Recycling of material and energy recovery from waste in a cement factory
Published on 08 February 2019
Spain
Andalucía
This is the good practice's implementation level. It can be national, regional or local.
About this good practice
The good practice of Cementos Portland is an alternative to waste recovery, avoiding its disposal in landfill. On the other hand, the use of waste in cement manufacture produces a reduction of raw materials and fossil fuels.
This good practise use wastes in three process:
1) WASTES USED AS RAW MATERIALS IN THE UNCOOKED PROCESS
In the Alcalá de Guadaíra’s factory, slags is used, reducing the consumption of limestones, pyrite and bauxite.
These mineral waste are added to the rest of raw materials before to go in the cement oven, and as a result, calcium, iron, silicon and aluminium are added, elements needed to make the clinker.
2) WASTES USED AS ADDITIVE
In Alcalcá de Guadaíra’s factory, a reduction of the use of clinker is obtained by its replacement by fly ash coming from thermal power plants and the metallurgical industry. Fly ashes is used like additive to the cement mill.
In 2016, 1,4 millions of industrial waste were used in this factory, which is like 21 football stadiums full of wastes, which did not finish in a landfill. Moreover this amount is the equivalent of 2 years of a medium-quarry exploitation.
3) WASTES USED AS FUEL
The use of alternatives to fossil fuels have economical and environmental improvements. Moreover, a huge amount of waste with high calorific value end in landfill which can be used as fuel in cement factories, in the place of oil coke.
This technique has not been implemented yet in the Alcalá de Guadaíra’s factory.
This good practise use wastes in three process:
1) WASTES USED AS RAW MATERIALS IN THE UNCOOKED PROCESS
In the Alcalá de Guadaíra’s factory, slags is used, reducing the consumption of limestones, pyrite and bauxite.
These mineral waste are added to the rest of raw materials before to go in the cement oven, and as a result, calcium, iron, silicon and aluminium are added, elements needed to make the clinker.
2) WASTES USED AS ADDITIVE
In Alcalcá de Guadaíra’s factory, a reduction of the use of clinker is obtained by its replacement by fly ash coming from thermal power plants and the metallurgical industry. Fly ashes is used like additive to the cement mill.
In 2016, 1,4 millions of industrial waste were used in this factory, which is like 21 football stadiums full of wastes, which did not finish in a landfill. Moreover this amount is the equivalent of 2 years of a medium-quarry exploitation.
3) WASTES USED AS FUEL
The use of alternatives to fossil fuels have economical and environmental improvements. Moreover, a huge amount of waste with high calorific value end in landfill which can be used as fuel in cement factories, in the place of oil coke.
This technique has not been implemented yet in the Alcalá de Guadaíra’s factory.
Resources needed
The use of waste in the factory began in the beginning of the factory, consequently installations have been adapted along the life of the factory.
Evidence of success
The reduction of raw materials is the main evidence of success of this good practices. For instance, the use of slags has eliminated the use of bauxite, which came from quarries sited thousands of kilometres away. Moreover, the Reference Document on Best Available Technique in the cement Industries includes the use of waste as raw material.
Potential for learning or transfer
The potential for learning and transfer of this good practices is supported by the fact of The Reference Document on Best Available Technique in the cement Industries includes the use of waste as raw materials. This BREF also includes references to the use of waste as fuel.
Further information
Website
Good practice owner
You can contact the good practice owner below for more detailed information.
Organisation
CEMENTOS PORTLAND VALDERRIVAS, S.A.
Spain
Andalucía
Contact
Asesor técnico en residuos