Aspen plus simulation of an inline calciner for white cement production with a fuel mix of petcoke and producer gas

Abstract

The white cement industry is facing the challenge of alternative fuel utilization replacing conventional fuel due to the impact of alternative fuel ash on the whiteness of clinker. On the other hand, municipal solid waste (MSW) disposal is a huge waste management problem worldwide. The present article focuses on utilizing MSW-based refuse derived fuel (RDF) as an alternative fuel in white cement. The ash-free producer gas derived via RDF gasification is proposed to overcome the challenge of direct RDF utilization. Aspen plus-based producer gas co-processing model for a calciner has been developed, considering 100% petcoke firing as the baseline scenario. The co-processing of producer gas further augmented the model to achieve a 15–20% thermal substitution rate (TSR). The developed model is validated using the actual plant data. The model results at 15% TSR predicted that the calciner outlet temperature will get reduced by 19 °C, with a 5.3% rise in calciner exit gas volume, which is manageable. CO2 mitigation potential at 15% TSR is estimated to be 11.33% of the baseline scenario. The TSR contribution of producer gas sensible heat at 593 °C is 2.7%, whereas the petcoke enters the system at 60 °C with negligible sensible heat.