Overview of Process Modeling Software: Utilizing Alternative Fuels in Cement Plant for Air Pollution Reduction

The use of process systems engineering tools, such as process modeling software enable the alternative generation of more efficient and sustainable processes. This paper presents the simulation of cement process using alternative fuels to replace coal. The process modeling is performed using Aspen HYSYS. Simulation results revealed that the substitution of fuel oil, natural gas and palm kernel shell for coal had a significant contribution for emission reduction in cement industry. The emissions for the base case scenario found to be 40,317 kg/h CO2, 806 kg/h NO2 and 146.8 kg/h SO2. Utilizing fuel oil mitigated 22% of CO2 and 92% of NO2 but increased 232% of SO2 emissions. Altering coal to palm kernel shell resulted in 46.16% of CO2, 73% of NO2 and 68% of SO2 emission reduction. In the best case 45.64 % reduction of CO2 emissions was achieved by replacing coal to natural gas and neither NO2 nor SO2 was generated. Key words: Cement plant; Process simulation; Aspen HYSYS; Alternative fuels; Air pollution reduction