Journal of Civil, Construction and Environmental Engineering
2020; 5(3): 35-41
http://www.sciencepublishinggroup.com/j/jccee
doi: 10.11648/j.jccee.20200503.11
ISSN: 2637-3882 (Print); ISSN: 2637-3890 (Online)
Review Article
Reduction of Coal Consumption by Using Municipal
Combustible Waste as a Fuel in Cement Kiln with Special
Focus on Hetauda Cement Industry in Nepal
Shyam Krishna Karki*, Khet Raj Dahal
Lumbini International Academy of Science and Technology, Lalitpur, Nepal
Email address:
*
Corresponding author
To cite this article:
Shyam Krishna Karki, Khet Raj Dahal. Reduction of Coal Consumption by Using Municipal Combustible Waste as a Fuel in Cement Kiln
with Special Focus on Hetauda Cement Industry in Nepal. Journal of Civil, Construction and Environmental Engineering.
Vol. 5, No. 3, 2020, pp. 35-41. doi: 10.11648/j.jccee.20200503.11
Received: May 6, 2020; Accepted: June 12, 2020; Published: July 4, 2020
Abstract: The paper aims to enlighten the financial benefits by reducing the coal consumption from use of municipal
combustible waste as a fuel in cement kiln of Hetauda Cement Industry of Nepal. Hetauda Sub Metropolitan and Hetauda
Cement Industries Ltd were selected for the present study and the study was conducted during the period from March to
December 2019. Published literature such as reports, manuals, paper, database and thesis were collected from different sources
and went on thoroughly, Conclusions were drawn on the basis of the studied materials. Depletion in nonrenewable source of fuel
energy, mining costs and its mining difficulties and also environmental consideration, the greater efforts are given in inventions
of alternative fuels. Most of the cement industries of developed country are following the use of alternative fuels. In this context,
possibility of applying such fueling technologies in cement industries of developing country like Nepal are to be studied by
considering economic, social and environmental aspects. This paper summarizes and reviews studies related to the use of
alternative fuel in cement industries of different country with different benefits. In addition, this paper serves as a valuable
reference for in-depth studies of use of combustible municipal waste of Hetauda Sub Metropolitan in Hetauda Cement Industry.
Keywords: Combustible Waste, Alternative Fuel, Energy, Coal, Cement
temperature above 1450°C [2]. In Nepal, most of the cement
1. Introduction industries are using coal to produce this heat energy in cement
After the hydropower and tourism, Nepal has a great kiln. Production capacity of cement in 2014 is estimated to be
potential in cement production sector due to the availability of 2.46 million MT which is expected reach 25.41 million MT by
huge amount of limestone mines in the country. It is found that 2030 [3].
about 7000 sq km area of Nepal is covered by mines of Cement industries are energy intensive, and they contribute
limestone [1]. Limestone, gypsum, iron ore and coal are the significantly to national employment and gross domestic
raw material required to produce cement. Limestone which is production. In Nepal, 77 cement industries are registered and
main ingredient of cement (60%-66%) is quarried from mines only 15 have their own clinker producing facilities that means
within Nepal itself but other ingredients like coking coal, they have kiln and consumes coal as burning fuel [4]. Till now,
gypsum and iron are used to import from other country mostly 26 cement industries have been in operation with the capacity
from India. In cement production process, powder of of 20 thousand tons of cement per day, and five new cement
limestone is burnt in kiln above 1450°C to produce clinker. industries are under construction. Due to significant
Huge amount of heat energy about 3000-6500 MJ is required achievement in the development and operation of the cement
to produce one ton of clinker by maintaining the cement kiln industries, the import of cement has decreased by producing
4.5 million tons of cement (above 90% of demand) in the
36 Shyam Krishna Karki and Khet Raj Dahal: Reduction of Coal Consumption by Using Municipal Combustible
Waste as a Fuel in Cement Kiln with Special Focus on Hetauda Cement Industry in Nepal
country [5]. cement, creating ample opportunities to exploit existing
Main sources of energy used in the cement industries in cement grade limestone and establish more cement and allied
Nepal are electricity and coal. Coal is mainly used in the kilns industries in Nepal. The profitability of the cement sector can
for calcination in limestone-based units and in some cases also be gauged by the possible entry of four foreign cement
used for electricity generation in plants having co-generation manufacturers, which have obtained approval from the
system. Approximate share of electrical energy used in Investment Board Nepal (IBN) for foreign investment with
Nepal's cement industry is 9%; thermal energy amounts to cumulative expected investments of approximately USD 1.5
91%. According to a baseline study in cement sector of Nepal billion as at December 2016 [10].
