-processing technology is a preferable alternative for sound
and environmental friendly waste disposal over incinerators & non-scientific methods. It is not only solution to the
waste disposal menace, but also reduces burden on secured landfills5
. The use of industrial wastes as an alternative
fuel in the cement industry is a reality in several countries because wastes are removed and economic incomes are
obtained preserving virgin materials6
. The use of alternative fuels and raw materials (AFR) for cement clinker
production is certainly of high importance for the cement manufacturer and also for the society as a whole.
Traditional kiln fuels are gas, oil and coal. Materials like waste oils, plastics, auto shredded residues, waste tyres and
sewage sludge (SS) are now being proposed as alternative fuels for the cement industry. Also the slaughterhouse
residues are used as fuel nowadays in cement plant. The plant to use any of the AFR in a cement kiln, it is necessary
to know the composition of the fuel and raw material. The choice is normally based on price and availability. The
energy and ash contents are also important, as are the moisture and volatiles contents7
. Alternative fuel and raw
material utilization in cement kilns is still progressing. While in some kilns up to 100% substitution rates have been
achieved, but in some cases other prevailing conditions do not allow for higher rates of AFR8
. The cement industry
has characteristics that make the burning of wastes viable, since it is characterized by high energy thermal process
necessary to produce the clinker. The clinker is obtained from the grinding, homogenization and burning (high
temperatures – 1450°C) inside rotary kilns with raw materials (limestone, clay, sand, iron ore). The next steps are
the cooling of the clinker, grinding the clinker with gypsum and other additives to produce cement and finally
storing, packaging and transporting the cement to the end user9, 10
. In any case, alternative fuel utilization requires
the adaptation of the combustion process, though modern multi-channel burners and thermograph systems allow
controlling the alternative fuel feed rate and the flame shape to optimize the burning behaviour of the fuels8
.
Wzorek11
showed that the fuels manufactured with the use of sewage sludge and waste materials offered a
satisfactory energy values for the cement industry as specified for alternative fuels. According to IEA statistics, the
OECD cement industry used 66 PJ of combustible renewable waste in 2003, around half of it industrial waste and
half wood waste. Worldwide, the sector consumed 112 PJ of biomass and 34 PJ of waste. There is apparently little
use of alternative fuels outside the OECD, although the comparison of country data from various sources with IEA
statistics tends to imply that alternative fuel use is under-reported. From a technical perspective, the use of
alternative fuels could be raised to 1 to 2 EJ, although there would be differences among regions due to the varying
availability of such fuels12
. Reusing industrial by-products is considered as the most promising and practical solution
to reduce the portion going to the landfill. These by-products can be reused by mixing with raw materials and fed to
cement process. Moreover these wastes can be substitute with clinker and can become a composition of final cement.
Fly ash is an example of such material. In case of fly ash, the by-product not only contributes to reduce raw
materials and energy requirement in the process but also able to improve concrete property. The organic part in the
fly ash is burnt and acts as the source of thermal energy and the mineral part is integrated into the process and
contributes as raw material and additive13,14
. Blast furnace slag is another example of materials which are being
utilized as a portion of feed. It consisted of silicates, alumina-silicates, and calcium-alumina-silicates thus it reduces
need of limestone and in consequence mitigates CO2 emissions due to limestone decomposition15
. An overall
assessment of the environmental effects of co-processing of cutting oil emulsions in cement plants through the
quantification of emissions of key pollutants, namely NOx, CO and VOC was presented by Giannopoulos et al.16
.
Tiwary et al.5
showed that co-processing is efficient, economized and environmental friendly, particularly for a
populated country, such as India, as there was no adverse effect on quality of cement, stack emission and air quality
of environment due to co-processing of variety of identified wastes in cement kiln. Many tests have investigated the
influence on the emissions and the product quality when waste materials are used to replace either fuels or raw
materials in clinker production. So far, no adverse impacts have been identified17, 18, 19
. Yen et al. 20
produced eco
cement from industrial waste like marble sludge, sewage sludge, drinking water treatment plant sludge, and basic
oxygen furnace sludge as a replacement for limestone, sand, clay, and iron slag, respectively. The utilization of

311Rahul Baidya et al. / Procedia Environmental Sciences 31 (2016) 309 – 317
sewage sludge as an alternative fuel and its effect was analyzed covering all process, health, safety and
environmental standard21
. The objective of the paper is to present a review of the co-processing of industrial waste
in cement kiln and its sustainability based on three case study approach. The study will show the economical and
environmental gain achievable by using industrial waste as AFR in Indian cement kilns. The study also identifies the
challenging issues in effective implementation of co-processing base on the literature and case study. The
organization of the paper is as follows: section 2 deals with the methodology applied for the study. Section 3
discusses the present status based on three case studies in three different part of India and analyses the economical
and environmental sustainability. Section 4 reveals the findings based on the analysis. Section 5 concludes the
papers.
