Alternative Fuel Handling Solutions

About the Alternative Fuel Industry

The alternative fuel industry is at the forefront of efforts to reduce greenhouse gas emissions, enhance resource efficiency, and support the transition to a circular economy. By utilizing waste-derived materials—such as biomass or refuse-derived fuels (RDF)—as substitutes for fossil fuels, this industry plays a critical role in the cement and lime sectors, where energy-intensive processes like calcination and clinker production dominate.

Composition and Source of Alternative Fuel

Biomass:
Biomass fuels, derived from organic materials like wood chips, sawdust, agricultural residues, or manure, are rich in carbon (C) and hydrogen (H) but produce significantly less sulfur dioxide (SO₂) or nitrogen oxides (NOₓ) during combustion compared to fossil fuels. Biomass is considered carbon-neutral because the CO₂ emitted during its combustion was previously absorbed during photosynthesis.

Refuse-Derived Fuels (RDF):
RDF consists of non-recyclable municipal solid waste (MSW) components such as plastic polymers, textiles, and other combustible materials. These materials are pre-processed—through shredding, drying, and sorting—to ensure homogeneity and optimize their calorific value for industrial use.

Application in the Cement and Lime Industries

Cement Kilns and Co-Processing

Cement production relies heavily on rotary kilns, where limestone (CaCO₃) is heated to temperatures exceeding 1,450°C to form clinker, the essential precursor to cement. Alternative fuel are introduced into the kiln as a supplementary energy source, reducing the demand for traditional fossil fuels like coal or petroleum coke.

Thermal Energy Contribution: RDF and biomass fuels provide the high calorific value necessary for maintaining kiln temperatures. Biomass fuels, for instance, have energy contents ranging between 16-19 MJ/kg, making them suitable for partial substitution of fossil fuels. The thermal kinetic energy in typical coal can be expressed through its calorific value, which ranges from 17 to 35 MJ/kg (megajoules per kilogram), depending on the type of coal.
Combustion Efficiency: Advanced feeding systems and secondary air inlets ensure that alternative fuels achieve complete combustion, preventing incomplete oxidation products such as carbon monoxide (CO) or other unburned hydrocarbons.

Lime Production

The lime industry utilizes rotary kilns or shaft kilns to thermally decompose limestone into quicklime (CaO), an essential material for construction and environmental applications. The introduction of alternative fuel into lime kilns reduces reliance on conventional fuel and supports carbon-neutral operations.

Environmental and Economic Benefits

Emission Reduction:
By substituting fossil fuels with biomass or RDF, industries significantly lower emissions of CO₂, SO₂, and NOₓ. For example, biomass combustion releases only biogenic CO₂, which does not contribute to net atmospheric carbon levels. The co-processing of RDF also minimizes methane emissions from landfill decomposition by redirecting waste to energy production.

Resource Optimization:
The alternative fuel industry embodies the principles of the circular economy, diverting waste from landfills and repurposing it into high-value energy. This not only extends the lifecycle of materials but also conserves finite fossil fuel resources.

Economic Viability:
Alternative fuel often come at a lower cost than traditional fossil fuel. Additionally, industries that integrate alternative fuel into their processes may benefit from carbon credits, tax incentives, and reduced waste disposal fees.

Technological Innovations and Standards

The successful integration of alternative fuel relies on precision and innovation. Pre-processing plants ensure that RDF and biomass are of uniform particle size and moisture content for optimal combustion. Advanced monitoring systems assess fuel composition, calorific value, and potential contaminants, adhering to strict regulatory standards for emissions.

Rotary kilns equipped with multi-fuel burners and optimized heat exchange systems enable smooth transitions between fuel types. These systems are complemented by 2 emission control technologies like scrubbers, electrostatic precipitators, and selective catalytic reduction (SCR) units to meet environmental compliance.