energy cost of product value in limestone-based cement
industries is with 48%. In clinker-based industries energy cost 2.1. Status of Energy Consumption in Cement Industries of
amounts to at least 5% of product value. Energy saving Nepal
potential on the product cost is estimated to be Limestone It is considered that, the optimum energy consumption in
based industry is above 19% [6]. cement manufacturing process is 105 kWh/Ton of cement
The histories of Nepalese cement industries started with the and 750 Kcal/kg (3.138 MJ/kg) of clinker in limestone-based
installation of Himal Cement Industry of 160 TPD in 1975. industries standardized by Energy Efficiency Centre, Nepal.
After some time, next unit of 200 TPD was added with the Similarly, in clinker based industries the standard energy
financial support of China. Similarly, two big plants; Hetauda consumption is 35 kWh/T of cement. But, it was estimated
Cement Industries Limited of 750 TPD and Udayapur Cement that, the average specific energy consumption in limestone
Industries Limited of 800 TPD were established. In 2002 the based industries are 148.56 kWh of electricity and 5.411
Himal Cement Industry was stopped due to the environmental MJ/kg of thermal energy. Similarly in clinker based
issues [4]. industries, the energy consumption is 48.69 kWh/T of
Hetauda Cement Industries Ltd. (HCIL) is one of the oldest cement [4]. From these we can estimate that the total coal
cement industries established under the government of Nepal. consumptions in cement industries of Nepal are 2.7 million
The plant has cement production capacity of 750 TPD located ton/annum costing NRs. 48 billion (USD 410 million) per
at Hetauda Sub metropolitan-9. It has four mines named as annum.
Bhaise, Okhare, Majhuwa and Jogimara. Currently it is
producing around 1,00,000 MT of cement annually and 2.2. Solid Waste Management Practices in Nepal
consumes about 22,000 MT of coal costing 42 crore rupees
(USD 3.6 million) [7]. Coal mines in Nepal are not If we look towards the urbanization of Nepal, it is found
significantly developed and it will be of time and cost taken that it is growing rapidly and haphazardly producing huge
work. This is creating situations of exiting national currency amount of waste and creating challenge in waste management
for import of coal and environmental pollution. Development work. Municipalities of Nepal are the major source of waste
of various methods and techniques to short out this problem is production.
use of alternative burning fuel rather than coal and it would be The earlier practice of solid waste management by the city
better that they are of waste, pollutants hazardous to dwellers in the Kathmandu valley is not clearly documented.
