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cement raw milling process

Biomass burning in cement kilns is a well-established technology, which can be purchased or custom-made in developing countries. Existing feeding systems of alternative fuels into kilns are robust and it is possible to feed in biomass ranging from small pellets to full-sized tyres. For ease of handling and achieving uniform calorific input into the kiln, it is important to reduce biomass materials to manageable sizes. For example, solid woody biomass needs to be chipped into small sizes, pre-dried, and unwanted materials such as stone and metal bits removed (Nicholls et al, 2008).

Alternative and biomass materials can be fed in 3 principal ways:

1. As shown in Figure 5, large-size biomass and alternative waste fuels such as tyres can be fed into the kiln in specially-made gates at the bottom of the precalcining region.

2. It is possible to grind wood along with cement raw materials to feed as pulverised fuel. However, this process may cause two potential problems (Mackes and Lightburn, 2003):

  • Due to the low ignition temperature of wood, fire may start during the milling process unless special precautions are put in place.
  • It may also affect the efficiency of the mill if the moisture content of the wood is high. Though it may make it easier to feed into the kiln, grinding the biomass adds to costs.

3. Companies that use coal as a main source of energy can blend biomass or alternative materials with coal to feed it into the kiln using a coal-feeding system.

Of the three methods described, feeding through specially-made gates at the precalcination region is the safest choice. There are already rotary valves or screw feeders on the market that can be easily installed. The screw feeder has certain advantages over the rotary valve as coarse materials can easily be pushed into the pre-calcining region and the feed rate of the biomass can be regulated by the speed of the screw. Figures 6a and 6b shows examples of large and small screw feeders.

Conveyer belts are used to transport biomass materials from storage to feeding hoppers. From the hoppers, a screw conveyor feeds the biomass into the precalcination region.