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Process Data set: clinker production;clinker;refuse-derived fuel (en) en zh

Key Data Set Information
Location ZZ-SD-CN
Geographical representativeness description Shandong Shenfeng Cement Group Co., Ltd
Name
clinker production;clinker;refuse-derived fuel
Use advice for data set Users of this data set should ensure that they account for the energy content and combustion characteristics of the RDF when substituting for traditional fuels in the cement kiln process. The quality parameters of the clinker, such as the lime saturation coefficient (KH), silicate modulus (SM), and aluminate modulus (IM), and thermal substitution rate (TSR) should be monitored and kept within specified limits to prevent any adverse effects on clinker quality. It is also vital to incorporate and adjust the raw materials' consumption, particularly the proportions of the alternative raw materials in the raw meal, as this impacts the overall material usage and energy efficiency of the process. Users should calculate the electricity consumption at each stage of production based on the electricity consumption index for cement production and take into consideration that wastewater generation is negligible in this process. Inclusion of environmental emissions or waste products in the assessment should be in line with the system boundaries stated: pulverized coal preparation, raw meal preparation, and clinker calcination.
Technical purpose of product or process The refuse-derived fuel (RDF) produced from municipal solid waste, as described in this data set, is intended for use in the production of clinker, a component of cement. This RDF is used as an alternative to traditional fossil fuels such as coal and is composed primarily of light combustibles including paper, plastic, and wood. The non-combustible fraction of the municipal waste, which mainly includes incombustibles like lime soil, bricks, ceramics, glass, and metal, is used as an alternative raw material in the clinker production process. The specific use case for this RDF is in a cement kiln within the Shandong Shenfeng Cement Group Co., Ltd as part of a drive to utilise waste-to-energy methods.
Classification
Class name : Hierarchy level
  • ILCD: Unit processes / Materials production / Inorganic chemicals
General comment on data set According to the Beijing Regulations on Domestic Waste Management (Beijing municipal commission of housing and urban-rural development, 2021), domestic waste was classified as food waste (FW), residual waste (RW), recyclable and hazardous waste. Converting domestic waste into refuse-derived fuel (RDF) as an alternative fuel for clinker production.The RW was divided into two parts with a sifter. The oversize mainly contained light combustibles, such as paper, plastic, and wood. They were crushed and compressed with 5% lime to make the refuse-derived fuel (RDF CDW), which was used as an alternative fuel in the cement kiln to replace part of the coal. The undersize mainly consisted of incombustible, such as lime soil, bricks, ceramics, glass, and metals, which were fed into the raw meal mill after being crushed. The FW was pre-homogenized with crushed limestone and then entered into the batching system. It has also been used as the alternative raw material. There was no drying for FW because its moisture was just utilized by limestone pre-homogenization. Clinker production in scenario 4 used limestone, sandstone, shale, iron powder, the undersize of RW and FW as raw materials, and used coal and RDFCDW as fuels. Coal ash and RDF CDW ash were also used as raw ma terials. The clinker quality parameters, thermal substitution rate (TSR), and proportion of alternative raw materials in the raw meal were considered as constraint conditions to adjust the material usage. The power consumption in each stage was calculated based on the electricity consumption index for cement production.
Copyright No
Owner of data set
Quantitative reference
Reference flow(s)
Technological representativeness
Technology description including background system In scenario 4, the RW was divided into two parts with a sifter. The oversizemainly contained light combustibles, such as paper, plastic, and wood. They were crushed and compressed with 5% lime (Li, 2017) to make the refuse-derivedfuel (RDF CDW), which was used as an alternative fuel in the cement kiln to replace part of the coal. The undersize mainly consisted of incombustible, such as lime soil, bricks, ceramics, glass, and metals, which were fed into the raw meal mill after being crushed. The FW was pre-homogenized with crushed limestone and then entered into the batching system. It has also been used as the alternative raw material (Cai et al., 2014). There was no drying for FW because its moisture was just utilized by limestone pre-homogenization (Cai et al., 2015). Clinker production in scenario 4 used limestone, sandstone, shale, iron powder, the undersize of RW and FW ( ́ Swiechowski et al., 2020) as raw materials, and used coal and RDFCDW as fuels. Coal ash and RDF CDW ash were also used as raw ma terials. The clinker quality parameters, TSR, and proportion of alternative raw materials in the raw meal were considered as constraint conditions to adjust the material usage (Cai et al., 2015). The power consumption in each stage was calculated based on the electricity consumption index for cement production(Cai et al., 2015; Wang, 2013; Li, 2017).
Flow diagram(s) or picture(s)
  • HzXHbK7bno8XlfxxoxLcDYVhnMd.png Image
Mathematical model
Model description Two functional units are defined, namely 1 ton of clinker and the amount of food waste and residual waste required to produce 1 ton of clinker.The system boundaries include pulverized coal preparation, raw meal preparation and clinker calcination.
LCI method and allocation
Type of data set Unit process, black box
Deviation from LCI method principle / explanations None
Deviation from modelling constants / explanations None
Data sources, treatment and representativeness
Deviation from data cut-off and completeness principles / explanations None
Data selection and combination principles First assume the proportion of raw material consumption, and then calculate the coal consumption, coal ash incorporation rate, raw meal ratio, raw meal ratio after ignition, clinker ratio and clinker quality parameters according to the formula, including lime saturation coefficient (KH) , silicate modulus (SM) and aluminate modulus (IM). The clinker quality parameters are KH=0.89±0.02, SM=2.5±0.1, IM=1.5±0.1. The quantity of wet material was calculated using the formula. The electricity consumption at each stage is calculated based on the electricity consumption index of cement production.
Deviation from data selection and combination principles / explanations None
Deviation from data treatment and extrapolations principles / explanations None
Data source(s) used for this data set
Completeness
Completeness of product model No statement
Validation
Type of review
Dependent internal review
Reviewer name and institution
Data generator
Data set generator / modeller
Data entry by
Time stamp (last saved) 2024-03-19T21:18:09+08:00
Publication and ownership
UUID a55ec787-2796-4dbe-acdd-ada5553cbcab
Date of last revision 2024-04-20T14:42:20.635929+08:00
Data set version 00.01.005
Permanent data set URI https://lcadata.tiangong.world/showProcess.xhtml?uuid=a55ec787-2796-4dbe-acdd-ada5553cbcab&version=01.00.000&stock=TianGong
Owner of data set
Copyright No
License type Free of charge for all users and uses