environment [8]. with (w should be smaller) a small population, low amount of
industrial (space) activity inside the Kathmandu valley and
with abandoned land available, the waste generated was
2. Overview of Cement Industries in dumped on the river banks on the outskirts of the urban core or
Nepal collected, decomposed and used as organic manure in the
agricultural field. The collection and disposal of these wastes
The use of cement in Nepal as binding material came into was assigned to kuchikars, which in Nepalese means cleaners
effect from the beginning of early 1950s. Early users of [11]. Nepal has big cities like Kathmandu, Lalitpur, Bhaktapur,
cement were dependent on imports from India to meet their Biratnagar, Birgunj, Hetauda, Bharatpur, Butwal etc. Hetauda
needs. The history of cement in Nepal dates back to 1970 is the capital city of Bagmati province having around 1,50,000
when Himal cement factory established. The cement was number of population. Nepal's largest industrial estate is
mostly imported from India china, South Korea (space), North located in Hetauda with area is spread up to 2829 ropanies and
Korea, Burma, Indonesia, Thailand, Hong Kong and many almost more than 80 number of industries are in operation
other countries before the establishment of Himal cement condition. Waste management of this city is done by Hetauda
factory in the Kathmandu valley in 1972. The restoration of sub metropolitan itself by disposing them in landfill site
democracy in 1990 gave the first initial thrust to the cement located in Bhutandevi Community Forest occupying 27,085
industry in Nepal and the industry started growing at a fast rate sq. m of land. About 12 tons per day of waste is disposed of at
in terms of production, manufacturing units, and installed a distance of 1.5 km from the main city. Such practice is under
capacity [9]. operation since 2058 [12].
The overall industry (production of cement) has been
growing at around 10% annually. There is currently a shortfall 2.2.1. Waste Generation and Composition of HSM
in domestic production to meet the increasing demand for The average HH waste generation rate in this municipality
is 0.20 kg/person/day. This rate is same as the national
Journal of Civil, Construction and Environmental Engineering 2020; 5(3): 35-41 37
generation rate and it is lower than the waste generation rate of (chlorinated/fluorocarbon solvents), oils, resins and many more.
the capital Kathmandu, which is 0.39 kg/person/day. The daily The list of candidate materials for use as alternative waste fuels
waste generation of Hetauda municipality is 30.57 tons. The continues to expand. Regulatory pressures, economic
composition of waste at source was found to be: paper 12 considerations, shrinking traditional solid waste disposal
percent, plastic 27 percent, rubber& leather 1%, organic waste capabilities, and a host of similar factors are reflected in the
51 percent, glass 1%, metal 5 percent textile <1% and 3% constant change of the candidate waste fuel universe [15].
others [12].
2.4. Use of MSW in the Cement Industry
2.2.2. Waste Management Methods and Techniques of
Hetauda Sub Metropolitan Waste to fuel as “the use of waste materials in
Solid waste management in Hetauda is done by Hetauda manufacturing processes for the purpose of energy and/or
Sub Metropolitan in correspondence with two organizations resource recovery and resultant reduction in the use of
named Green and Clean City services Pvt. Ltd. and Clean the conventional fuels and/or raw materials through substitution
Nepal. It is doing by collection & segregation, primary [16]. This is also a concept in industrial ecology, related to the
transportation and transfer station, resource recovery methods potential role of industry in reducing environmental burdens
(recycling, composting, special waste management) [12]. throughout a product’s life-cycle. The Basel Convention
further defines co-processing as an operation “which may lead
2.3. Classification of Fuels for Cement Kilns to resource recovery, recycling, reclamation, direct reuse or
alternative uses”.
a) Coal and petroleum coke Waste as fuel has been practiced for more than 20 years,
Coal is a complex polymer made up of carbon, hydrogen, especially in developed countries/regions such as Europe,
oxygen, nitrogen and sulphur. It is a compact, aged form of Japan, the United States, and Canada [17].
