On several occasions, we have assisted customers with the full development of an alternative resource strategy. The executive leadership of the companies had decided that co-processing had to become a strategic imperative. They launched fossil-fuel replacement projects only to find out the hard way that the projects failed to deliver. They didn’t realize that the implementation required a methodical change management approach, as well as a solid strategic foundation and a firm top-down commitment. We developed and guided them through all the functional elements an implementation requires, such as developing a vision, business plan, qualitative and quantitative market study, the legal aspects, a communication plan, operational factors, investments etc.

In 2017, a leading cement manufacturer in the Far East experienced a series of deflagrations in their alternative fuel feed system in the preheater tower, while co-processing solid fuel. The damage was important, but luckily no one was harmed. The fuel is a homogenous mix of non-hazardous and hazardous waste materials. Some of the wastes have very low flashpoints. We performed an in-depth causal investigation, and concluded that (a) certain unknown waste materials had made it through the approval chain, and (b) state-of-the-art safety and control measures were not sufficient. A multi-level risk-mitigation plan was developed and implemented.

A US based business, operating multiple rotary kilns, was relying solely on high-grade coal. They had piloted a small-scale trial to determine if the use of an alternative fuel was possible. The trial was inconclusive due to a variety of issues with the process, as well as difficulties with handling the waste material. We assisted with setting up a new trial, which included auditing and modifying the combustion system, developing the proper handling system, implementing trial process and quality controls, trial monitoring etc. Over a period of 5 days, we went from 100% coal, to 50% alternative fuels, with different types of waste materials. The trial setup was not decommissioned and they continued to use alternative fuel for well over one year. The ROI of the trial was less then a month!

Due to the shutdown of powerplants, or their conversion from coal to gas firing, the global supply of quality fly-ash for the cement manufacturing and construction industries is becoming scarce. In certain markets, the value of ash exceeds the price of cement! Over the years, we developed several strategic market positioning studies to identify opportunities, as well as evaluate the most sustainable value chains. We looked at the global supply chain, as well utilizing other SCM’s such as slags and other waste raw materials. We were able to identify cost-effective supply options, which were implemented swiftly.