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The impact of specific number of airs to clinker on a clinker cooling process in grate coolers in a cement plant was investigated. Clinker cooling process is a complex process due to the vast number of interacting operating parameters such as: clinker cooler length, ambient temperature, clinker cooler width, clinker cooler drives speed, clinker cooler fan speed, clinker and air mass flow rates, and clinker density and air densities. This research examines heat transfer and multiphase fluid flow analysis as relating to specific number of air to clinker in a clinker cooling system. It employs a physical “dimensionally scaled-down” model. A 3D model of the clinker bed was developed using SolidWorks 2014 based on geometric parameters adopted in the scaled conceptual design after an existing running clinker cooler. The designed model was scaled down by ratio 25:1, that is, existing cooler being twenty-five times higher than the modelled with length 1.3 m, width 0.3 m and variable clinker bed height of 0.3 m, 0.4m and 0.6m as geometric dimensions. Numerical experimentation done involved high temperature clinker entering the clinker cooler from the heating-up furnace (HUF) at 1350 °C, specific numbers of 2.2041 and 1.7959 Nm3/kg clk, air inlet temperature of 32 °C, inlet mass flow rate of air at 0.45 kg/s at clinker 0.15 kg/s. It was observed that at a specific number of 2.2041 Nm3/kg clk at a bed height 0.6 m an optimal energy recoverable efficiency of 70% was recovered into the system and with an improved lower outlet clinker temperature of 68 °C. While, at a specific number of 1.7959 Nm3/kg clk and at a clinker bed height of 0.3 m, the lowest recoverable efficiency of 57.52% was recovered into the modelled clinker cooler and with highest outlet clinker temperature of 168.7 °C. Hence, specific number of airs to clinker also plays a significant role in clinker cooler performance.

Environmental pollution caused by waste disposal namely palm oil clinker and fly ash from palm oil industry and coal power plant respectively needs to be resolved. The present investigation explores the influence of fly ash (FA) as partial cement replacement on workability, compressive strength and flexural strength of palm oil clinker lightweight aggregate concrete. A total of five types of mixes consisting 0%, 10%, 20%, 30% and 40% FA as cement replacement were used. All specimens were subjected to curing process by immersing it in water until the testing date. Concrete specimens were subjected to compressive strength and flexural strength test at 7 and 28 days. Incorporation of fly ash as partial cement replacement influences the fresh and hardened properties of this lightweight aggregate concrete. This novel finding shows that integration of up to 20% FA increases workability and contribute to strength enhancement of palm oil clinker lightweight aggregate concrete.

This study aims to provide a decision making model to determine clinker export proportion. Cooperative game theory approach used to build the model. Players in this game are manager of production & material planning, and manager of cement production. Payoff matrix of the game composed using Mixed Integer Linear Programming (MILP) based equation. Expected contribution of this study is to provide a decision making model in determining acceptable proportion between clinker amount to export, and clinker amount to be grinded. Furthermore, this study expected to support revenue maximizing in the company.

The anthropogenic load on the natural resource potential of the planet is growing rapidly. Therefore, special attention is paid to the development of less costly and low energy-consuming technologies for obtaining new building materials. Those materials do not require high-temperature and expensive technological processing, and this will allow the use of local secondary and substandard raw materials. The development of formulations for linker-free binders of alkaline activation based on fine powders of aluminosilicate nature will make it possible to obtain new effective building composites. The work reveals issues related to the theoretical foundations of the structure formation and strength of cement stone based on an alkaline activator. The research results, in our opinion, have a practical importance for the construction industry, since the proposed formulations of clinker-free cements can replace expensive and energy-intensive Portland cement, allowing creating strong and durable concrete and reinforced concrete structures. The results presented in this article were obtained in the framework of research on the implementation of scientific project No. 05. 607.21.0320. “Development of technology for new building composites based on linker-free binders of alkaline activation using substandard natural and secondary raw materials” supported by the Federal Target Program “Research and Development in Priority Areas of Development of the Scientific and Technological Complex of Russia for 2014-2020” The unique identifier for the agreement is RFMTFI60719X0320.