biomass containing volatile matter, moisture and mineral The European Integrated Pollution Prevention and Control
matter. The chemical properties of coal depend upon the Bureau has identified the following characteristics of cement
relative proportions of the chemical constituents present at production that allow for the co-processing of waste materials
deposition, the nature and extent of changes over time, and the [18]:
presence of inorganic matter. Coal rank indicates the relative a) Maximum temperatures of approximately 2,000°C
proportions of volatile matter (VM) and fixed carbon (FC) (main firing system, flame temperature) in rotary kilns
present in the coal [13]. Coal rank increases with decreasing b) Gas retention times of about 8 seconds at temperatures
VM. Typically, a medium rank coal consists of 40% VM and greater than 1,200°C in rotary kilns
60% FC, while a high-rank coal has about 10% VM. c) Material temperatures of about 1,450°C in the sintering
Petroleum coke is a high carbon content (90–95%), low zone of the rotary kiln
hydrogen content, black solid residue obtained from the d) Oxidizing gas atmosphere in the rotary kiln
thermal decomposition and carbonization of petroleum- e) Gas retention time in the secondary firing system of
derived feedstock. It is a product of additional processing of more than 2 seconds at temperatures greater than 850°C;
the crude residue collected after refining crude oil. Coal and in the proclaimer, correspondingly longer retention
petroleum coke are the conventional solid fuels used in times and higher temperatures
cement kiln burners for pulverized fuel combustion [13]. f) Solids temperatures of 850°C in the secondary firing
b) Alternative Fuels system and/or the calciner
Alternative fuels and alternative sources of energy usually g) Uniform burnout conditions for load fluctuations
fall under eight broad headings: biofuels; natural gas; because of high temperatures and sufficiently long
waste-derived fuels; wind energy; hydroelectric power; solar retention times
energy; hydrogen; and nuclear energy. Alternative fuels h) Destruction of organic pollutants because of high
discussed in this chapter are predominantly agricultural temperatures and sufficiently long retention times
biomass, non-agricultural biomass (e.g. animal waste and i) Sorption of gaseous components like hydrogen fluoride
by-products), chemical and hazardous waste, and (HF), hydrogen chloride (HCl), and sulfur dioxide (SO2)
petroleum-based fuels [14]. on alkaline reactants
Biofuels are from organic origin (plants or animals based) j) High retention capacity for particle-bound heavy metals
including organic waste, residues from agriculture and energy k) Short exhaust-gas retention times in the temperature
crops, meat and bone-meal, methane from animal excrement range known to lead to de-novo synthesis of dioxins and
or as a result of bacterial action, ethanol and biodiesel from furans
plant materials, as well as the organic part of waste [14]. l) Complete utilization of burnt waste ashes as clinker
Candidate materials for the hazardous waste fuel/waste components
derived fuels are too many to list. They include almost every m) No product-specific wastes because materials are
residue from industrial or commercial painting operations from completely incorporated into the clinker matrix (some
spent solvents to paint solids including all of the wash solvents European cement plants dispose of bypass dust)
and pot cleaners, metal cleaning fluids, machining lubricants, n) Chemical-mineralogical incorporation of nonvolatile
coolants, cutting fluids, electronic industry solvents heavy metals into the clinker matrix
38 Shyam Krishna Karki and Khet Raj Dahal: Reduction of Coal Consumption by Using Municipal Combustible
Waste as a Fuel in Cement Kiln with Special Focus on Hetauda Cement Industry in Nepal
Not all waste materials are suitable for co-processing in the heat generated to manufacture portland cement. Therefore a
cement industry. When wastes are selected for co-processing, cement facility serves in both ways [23].
several factors must be considered, including the chemical
composition of both the wastes and the final product (cement) 2.7. Disadvantages of Alternative Fuels
and the environmental impact of co-processing. Examples of In order to make educated decisions concerning the use of
wastes that are not suitable for co-processing in the cement alternative fuels in cement production, the disadvantages must
industry are waste from nuclear industry, infectious medical be addressed and, if possible, overcome. Fundamentally, the
waste, entire batteries, and untreated mixed municipal waste. co-firing of alternative fuels must be carried out under
GTZ/Holcim, 2006 gives a full list of waste materials suitable conditions guaranteeing total efficiency of combustion.
for co-processing [19]. Otherwise, problems associated with the quality of the product
2.5. MSW and Its Conversion into Energy and/or environmental protection may occur [20]. Additionally,
in order for alternative fuels to be implemented, many
MSW constitutes a complex and very variable fuel due to logistical problems such as fuel preparation and conditioning,
their heterogeneous composition. The availability of the MSW storing, dosing, feeding, and burning must be overcome [24].