The Role of WTW Americas in Alternative Fuel

WTW Americas specializes in designing and supplying equipment for handling and processing alternative fuel in cement and lime production. Our systems are designed to manage biomass and refuse-derived fuels (RDF), ensuring efficient unloading, transport, and storage of the materials. Some of our many Alternative Fuel references include Titan Cement, Heidelberg Cement, LaFarge, Holsom, E.ON / Stratkraft GmbH, Onyx Kraftwerk Zolling, Tauron, ENEA, PGE, RWE Power, Bouygues Energies & Services, Lagan Cement, Uniland, Cylde Bergemann, and many more.

With a focus on efficiency and sustainability, our solutions help optimize the use of alternative fuel while reducing CO2 emissions, playing a critical role in advancing environmental goals. WTW Americas’ technology ensures that raw materials are processed accurately and efficiently, complying with both emissions standards and the high-quality demands of the industry.

Material Receival for the Alternative Fuel Industry

In the alternative fuel sector, where sustainable energy sources such as biomass and refuse-derived fuels (RDF) are utilized in processes like cement and lime production, power generation, and efficient material receival systems are essential. WTW Americas Truck Discharge Machine (TDM) provides a versatile, cost-effective solution for handling raw materials.

The TDM is engineered to streamline the unloading process, eliminating the need for extensive excavation and minimizing civil work. This advanced machine can receive bulk materials with varying particle size, density and moisture content, from trucks, front-end loaders, barges, and railcars, ensuring seamless integration into the processing facility. It can discharge materials at rates ranging from 0 to 1,200 t/h, with the ability to handle a variety of alternative fuel, including:

Biomass fuels, such as wood chips, agricultural residues, and other organic waste.
Refuse-derived fuels (RDF), processed from municipal solid waste for high calorific value.
Other bulk materials, such as pre-sorted industrial waste or synthetic gypsum.

The TDM’s precision engineering ensures consistent material flow into downstream processes, optimizing the operational efficiency of facilities adopting alternative fuel.

WTW Americas Trailer Docking Station

The WTW Americas Trailer Docking Station (TDS) is a modular design with small dimensions, which requires minimal site prep, no pit, and no underground hopper. It is easy to install and a functional and economical solution for unloading trucks with walking floor trailers which typical carry bulk materials such as wood ships, sawdust, wood waste, alternative fuel, RDF, and more.

Bulk material is pushed directly out of the trailer into the docking station. Live bottom screws located in the bottom of the TDS convey the material to an elevating chain conveyor. The chain conveyor brings the material up to a manageable height, or directly into a feeder.

If required, TDS can be provided in high degree dust-free execution. A stationary hydraulic power pack is also available to decouple the semi-trailer from the truck and to be able to empty it autonomously, thus using the trailer as a small storage silo.

Conveying Alternative Fuel

WTW Americas provides cutting-edge solutions for the transport of alternative fuel and other bulk materials within industrial operations. Our TKF Chain Conveyors, designed to handle sticky, abrasive, or high-temperature materials (up to 750°C), offer unmatched reliability and versatility.

Key features include:

Material Compatibility: Handles challenging materials like synthetic gypsum and other alternative fuel at rates up to 1,000 t/h.
Durability: Chain components, including high-quality alloy steel connectors and pins, undergo specialized treatments to resist wear and tear, ensuring long-term performance.
Flexible Configurations: Supports horizontal, inclined, and vertical operations, with widths from 25 to 2 meters, making it adaptable to various facility layouts.

These conveyors are integral to processes that transport and distribute alternative fuel from one stage of processing to the next, ensuring uninterrupted flow and high operational efficiency.

Dust-Tight Discharging, Feeding, and Distribution

Efficient storage, handling, and feeding of alternative fuel are critical in cement and lime production, particularly when using biomass and RDF. WTW Americas offers solutions designed to maintain material integrity and comply with stringent emissions standards.

Silo Discharge Machine (SDM)

WTW’s Silo Bin Discharger is our most versatile and flexible discharge system. Available in sizes from 1.5 to 6 meters in diameter and discharge capacities up to 1,000 t/h, WTW’s Silo Discharge Machine is one of our most requested installations.

The task of the central discharge unit Silo Discharge Machine is to extract wet, hot, cohesive, sluggish, and other non free flowing bulk material stored or buffered in bins or silos.

