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Co-processing in cement kiln achieves effective utilization of the material and energy value present in the wastes, thereby conserving the natural resources by reducing the use of virgin material. In India, a number of multifolded initiatives have been taken that take into account the potential and volume of waste generation. This paper studies the factors which might influence the sustainability of co-processing of waste in cement kilns as a business model, considering the issues and challenges in the supply chain framework in India in view of the four canonical pillars of sustainability. A pilot study on co-processing was carried out in one of the cement plant in India to evaluate the environmental performance, economical performance, operational performance and social performance. The findings will help India and other developing countries to introduce effective supply chain management for co-processing while addressing the issues and challenges during co-processing of different waste streams in the cement kilns.

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An integrated steel plant generates a large amount of blast furnace flue dust – about 18–22 kg/t of hot metal – as a by-product of the production process. The major component of this flue dust is iron oxides and coke fines. The recovery and reuse of this iron and coke is very important with increasing price of conventional resources. Cement plants on the other hand are looking for alternative fuel and raw materials as a substitution to the traditional fuel and raw materials, thus co-processing of the flue dust is a solution for both the industries. The study gauges the potential of flue dust utilization in a cement plant in India, using an experimental trial of one month and also analyses the techno-economic feasibility of the co-processing route. Since flue dust contains iron which is a limiting constituent in the limestone deposit of this plant, feasibility of reducing the iron content in the flue dust was evaluated through the magnetic separation route. The objective was to utilize maximum quantum of flue dust with acceptable iron content and high energy content. It was observed that the magnetic separation does not effectively segregate the iron present in the flue dust and neither increases the energy content. The cost analysis of the usage of flue dust also revealed that flue dust can be used effectively by the cement industry if its cost ranges in an acceptable range of USD 35–39 (approximately).