The main objective of an Alternative Fuel (AF) project is generally to reduce the clinker production cost in a sustainable and environmentally friendly way.

The AF feeding line is an important tool to serve this objective but is not sufficient as such. Particularly if the plant starts AF co-processing: in this case the best way to achieve the financial target is to implement a true AF development process.

This process aims at evaluating which performances can be expected, and then at achieving them sustainably. It needs to take into account all aspects of the value chain, the business model adopted (purchase / semi integrated / integrated) and the specific process and conditions of the plant.

AF can have a significant positive impact on fuel cost and fossil CO2 emissions. However negative impacts on the clinker process and on the clinker quality must be evaluated and mitigated. Co-processing can start when kiln operation is generally steady and stable, a required condition for minimizing the negative impacts.

The AF development process is generally the following (some of the steps are made simultaneously):
- AF market analysis
- Permitting & Communication.
- Process baseline setup & AF scenarios
- AF line concept selection
- AF line tendering
- AF line supply and erection
- AF line commissioning and ramp-up

“Typical failures” of AFR project can be avoided by a systematic and pragmatic approach and appropriate training of the staff.

Working with a broad network of selected partners, Alterline can deliver integrated solutions, from waste sourcing and permitting to fine-tuning and industrial operation, always involving the appropriate expertise.

• Technology and Equipment design & selection:
  • Concept development & Basic design
  • Feasibility study
  • Tender specification
  • Proposals alignment & evaluation
  • OPEX/CAPEX estimation
• Technical Audits & Performances Improvement Programs [Optimization - Evolution - Revolution]
• Evaluation and mitigation of the negative impacts on kiln process
• Process training
• Support for project execution, commissionning, ramp-up
• Technology watch & benchmarking:
  • Preprocessing: Shredding, MBT, drying, screening & separation, pyrolysis, gasification etc
  • Co-processing: conveying, dosing, feeding etc
• Due Diligence

• Management and support of R&D projects in environmental technologies: equipment, specific waste pretreatment, sorbent etc
• Interface with universities and research centers
• R&D partners findings

• Finding the best way to recover your waste according to the waste treatment hierarchy

• Identifying the right waste to substitute your raw material

We support you for process safety: safety management, operational safety and design safety

• Development of AFR safety & environmental policies
• Risk assessments related to equipment, waste streams, operation etc
• Fire and explosion protection
• Chemical exposition risk
• ATEX zoning
• Safety audits
• Trainings

• Technology and Equipment design and selection
  • Concept development & Basic design
  • Feasibility studies
  • Tender specifications
  • Proposals alignment & evaluation
  • OPEX/CAPEX estimations
• Support for project execution and commissioning
• Technology watch and benchmarking: acid gas removal, VOC's removal, catalytic and non-catalytic DeNOx, odor destruction etc