makes it one of the most alternative fuels in cement
manufacturing. Refuse-derived fuel (RDF) is the homogenous 2.8. Effect of Municipal Combustible Waste on Clinker and
part of MSW and preferred as alternative fuel due to their high Product Quality
calorific value and low moisture content [20]. Over time, as The combustible solid alternative fuels contain ash in such
the world population grows, the excess amount of MSW amount that they can affect the mineralogical composition of
becomes an environmental concern, and cement industry clinker and so the cement quality. High levels of alkalis such
seizes that opportunity to replace coal by the alternative fuel as (K2O and Na2O) in cement can, in the presence of moisture,
MSW. give rise to reactions with certain types of aggregates to
Cement kilns are potentially the best option over produce a gel which expands, leading to cracking in concretes
incineration of MSW in thermal power plant and and mortars [25]. In order to maintain the kiln exhaust gas
co-combustion in a biomass combustor. Generally MSW temperature and hence keep the clinker quality unchanged
contains various components including plastic, paper rubber, when replacing around 45% of the primary coal energy,
wood, and textile [20]. production capacity may have to be reduced by 1.2% to 14.7%
The following process flow diagram, Figure 1 presents the [25]. The waste materials used were solid hazardous waste
activities that would need to be undertaken in the production (SHW), RDF, waste wood and liquid hazardous waste (LHW).
of pellets from municipal wastes.
2.9. Financial Analyses of Using Municipal Waste as
Alternative Fuel
The CMW is considered here as a stand-alone capital
project: an initial investment that earns a net benefit over time
Figure 1. Production of pellet from municipal waste through an annual net income or savings that occurs due to the
project, which effectively “pays off” the initial cost of the
Then MSW can be dried and pelletized to form dens RDF. project. The following three common methods for analyzing
MSW typically has a calorific value of 8–11 MJ/kg, while the capital projects are used in this paper: net present value (NPV),
calorific value of RDF ranges from 15 to 20 MJ/kg [20]. Belt payoff period and internal rate of return (IRR). Overviews and
conveyor is used to feed MSW or RDF directly to the burning equations associated with these terms are presented here under
zone. From environmental point of view, SOx and NOx [26].
emissions decrease when MSW is utilized in cement kiln [20]. a) Net Present Value (NPV)
2.6. Advantages of Alternative Fuels NPV is a measure of the total current value of the cash
inflows and outflows throughout the life of a project; a
One major environmental advantage of substituting positive NPV signifies a profit over the life of the project,
alternative fuels in the cement industry is the reduction of while a negative NPV shows a loss. It can be calculated using
waste disposal sites. As the consumption of goods increases to Equation
satisfy our consumer-driven life-styles, the manufacturing
wastes also build up considerably [21]. As industries produce NPV NCF (1)
wastes such as oils, plastics, tires, etc., the environmental
impact of landfilling or incinerating these wastes becomes a Where:
serious problem [22]. Landfills require large areas of land that n=life of the project
may become unsightly and ecologically detrimental. The i=required rate of return
waste incinerators too are hazardous to the environment. NCF =the net cash flow at time t.
Incinerators burn garbage, but do not use the heat generated; NCF Initial Investment.
however a cement plant does the same thing while using the NPV helps investors to understand not only if the proposed
Journal of Civil, Construction and Environmental Engineering 2020; 5(3): 35-41 39
investment will result in a profit, but also whether it is the scale-up of operations over time, but here it is assumed
attractive compared to other options. These unspecified that these figures only rise with inflation (as shown in
“options” are represented by the discount rate, which is the Equation 4). The remainder of this chapter is dedicated to
estimated return that the investor’s capital could achieve justifying the figures used to calculate the initial investment,
elsewhere. Many firms have a certain discount rate that all annual costs and annual benefits [26].
investments must exceed. d) Sensitivity Analysis
b) Payback Period A sensitivity analysis determines how different values of an
Payback period is the time it takes for an investment to be independent variable affect a particular dependent variable
repaid. It does not take the time value of money into account under a given set of assumptions. In other words, sensitivity
as NPV does. Payback period can be calculated as follows: analyses study how various sources of uncertainty in a
- ./ -012 31-
mathematical model contribute to the model's overall
"#$%#&' "()*+, (2) uncertainty. This technique is used within specific boundaries
.014.51 .--6./ -1 7.28 9/:;
that depend on one or more input variables [26].