Inputs

Type of flow Classification Flow Location Mean amount Resulting amount Minimum amount Maximum amount
Product flow
Materials production / Other mineralic materials 1329.974 kg1329.974 kg
General comment Limestone
Product flow
Materials production / Other mineralic materials 99.92 kg99.92 kg
General comment Sandstone
Elementary flow
Resources / Resources from ground / Non-renewable material resources from ground 36.448 kg36.448 kg
General comment Shale
Product flow
Materials production / Metals and semimetals 26.678 kg26.678 kg
General comment Iron powder
Waste flow
Wastes / Post consumer waste 149.302 kg149.302 kg
General comment Food waste (FW)
Waste flow
Wastes 42.982 kg42.982 kg
General comment Undersize of residual waste (RW). Regulations stipulate that wood, lime soil, bricks, and ceramics should be sorted as RW.
Elementary flow
Resources / Resources from ground / Non-renewable energy resources from ground 87.5 MJ87.5 MJ
General comment Coal
Product flow
Energy carriers and technologies / Electricity 218.45520000000002 MJ218.45520000000002 MJ
General comment Electricity. The power consumption at each stage was calculated according to the electricity consumption index for cement production (Wang, 2013). The background processes data from GaBi databases: electricity production, “CN: Electricity grid mix PE”.
Waste flow
Wastes / Radioactive waste 47.424 kg47.424 kg
General comment RDFCDW: refuse-derived fuel (RDF) by using classified domestic waste (CDW). Alternative fuel for clinker production.Calculation of the calorific value of RDFCDW The domestic waste considered in this study originated from urban and rural areas. Ac cording to the proportion of urban and rural populations (61.51% and 38.49%, respectively) (National Bureau of Statistics, 2020b) and waste components (Li et al., 2018), the components of urban-rural integrated waste can be obtained. After being classified according to the Regulations, the components of the RW and FW can be obtained. The domesticwaste and RDFCDW components are presented. The calorific value of the RDF CDW was calculated using Equations. The RDFCDW substitution rate was chosen to be 30% for the commoninternational TSR (Bourtsalas et al., 2018). The RDFCDW consumption was calculated using Equation. LHV=HHV×(1-MC)-MC×44/18×10^3, MC=∑_j▒f_j c_j, HHV=∑_j▒〖Q_j c_j 〗. Where LHV is the lower heat value of RDFCDW (kJ/kg), 44 is the latent heat of water evaporation (kJ/mol), 18 is the molecular weight of water, MC is the moisture of the RDFCDW (%), fj is the moisture of the jth component in the RDFCDW (43.2% for paper, 43.5% for plastic, 44.2% for wood, and 0% for lime), HHV is the higher heat value of RDFCDW (kJ/kg), Qj is the heat value of the jth component in the RDFCDW (15656 kJ/kg for paper, 39003 kJ/kg for plastic, 22128 kJ/kg for wood, and 0 kJ/kg for lime), and cj is the proportion of the jth component in the RDFCDW (%).m_(RDF_CDW )=(30%×"q" )/LHV. Where is the consumption of RDFCDW in the cement kiln (kg), 30% refers to the TSR, and q is the heat consumption of clinker generation (kJ/kg).