2. Methodology
The study follows a case study approach and involves the following steps; firstly a detail literature review has
been carried out to find out the practices on co-processing of waste in cement kiln around the world. Secondly three
primary field studies were carried out to get a first hand view of the existing co-processing plant status and
sustainability in term of economical and environmental aspect. Thirdly the case were discusses based on the detail
data of last financial year obtained based on the primary field study. Fourthly the findings were discussed based on
the case study and co-processing as an effective way of utilization of industrial waste was elaborated. Fifthly the
study was concluded with emphasizing of industrial waste disposal in cement kiln.
3. Discussion and analysis
3.1. Case-1
The cement plant is one of the oldest plants in central part of India. It has three functioning kiln with two kiln i.e.
kiln-1, kiln-2 which are running an outdated semi dry process system and kiln-3 has modern wet process system
incorporating a five stage cyclone based pre heater system for clinker production. The plant has total capacity of
2400 ton/day. The kiln-3 has a feeding system for alternative fuel (AF). The AF feeding capacity is very less as it
has a basic manual operated feeding system, the capacity of which is approximately 1.5 ton/day. The feeding
requires five operators it is a labour intensive system and also safety of the worker is an issue, being a manual
system with machine and man interface. The producer of industrial waste pays a certain tipping fee on per/ton basis
and also provides free transport of the waste to the plant. The types of industrial waste which are co-processed as
alternative fuel and raw material are dolachar, flue dust, coal rejects, trade rejects, spent carbon, ETP Sludge and
expired trade products. The trade rejects mainly consists of expired products like shampoos, coffee sachet, napkins,
toothpaste, noodles, sauce etc from major FMCG companies. There are also other non industrial wastes which are
added as impregnation to reduce the water content, which includes saw dust and rice husk. The characteristics of the
waste which is used as a alternative fuel is that of mixed waste with calorific value ranging from 1500 to 2200
kcal/kg the waste are generally of large size containing plastic, papers, organic fragments and to some extent glasses
also. The waste is being directly feed in to a kiln inlet in combination with the secondary coal firing. The waste
comes by trucks and this are unloaded manually and stored in the storage facility and from this storage facility the
wastes are being taken and unpacked manually and feed in to the hopper through the lift system. This waste hopper
has a feeding belt below it the waste is carried by this belt to the chute and through the chute the waste moves in to
the kiln inlet via three shut of gate. This shut of gate prevents the back fire. The industrial waste as a raw material is
used in the preparation of the raw meal. The total quantity of AR which is being in the year 2014 stands at 7,976 tons.
The co-processing statistical data has been analysed to gauge the sustainability of using industrial waste. The
quantity of AFR uses has been plotted for the year 2014 on a month wise basis and around 12054 ton of industrial
waste has been used in the plant reducing the use of virgin fuel and raw materials. The use of alternative fuel and
raw material was not uniform which has been contributed due to supply chain constraints and production fluctuation.
The highest quantity of feed was carried out in the month of February with firing of 4187 ton of industrial waste

(figure 1). The quantity of traditional fuel (TF) and traditional raw material (TR) replaced, shows a similar trends.
The total amount of TF and TR saved due to utilization of AFR is amounting to 8861 ton (figure 2).
Figure 1. Quantity of AFR fired in the year 2014 Figure 2. Quantity of TF & TR replaced in the year
2014
The thermal substitution rate (TSR %) which is being achieved shows an effective energy recovery potential from
the industrial waste without any hindrance to the normal firing and energy need (figure 3). The economical analysis
based on the total financial benefit achieved by the plant in last year shows an enormous amount with huge
economical gain (figure 4). The TSR % achieved also shows the environmental sustainability of the co-processing
methodology.