The rotating discharge arm conveys the bulk material toward the opening in the center of the floor and discharges it through this opening. To prevent the bulk material from flowing out in an uncontrolled manner, the discharge opening is covered by an inner cone. The discharge arm passes underneath the inner cone and activates the entire silo bottom during the discharge operation.

Bunker Discharge Machine

WTW Americas’ Bunker Discharge Machine (BDM) is a mechanism for reclaiming tough to manage bulk materials from silos, bunkers, hoppers, bins, stockpiles, and dome type storages. The Bunker Discharge Machine can travel to reclaim from long stockpiles or hoppers and discharge it onto a gathering conveyor.

WTW’s Bunker Discharge Machine is specifically designed for reclaiming hard to handle, wet, and cohesive bulk materials from bunkers, hoppers, bins, silos, stockpiles, and dome type storages.

When discharging, the BDM can travel on rails. Its rotating discharge wheel reclaims the bulk material out of the storage pile or hopper and conveys it to a conveyor below the bunker discharge machine. T

he BDM’s discharge wheel has six logarithmic shaped discharge arms which guarantee consistent feeding of any bulk material. Discharge arms are lined with wear resistant liner plates designed to increase the life of the discharge arms. With reclaim rates from 10 to 2,500 t/h, WTW’s Bunker Discharge Machine has the capability to reclaim materials from massive stockpiles, extremely large silo diameters, large hoppers, free-range and longitudinal bunkers.

Sweeping Auger System (SAS)

The Sweeping Auger System (SAS) is an innovative solution for reclaiming light-density and sticky, non-free-flowing materials stored in large silos. Designed to handle materials such as RDF, alternative fuel, wood chips, and grains, the SAS ensures consistent material flow and efficient discharge.

The profiled screw rotates 360° around the silo bottom, guiding stored bulk material toward the central discharge opening. With a diameter range of 4 to 18 meters, the SAS is adaptable to various silo sizes and can be fitted to existing silos without requiring significant modifications.

Key benefits include:

Compatibility with existing silos, minimizing installation costs.
Durable design, encased and supported to withstand the weight of fully loaded silos.
Accessible drive components, simplifying maintenance and ensuring uninterrupted operation.

The SAS exemplifies reliable and efficient material handling, making it an ideal choice for facilities using alternative fuel or managing challenging bulk materials.

Integration with the Cement and Lime Industries

Rotary Kilns and Alternative Fuel

Alternative fuel are fed into rotary kilns, where high temperatures (up to 1,450°C) are essential for processes like calcination (conversion of limestone, CaCO₃, into quicklime, CaO) and clinker production. The use of biomass and RDF:

Reduces reliance on traditional fossil fuel.
Minimizes CO₂ emissions, with biomass often being carbon-neutral.
Complies with stringent emission standards for NOₓ, SO₂, and particulate matter.

Emission Reduction and Sustainability

Advanced feeding and combustion systems ensure complete oxidation of alternative fuel, minimizing the release of incomplete combustion products like CO. The integration of emission control technologies, such as electrostatic precipitators and selective non-catalytic reduction (SNCR) systems, further supports sustainability goals.

Tailored Equipment for Alternative Fuel

WTW Americas’ suite of equipment is purpose-built to meet the specific needs of the alternative fuel industry. From truck discharge machines to chain conveyors, silo discharge machines, and bunker reclaim systems, each component is designed for:

Efficient material handling: Ensures consistent feed rates and minimizes downtime.
Durability in harsh conditions: Resistant to wear, heat, and abrasion.
Emission compliance: Supports sustainability and regulatory adherence.

By integrating WTW Americas’ advanced systems, cement and lime producers can achieve high process reliability while embracing alternative fuel. These innovations not only optimize operational efficiency but also contribute to the industry’s broader goals of sustainability and emission reduction.

For more information on how our equipment supports the alternative fuel industry, visit our equipment page.

Learn More

To learn more about WTW Americas equipment and experience in the Alternative Fuel Industry email info@wtwamericas.com or call +1705-749-3544.

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