Outputs

Type of flow Classification Flow Location Mean amount Resulting amount Minimum amount Maximum amount
Elementary flow
Emissions / Emissions to air / Emissions to air, unspecified 682.586109 kg682.586109 kg
General comment CO2. E_(CO_2 )=E_"coal" +E_(CaCO_3 ), E_coal=NCV×FC×CC×OF×44/10, E_(C"a" CO_3 )=(FR_1-FR_10)×44/56+(FR_2-FR_20)×44/40. Where E_(CO_2 ) represents CO2 emissions from the cement kiln (t), E_"coal" represents CO2 emissions from coal combustion (t), E_(CaCO_3 ) represents CO2 emissions from the carbonate decomposition of raw materials (t), NCV is the lower heat value of coal (19.570 GJ/t), FC is the consumption of coal (t), CC is the carbon content per unit heat value of coal (0.0261 t C/GJ), OF is the carbon oxidation rate of coal (98%), FR1 is the content of CaO in clinker (%), FR10 is the content of CaO in clinker that is not derived from carbonate decomposition (%), FR2 is the content of MgO in clinker (%), FR20 is the content of MgO in clinker that is not derived from carbonate decomposition (%), and 44/56 and 44/40 are the molecular weight conversion between CO2 and CaO, MgO respectively.FR_10=(FS_10)/((1-L)×F_"c" ), FR_20=(FS_20)/((1-L)×F_"c" ). Where Fc is the conversion factor of coal ash content in clinker (1.04), FS10 is the content of CaO in raw meal that is not in the form of carbonate (%), and FS20 is the content of MgO in the raw meal that is not in the form of carbonate (%).FS_10=(∑_"n" ▒〖(m_n×r_10n)〗)/m, FS_20=(∑_"n" ▒〖(m_n×r_20n)〗)/m. Where mn is the mass of the nth raw material except limestone (kg), r10n is the content of CaO in the nth raw material except limestone (%), r20n is the content of MgO in the nth raw material except limestone (%), and m is clinker consumption (kg).
Elementary flow
Emissions / Emissions to air / Emissions to air, unspecified 0.316783 kg0.316783 kg
General comment SOx. P_(SO_2 )=64/80×"m"×SO_3 (1-X)×〖10〗^3, where P_(SO_2 ) is the SO2 emission from the cement kiln (kg), 64/80 is the molecular weight ratio of SO2 to SO3, m is clinker consumption (t), SO3 is the SO3 content in the raw meal (%), and X is the SO3 absorption rate of the raw meal (88%).
Elementary flow
Emissions / Emissions to air / Emissions to air, unspecified 0.9275 kg0.9275 kg
General comment NOx. P_(NO_x )=(R_Y×16+R_L×7)×m_coal×〖10〗^(-3), Where P_(NO_x ) is the NOx emission from the cement kiln (kg), R_L and R_Y are the ratios of fuel used in the rotary kiln and precalciner (0.6 and 0.4, respectively), and m_coal is the coal consumption of clinker generation (kg).
Product flow
Materials production / Other mineralic materials 1000.0 kg1000.0 kg
General comment Clinker