Figure 3. Thermal Substitution Rate achieved (TSR%)
for the year 2014
Figure 4. Trends in cash benefit of using AFR in the
year 2014
3.2. Case-2
The case organization has three kilns with AFR feeding system incorporated in to the kiln- 3. The kilns present in
the plant are a dry process type. The kiln-3 has a similar feeding system arrangement as discussed in the case-1. The
feeding system requires five operators and the capacity is 3 ton/day. The producer of industrial waste pays a tipping
November-14September-14July-14May-14March-14January-14
4000
3000
2000
1000
0
Month
QuantityofAFR(Tons)
Quantity of AFR (Tons)
3500
3000
2500
2000
1500
1000
500
0
Month
QuantityofTF&TRReplaced(Tons)
Quantity of TF & TR Replaced (Tons)
20
15
10
5
0
Month
TSR(%)
TSR (%)
Month
Trends in Cash Benefit of AFR

fee on per/ton basis and also provides free transport of the waste to the plant but the plant also uses some biomass
which is being brought by the plant and transportation cost is barred by the plant. The co-processing capacity of AF
is limited as the feeding system doesn’t allow feeding in bulk quantity and absence of pre-processing platform
doesn’t allow feeding of large size waste. The type of industrial waste co-processed are ETP sludge, iron slug,
grinding muck, grinding dust, boiler carbon, boiler ash, chemical sludge, brake shoe liner, spent carbon, paint sludge,
trade rejects, oily rags, ETP bio sludge, expired products from FMCG companies. The characteristics of the waste as
an AF are that of mixed waste with calorific value ranging from 321 to 5396 kcal/kg. The waste are generally of
large size as no pre-processing platform exists, the waste consists of plastic, papers, organic fragments and to some
extent glasses also. The size and metal contents is an issue for feeding. The supply chain frame work is similar to the
case-1 as discussed above. The alternative raw material is used in the preparation of raw meal. The quantity of AR
which has been used in the year 2014 is 6,467 tons. The co-processing statistical data from the last year has been
analysed to gauge the sustainability of using industrial waste as a substitute for virgin material. The quantity of AFR
uses has been plotted for the year 2014 on a month wise basis and around 9098 ton of industrial waste has been used.
The use of alternative fuel and raw material feeding was non-uniform due to supply chain constraints and production
fluctuation. The highest quantity of feed was carried out in the month of April with firing of 1951 ton of industrial
waste (figure 5). The quantity of traditional fuel (TF) and traditional raw material (TR) replaced, shows a similar
trends in firing. The total amount of TF and TR saved due to utilization of AFR is amounting to 9422 ton (figure 6).
Figure 5. Quantity of AFR fired in the year 2014 Figure 6. Quantity of TF & TR Replaced in the year
2014
The thermal substitution rate (TSR %) follows a similar trend, the fluctuation in graph is directly proportional to the
feeding rate, high rate of TSR% has been achieved by the plant thus showing high energy recovery potential from
the industrial waste without any hindrance to the normal firing and energy need (figure 7). The economical analysis
based on cash benefit achieved by the plant in last year shows an enormous amount with high economical gain
(figure 8). The TSR % and quantity of TR and TF saved shows high environmental sustainability of co-processing
methodology. The month of December is not presented in the analysis as the kiln was in a shut down state for the
annual maintenance.
2000
1500
1000
500
0
Month
QuantityofAFR(Tons)
2500
2000
1500
1000
500
0
Month
Quantity of TF & TR Replaced (Tons)

Figure 7. Thermal Substitution Rate achieved (TSR%)
for the year 2014
year 2014
3.3. Case-3
The case organization has single kilns with AFR feeding system it is one of the oldest plant in western part of
India it has been established in 1917. The kiln in the plant is a dry process type. It has a similar type of feeding
arrangement for the AF, it has feeding capacity of 3 ton/day. The plant setup is of the same make as the other two
cases discussed above. Like other two cases the producer here also pays a tipping fee on per/ton basis and also
provides free transport of the waste to the plant. The plant also uses saw dust which is being brought by the plant and
transportation cost is barred by the plant. The co-processing capacity is limited due to the feeding system which
doesn’t allow feeding in bulk quantity and absence of pre-processing platform doesn’t allow feeding of large size
waste. The type of industrial waste co-processed is ETP sludge, paint sludge, trade rejects, carbon black, spent
carbon, ETP bio sludge, dying sludge and expired products from FMCG companies. The characteristics of the waste
are that of mixed waste with calorific value ranging from 435 to 4936 kcal/kg. The supply chain frame work is
similar to the Case-1 as discussed above. The co-processing statistical data from the last year has been analysed to
gauge the sustainability of using industrial waste as a substitute for virgin material. The quantity of AFR uses has
been plotted for the year 2014 on a month wise basis and around 98693 tons of which bulk of the portion are
alternative raw material. The quantity of AR used in the raw meal is amounting to 92,730 tons and the rest of the
material was AF. The fluctuation of feeding is contributed to supply chain constraints and production fluctuation.