Disposal of palm oil mill waste material has become a significant factor impacting the environmental situation. Among the palm-oil waste the Palm Oil clinker (POC) is usually discarded in the landfill with no economic use. The use of waste materials as modifiers for bitumen mixtures is one of the better alternatives. For this study, the impact of short-term aging on Palm oil clinker fine (POCF) modified asphaltic mixtures was investigated. The POC chunks were initially grounded and sieved through the British standard (BS) 0.075 mm sieve to obtain the POCF that can be utilized as a bitumen modifier at 4%, 6%, and 8% by weight of bitumen. In this investigation, 4.9% optimum bitumen content was selected with a 60/70 penetration grade bitumen to investigates the properties of the POCF on the ACW 14 modified asphalt mixture before and after aging. The study implemented a laboratory simulation of short-time aging (S-TA). Volumetric and Marshall properties were evaluated and analysed to compare the unaged and aged samples. Furthermore, the regression model validates significantly (R2 value 0.89-0.99) that variation in the aging condition and POCF content is directly related to the variation in the Marshall and volumetric properties. The investigation shows that the aging condition and POCF content had a significant effect on voids, Marshall stability, and Marshall quotient, as the S-TA sample showed better results compared to unaged this finding was also verified by ANOVA analysis. The research finding indicates that mixtures with POCF-MB have better performance as compared to conventional mix even under S-TA.

The article presents the results of technological studies on the enrichment of a sample of Waelz clinker from zinc cakes from the Chelyabinsk Zinc Plant by magnetic and flotation methods. The phase and chemical composition of the Waelz clinker of various enterprises is considered, the analysis of the main components of the clinker is carried out. Clinker is a large tonnage solid waste of the zinc sub-industry of non-ferrous metallurgy, has a complex multicomponent composition and is characterized by high contents of iron (36.41%), non-ferrous (Cu 5.28%, Zn 0.93%) and noble (Au 3.8 g / t, Ag 332.2 g / t) metals. Apart from that, there is noticeable content of waste rock, including free carbon (coke breeze), silicone dioxide, calcium oxide, magnesium oxide, alumina. It is shown that, in principle, Waelz-clinker can be separated according to the magnetic flotation scheme without recycle operations to produce four products: a non-magnetic carbon-containing product βC = 21.7%), copper middlings βCu = 11.39-11.69%), flotation coal product βC = 22%) and an iron-containing concentrate in the form of flotation tailings βFe = 60.23%).

Currently, utilization of waste by-products or waste materials have received attention globally as it brings significant economic and environmental impacts. In this study, palm oil clinker (POC) which is one of the waste by-products generated in the processing of palm oil was utilized as submerged fixed media in Sequence Batch Reactor (SBR). By using POC as filter media for wastewater treatment, it is able to extend the useful life of POC and reduce the demand manufacturing new media. SBR is a fill-and-draw type reactor system which allow all activated sludge process to occur over a series of time in a single complete-mix reactor. During the operational steps of SBR, the combined attached growth/activated sludge system will promote the growth microorganism that attached on the media in the activated sludge process to remove pollutants such as organic matters and nutrients passes through the media. Laboratory-scale of two Sequence Batch Reactors (SBR) was fabricated with one of the reactors filled up with POC submerged fixed media. Influent of domestic wastewater from Universiti Teknologi Petronas (UTP) ‘s Sewage Treatment Plant (STP) was adopted for wastewater treatment. Based on the result obtained, SBR reactor with POC submerged fixed media has higher ammonia removal efficiency, which approximately 90% than the SBR reactor without POC submerged fixed media, which approximately 85%.

One of the issues faced by several cities in Indonesia is the management of their increasing generation of solid wastes. One of the largest waste generators include the commercial area, such as malls, restaurants, office buildings, motels, and others, which need to manage their wastes via more sustainable routes such as the application of these wastes as refuse derived fuel to mitigate the climate change causing by fossil fuel. This study aims to analyse the potential use of wastes generated from commercial areas such as refuse-derived fuel (RDF) in the cement industry for reducing CO2 emissions. Five variants of RDFs were developed on the basis of commercial solid waste compositions. Results revealed that RDF variation 3 comprising 20% paper and 80% plastics exhibits the highest energy of 6272 kcal/kg. As preliminary study, cement industry Y is investigated as an example. During the simulation of the clinker production, RDF variation 3 is combined with petroleum coke, coal, fuel oil, or natural gas. Compared to other fuels, the combination of petroleum coke and RDF variation 3 exhibits the best CO2 reduction of 2, 155.3 106 Kt CO2/year, with the total annual clinker production of 12.64 million tons. These findings should aid policy and decision makers of waste management service provision and industry to design financially viable management systems based on resource recovery options.