However, given that cash flows are rarely consistent from
year to year, it is easiest to find the payback period by
calculating a cumulative net cash flow for each year, and then 3. Waste Generation in Hetauda Sub
finding the year in which that cumulative cash flow exceeds Metropolitan (HSM)
the initial investment. Due to this caveat, the measure’s lack of
accounting for the time value of money and its inability to Since the waste generation is proportional to number of
quantify project value after the payback period, many person located in particular wards, it was found to be highest
organizations prefer other financial benchmarks. However, waste generation of 2994Kg is in ward number 4 which is at
payback period is the financial measure that is often easiest to the core location of city and lowest of 872.2 Kg in ward no 7
communicate to those not familiar with finance or other (Figure 2) [27].
technical aspects of projects.
c) Internal Rate of Return (IRR)
Internal rate of return (IRR) is defined as the discount rate at
which the NPV of a project is zero. It is a measure of the
profitability of a project over its life, with higher IRRs being
more desirable. To calculate IRR, the NPV equation is set
equal to zero with as an unknown, as shown in Equation
2.16-3. In order to find the IRR then, the unknown is solved
for.
NPV 0 NCF (3) Figure 2. Ward wise waste generation of HSM [27].
But the existing collection practice and requirement
Where: shows the highest amount of 2994 Kg from ward no 4 and
n=life of the project lowest i.e. no waste from ward no. 18 at the landfill site
i=required rate of return (Figure 3) [27].
NCF =the net cash flow at time t.
NCF Initial Investment.
Since cash flows are often not uniform, it is necessary to use
numerical or graphical methods to find IRR. In Microsoft
Excel, the formula IRR (values,[guess]) can be used.
For each of the three economic analyses, annual cash flows
(after year zero) are found by
NCF Annual Benifit Annual Cost x 1 D j (4)
Where:
NCF =Net cash flow at year t
j=assumed rate of inflation Figure 3. Waste at the landfill side of HSM [27] (GCC/HSM, 2019).
t=year of the cash flow
If we see at nature of generated waste it was found that food
In its simplest form, then, the economic analysis of a capital
waste (organic) were dominant in the household of Hetauda
project can be completed with three pieces of information: the
Municipality which was around 51%. Paper and plastic
initial investment, the annual costs and the annual benefits. In
products were generated around 12% and 27% respectively.
reality, annual costs and benefits will shift significantly
Remaining 10% constituted of leather, glass and some metals
depending on many factors, such as worker competency and
and textiles [27].
40 Shyam Krishna Karki and Khet Raj Dahal: Reduction of Coal Consumption by Using Municipal Combustible
Waste as a Fuel in Cement Kiln with Special Focus on Hetauda Cement Industry in Nepal
need high temperature to make the limestone powder to form
clinker. Mostly coal is used as burning fuel in cement kiln
which is non renewable sources of fuel. Now days, the world
is seeking a suitable renewable sources of fuel energy for
cement industy. The research shows that municipal wastes can
be used as alternative fuel in cement industries due to its
chemical composition. Combustible waste having calorific
value of required degree can be used in cement industry.
Therefore, the combustible waste which has greater calorific
value of Hetauda Sub Metropolitan can be used in Hetauda
Cement Industry by doing some waste to energy conversion
process and modification in waste feed mechanism of industry
Figure 4. Waste generation of HSM [27].
results in reduced in coal consumptions and achievement of
great economic, social and environmental benefits.
4. Assumptions to be Considered While
Doing Financial Evaluation.
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