Sustainable Cement Production: The Role of Solid Recovered Fuels and Refuse Derived Fuels

By utilizing Solid Recovered Fuels and Refuse Derived Fuels in cement production, we can reduce our carbon footprint and promote sustainable waste management practices, turning waste into a resource

The use of Solid Recovered Fuels (SRF) and Refuse Derived Fuels (RDF) is becoming increasingly popular in cement factories around the world as a way to reduce greenhouse gas emissions and promote sustainable waste management practices. India, which is one of the largest emitters of greenhouse gases in the world, can learn from the international experiences of using SRF and RDF in cement factories. In this article, we will discuss the benefits of SRF and RDF in cement factories, as well as international and Indian case studies of cement manufacturers using alternative fuels.

Solid Recovered Fuels (SRF) and Refuse Derived Fuels (RDF)

SRF and RDF are waste-derived fuels produced from Municipal Solid Waste (MSW). SRF is produced by shredding and separating non-recyclable waste materials like paper, plastics, textiles, and wood. RDF is produced by shredding and separating MSW, which is then dried and processed to remove impurities.

Benefits of SRF and RDF in Cement Factories

The use of SRF and RDF in cement factories has several benefits. Firstly, it reduces the use of fossil fuels like coal and reduces greenhouse gas emissions. Secondly, it reduces the amount of waste sent to landfills, promoting sustainable waste management practices. Thirdly, it provides an alternative source of fuel for cement factories, reducing their dependence on volatile fossil fuel markets.

International Case Study: LafargeHolcim, France

LafargeHolcim, a leading cement manufacturer in France, has been utilizing SRF and RDF in cement production since 1980. In 2019, LafargeHolcim’s plant in Martres-Tolosane produced 90,000 tonnes of clinker using 17,000 tonnes of SRF and 7,000 tonnes of municipal solid waste. The use of SRF and RDF reduced the plant’s CO2 emissions by 13,000 tonnes, equivalent to taking 9,000 cars off the road. LafargeHolcim is also participating in the European Cement Research Academy’s Carbon4PUR project, which aims to develop a process to capture CO2 from cement production and convert it into polyurethane products.

Indian Case Study: ACC Limited, India

ACC Limited, a leading cement manufacturer in India, has been co-processing waste in cement kilns since 2002. In 2020, ACC’s Wadi cement plant in Karnataka used 73,000 tonnes of hazardous and non-hazardous waste, including RDF and plastic waste, as alternative fuels. The use of waste in cement production has helped ACC reduce its dependence on fossil fuels and traditional raw materials. In 2020, the company’s energy consumption was 50.75 kWh per tonne of cement, which is one of the lowest in the industry.

Indian Case Study: UltraTech Cement, India

UltraTech Cement, a subsidiary of Aditya Birla Group, is the largest cement manufacturer in India. The company has been using alternative fuels like SRF and RDF since 2011. In 2020, UltraTech’s various plants across India co-processed more than 1.5 million tonnes of waste, including RDF, biomass, and municipal solid waste. The use of waste as fuel and raw material has helped UltraTech reduce its carbon footprint and improve energy efficiency. In 2020, the company’s specific energy consumption was 68.57 kWh per tonne of cement, which is lower than the industry average.

Learning from International Experiences

India can learn from the international experiences of using SRF and RDF in cement factories to promote sustainable waste management practices and reduce greenhouse gas emissions. Indian cement manufacturers can explore the use of alternative fuels like SRF and RDF to reduce their dependence on coal and promote sustainable waste management practices. International experiences can provide insights into best practices for the production, handling, storage, and co-processing of SRF and RDF.

One of the key takeaways from international experiences is the need for collaboration between the waste management and cement industries. In France, LafargeHolcim collaborates with waste management companies to ensure a steady supply of high-quality SRF and RDF. In India, ACC Limited has partnered with local municipalities to source waste for co-processing in cement kilns. Collaboration between the waste management and cement industries can help promote sustainable waste management practices, reduce greenhouse gas emissions, and improve resource efficiency.

Another takeaway from international experiences is the need for regulatory support and incentives to encourage the use of alternative fuels in cement factories. In Europe, the European Union’s Waste Framework Directive and Industrial Emissions Directive provide a regulatory framework for the use of alternative fuels in cement factories. In India, the Ministry of Environment, Forest and Climate Change has issued guidelines for the co-processing of waste in cement kilns. The Indian government can provide incentives like tax credits and carbon credits to encourage cement manufacturers to use alternative fuels and promote sustainable waste management practices.

The use of Solid Recovered Fuels (SRF) and Refuse Derived Fuels (RDF) in cement factories is an effective way to reduce greenhouse gas emissions and promote sustainable waste management practices. International experiences provide insights into best practices for the production, handling, storage, and co-processing of SRF and RDF. Indian cement manufacturers can learn from international experiences and explore the use of alternative fuels to reduce their dependence on coal and promote sustainable waste management practices. Regulatory support and incentives can help encourage the use of alternative fuels and promote sustainable waste management practices in the cement industry.