The highest quantity of feed was carried out in the month of February with firing of 14440 ton of industrial waste
(figure 9). The quantity of traditional fuel (TF) and traditional raw material (TR) replaced, shows a similar trends as
AFR firing. The total amount of TF and TR saved due to utilization of AFR is amounting to 91957 tons (figure 10).
2.0
1.5
1.0
0.5
0.0
Month
TSR(%)
TSR (%)
Month

Figure 9.Quantity of AFR fired in the year 2014 Figure 10. Quantity of TF & TR Replaced in the
year 2014
The thermal substitution rate (TSR %) follows a similar trend as the quantity of AFR and quantity of TF and TR
replaced, the TSR% is directly proportional to the fluctuation in feeding rate, high rate of TSR% has been achieved
by the plant thus showing high energy recovery potential from the industrial waste (figure 11). The economical
analysis revealed enormous amount of cash gain (figure 12).
Figure 11.Theraml Substitution Rate achieved (TSR%)
for the year 2014
year 2014
4. Findings
The robustness of co-processing of industrial waste in Indian cement plant has been revealed based on the three
case analyses. There is high economical gain and environmental sustainability achievable in term of using AFR. The
cement production process is highly suitable of treating industrial waste and in some cases also enhances the product
property. The co-processing of industrial waste is an effective methodology for CO2 mitigation as it reduces the
carbon emission by reducing the use of virgin material. The process is highly sustainable in number of countries but
still lacks full scale implementation in India due to number of supply chain constraints which needs proper
addressing. The major constraints as coined by number of literature and also revealed by the case studies are
20000
15000
10000
5000
0
Month
QuantityofAFR(Tons)
18000
16000
14000
12000
10000
8000
6000
4000
2000
0
Month
Quantity of TF & TR Replaced in Tons
8
7
6
5
4
3
2
1
Month
TSR(%)
TSR (%)
Month

availability of waste, transportation and storage, installation requirement-technological aspect, composition of the
waste, quality of clinker, emission factors and government support7, 8, 22-24
. The three cases showed that high quantity
of industrial waste as a raw material has been utilized, in all the cases, based on the statistical data of last year and
the analysis showed that the bulk of the ARF material is AR which thus reduces the consumption of natural
resources and decreases the carbon emission which would have otherwise taken place if the conventional fuel were
used. The co-processing also leads to the reduction of waste going to the land filled thus also reduces indirect GHG
emission which would have taken from the landfill site. Even in the present scenario the co-processing is showing a
high sustainability and if the constraints are addressed it can lead to most effective waste management solution for a
populated country like India. The economical aspect gauged, based on the quantity of TFR saved and TSR%
achieved for the three cases is immense, the cases indicates highly profitability of the process and the cash benefits
achieved runs to crore of INR. The emission and setup cost for co processing is very less compared to the other
waste disposal technology and plant requirements, India being the second largest cement producer, with high number
of cement plants can dispose of large quantity of industrial waste and even municipal solid waste if the supply chain
constraints are removed. The co-processing is zero waste process without generation of by products like ash, slug etc.
The emission equipment already present in cement plants are enough in-term of the feeding rate practiced which is a
deciding factor for emission an quality of the clinker number of parameters effects the quality of the finished
products. Thus the co-processing in cement plant is highly robust process as mentioned from the analysis and also
the auxiliary technology requirement is less thus making the process a sustainable waste disposal and carbon
mitigation process.
5. Conclusion
The paper presents a study based on the present practices of industrial waste recycling and energy recovery in
cement plant by the process of co-processing. The economical and environmental sustainability of the co-processing
process in India has been shown via a three case analyses. The findings reveals if the process is implemented
effectively the waste going to the landfill can be reduced and plants carbon foot print can be reduced. The financial
gain is also immense and conventional fuel is also saved. There exists some pertaining issues in the supply chain
which are to the some extend hindering the implementation of the co-processing process.
Acknowledgement
Authors acknowledge the support provided by the UK India Educational Research Initiative (UKIERI) project,
“Waste to Energy from Municipal Waste – DSS for planning and implementation in India” at the department of
mechanical engineering, Jadavpur University, India and Aston University, UK. The authors acknowledge the support
of the research project “Sustainability of Co-processing of wastes in cement kiln and improvement in technology” by
Geocycle India, ACC Limited, and International Society of Waste Management, Air and Water” (ISWMAW).
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