The growing demand for sand supply for construction industry use especially in concrete production drives the sand mining industry to flourish. However, excessive sand mining would affect the river environment, aquatic life and water quality. At the same time, the increasing quantity of palm oil clinker, which is a by-product at palm oil mill disposed at landfill, poses negative impact to the environment. The use of palm oil clinker waste as sand replacement in concrete production would be able to reduce the use of natural sand from the river and dumping of clinker waste at landfill. The current research investigates the fresh and mechanical properties of concrete containing palm oil clinker as partial fine aggregate replacement. A total five concrete mixes were produced. The control specimen was prepared by using 100% natural sand. Other mixes were formed by integrating crushed palm oil clinker as partial fine aggregate replacement ranging from 10%, 20%, 30% and 40%. All specimens were water cured up to 28 days. The specimens were subjected to slump test, compressive strength test, flexural strength test and water absorption test. The finding shows that suitable amount of palm oil clinker can be used as partial fine aggregate replacement in concrete production. Concrete containing palm oil clinker up to 40% replacement exhibits water absorption value lower than 10%, thus classified as good quality concrete.

The article describes the grinding process by pressure in order to study the effect of pressing on the fineness of grinding at its different granulometry. Experimental studies have been conducted to study the compressible layer height effect on the clinker grinding fineness, taking into account the initial granulometry.

The influence of secondary fuels components used for Portland clinker production on emission value of heavy metals is presented in this paper. Analyses and studies of hazardous substances emission (heavy metals) from cements and concretes were conducted according to standards developed by Technical Committee CEN TC 351. The contents of following heavy metals were analyzed: Cr, Zn, Cd, Pb, Co, Ni, Mn, Cu, Sr, Ba and P in secondary fuels used by cement industry in Poland for Portland clinker production. Total heavy metal contents in cements and their leaching from cements CEM I were studied. Leaching of heavy metals from CEM I-based concretes to environment was also determined. Obtained tests results allow to conclude that changes in technology of cement clinker production leading to the usage of waste materials and secondary fuels does not cause an increase in heavy metals emission in level, which requires qualifying cement as material, which has to be regularly controlled for harmfulness on man and natural environment.

Noise pollution from traffic is an increasing environmental problem worldwide. The most popular mitigation measure is the control of path by means of construction of noise barriers. Current concrete barrier incorporated with perforated surface infilled with non-mineral fibre sound absorbing material on the highway side are the commonly found. The disadvantage of this type is it’s easily damaged and the non-mineral fibre is so dreadful to human health. On the other hand, palm oil clinker (POC) is a by-product waste material produced in palm oil mills, are currently dump in open land or landfill sites, which leads to environmental problems. POC is internally porous and if it replaces the aggregate in porous concrete it may absorb sound better than standard porous concrete which is the most important characteristic for noise barrier development. This paper discusses how the palm oil clinker substitution will make concrete noise barrier material to be labelled as green and sustainable. A framework for developing green noise barrier made of palm oil clinker concrete will also be presented and discussed.

The article describes the energy-saving technology and equipment for production of composite binding material with up to a 50% reduction in energy consumption of the process due to a synergistic effect in mechanical activation of the raw mix where a clinker component is substituted with an active mineral supplement. The impact of the gap between the rollers on the final performance of the press roller mill was studied.

The utilization of rubber seed as raw material of biodiesel production is seen highly potential in Indonesia. The availability of rubber seeds in Indonesia is estimated about 5 million tons per annum, which can yield rubber seed oil about 2 million tons per year. Due to the demand of edible oils as a food source is tremendous and the edible oil feedstock costs are far expensive to be used as fuel, production of biodiesel from non-edible oils such as rubber seed is an effective way to overcome all the associated problems with edible oils. Various methods for producing biodiesel from rubber seed oil have been reported. This paper introduces an optimum condition of biodiesel production methods from rubber seed oil. This article was written to be a reference in the selection of methods and the further development of biodiesel production from rubber seed oil. Biodiesel production methods for rubber seed oils has been developed by means of homogeneous catalysts, heterogeneous catalysts, supercritical method, ultrasound, in-situ and enzymatic processes. Production of biodiesel from rubber seed oil using clinker loaded sodium methoxide as catalyst is very interesting to be studied and developed further.

Technological process of steel production in converters using clinker-steel cakes and iron-bearing concentrates of "EVRAZ ZSMK" JSC slag processing unit ensuring liquid-phase reduction of iron from oxides is designed. Developed technology allows implementation of iron-containing materials recycling, reduces consumption of scrap, increases liquid metal yield, improves environmental safety in the region.