The use of Alternative fuels are an effective first step towards a more sustainable cement production process. Not only can they significantly lower your environmental footprint, but they also offer the potential to cut fuel costs. However, transitioning to alternative fuels comes with its own set of challenges, such as variability in fuel characteristics and size, storage and dosing and operational risks. The good news is that these obstacles can be overcome with the right expertise and technology. That’s where Fuller comes in. With over 140 years of experience in the cement industry and decades of expertise in alternative fuel solutions, we ensure your transition is seamless, impactful, and tailored to your plant’s unique needs.
Looks like coal? Good news: it isn't! Shredded tyres.
Most alternative fuels have a larger particle size, higher volatility and moisture contents, and a lower heating value than conventional fossil fuels. These differences pose challenges for efficient use, which is why flexibility is essential from the outset.
Flexibility for Fuller means providing the ability to use fuels with varying sizes, characteristics and combustion properties, ensuring your plant operates efficiently no matter the fuel source.
It also means offering tailored solutions that meet your specific needs - whether you’re just starting your journey into alternative fuels or striving to maximize your total substitution rate.
Whatever your ambitions or maturity in alternative fuels, we’re committed to supporting you, ensuring that from fuel delivery to the final clinker, every phase of your process runs smoothly and efficiently.
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For plants ready for their first real move...
the PFISTER® AF Starter Kit offers a simple, low-risk solution. This easy-to-integrate system enables the use of materials like wood chips, rice husks, or RDF, providing immediate benefits with minimal investment - applicable for both kilns and calciners.
Total substitution rate (TSR)
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For plants seeking higher TSR (Total Substitution Rate) levels...
more advanced solutions become necessary. Software such as ECS/ProcessExpert® (PXP) advanced process control solution and QCX/BlendExpert™ quality control software and specialized equipment such as the HOTDISC® Reactor and FUELFLEX® Pyrolyzer are essential.
Total substitution rate (TSR)
Beyond the calciner
Achieving the highest levels of overall TSR requires replacing fossil fuels in the kiln. Our JETFLEX® 2.0 burner is ideally suited for the use of liquids and fine solids, whereas our Satellite burner enables the use of solids. A Pfister® TRW-S/D provides accurate and reliable dosing of smaller sized solid fuels and biomass.
Total substitution rate (TSR)
Our alternative fuels solution portfolio has been developed to work together throughout the cement plant flowsheet in an optimized and harmonious way. While each solution is a performance leader in its own right, the maximized value comes by using the portfolio of solutions in combination. That’s why we work closely with customers to understand how and in what combination our solutions can deliver the best results for them.
1 | Waste sourcing
A variety of different waste is collected and transported to one or more locations for pre-treatment.
2 | Waste preparation
A complex process of shredding, sorting, drying and sizing, converting the waste to different fuel qualities.
3 | Material handling and storage
The fuels are transported, stored and if necessary, dried to become part of the fuel mix.
4 | Dosing
The extracted fuel is accurately dosed to meet the pyro process requirements.
5 | Pyro processing
The alternative fuel enters the calciner or main burner where it substitutes coal or other fossil fuels.
6 | Clinker cooler
Designed to give you reliable long-term performance, our range of clinker coolers deliver efficient heat recuperation and high uptime.
7 | Process and quality control
Ensuring clinker quality, enabling the control system to compensate and optimise the fuel mix.
1 | Waste sourcing
A variety of different waste is collected and transported to one or more locations for pre-treatment.
2 | Waste preparation
A complex process of shredding, sorting, drying and sizing, converting the waste to different fuel qualities.
3 | Material handling and storage
The fuels are transported, stored and if necessary, dried to become part of the fuel mix.
4 | Dosing
The extracted fuel is accurately dosed to meet the pyro process requirements.
5 | Pyro processing
The alternative fuel enters the calciner or main burner where it substitutes coal or other fossil fuels.
6 | Clinker cooler
Designed to give you reliable long-term performance, our range of clinker coolers deliver efficient heat recuperation and high uptime.
7 | Process and quality control
Ensuring clinker quality, enabling the control system to compensate and optimise the fuel mix.
We’re here to make your transition as seamless and stress-free as possible. From detailed planning and tailored strategies to installation and commissioning, we optimize your system for peak efficiency and performance. Once installed, our expert service team/support team is here to provide ongoing maintenance, monitoring, and process optimization, ensuring your equipment runs smoothly and delivers lasting value.
With Fuller, you're not just investing in innovative technology - you're gaining a trusted partner for every step of the way.
Fuel flexibility reaches new heights (and new carbon lows) at Mannok Cement
The Pfister® FEEDflex is an upgrade to the proven and widely used Pfister® DRW Rotor Weighfeeder, with the advantage of a much lower minimum feed rate – down to as little as 60 kg/h – with no change to the maximum feed rate.
Continental Cement entrusts Fuller with a contract for innovative alternative fuel technology
Having been impressed with the first pre-commercial installation of the FUELFLEX® Pyrolyzer at the Mannok cement plant in Ireland, Continental Cement has awarded Fuller a contract for the first commercial installation of this new technology at its Davenport cement plant in Buffalo, Iowa in the United States.
Mannok and Fuller successfully make cement production more sustainable with innovative technology to displace fossil fuels
The team in Mannok’s cement facilities are celebrating the successful implementation of the FUELFLEX® Pyrolyzer, a new combustion system which is set to eliminate the need for fossil fuels in the clinker production process at the plant, the most carbon intensive stage of cement production.
Fuller's HOTDISC® Reactor helps China reach targets on emission reductions
In 2020, Chinese government announced that China would attempt to reach ‘peak carbon’ by 2030 and achieve carbon neutral status by 2060. As a result, all the country’s heavy emitters are seeking ways to reduce their carbon emissions and meet this ambitious target. The pressure on the cement industry is high. Fuel substitution is one of the most straightforward routes to emissions reduction, as something that can be done immediately with readily available technology.
Ssangyong Cement supports new HOTDISC-S design
Ssangyong Cement wanted to increase alternative fuels (AF) use at its Donghae and Yeongwol cement plants. They were interested in using the HOTDISC® reactor, one of our MissionZero flagship products. But, it didn’t fit within their existing SLC calciner layouts and a conversion to an ILC calciner to increase AF firing was not economically or technically feasible. They challenged us to redesign the HOTDISC reactor to suit an SLC calciner system.
Fuller's HOTDISC® to help slash New Zealand’s tyre mountains
It’s a growing problem for many countries around the world: used car tyres piling up as authorities struggle to find effective disposal solutions. Heating and power plants can help solve the problem by burning tyres and other solid materials, creating energy for use in households and industry, including cement production.
HOTDISC® Reactor - for alternative fuels
The HOTDISC® Reactor is the best way to substitute calciner fuel with coarse alternative fuels – enabling efficient operation and lower operating costs without compromising performance. A safe, simple and effective alternative fuels solution, this large, moving hearth furnace is integrated with the preheater and calciner systems for maximum kiln availability.
Green Innovation and FUELFLEX® Pyrolyzer - presentation by Lars Skaarup Jensen
Lars Skaarup Jensen, R&D Specialist and Project Manager, PhD Chem. Eng., presentation at EnviroTech 2024, "Ways to Transition to Green". Content includes the development of the FUELFLEX® Pyrolyzer at Mannok Cement.
With financial support from Innovation Fund Denmark, the CircFuel research project was established to investigate whether the FUELFLEX Pyrolyzer could be modified to produce a pyrolysis oil product suitable for firing in the main kiln burner or as a marine fuel or refinery feedstock.
15.12.2025 |
3.00 MB |
English
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