1. A method for using unshredded municipal solid waste (MSW) in a cement kiln system for clinker synthesis, comprising; introducing hot air generated from unshredded MSW into a high-temperature zone of the kiln system, characterized: in that a high-velocity preheated air injection manifold delivers air at 20-80 m/s and ≥800°C at the MSW entry point to induce turbulent mixing, boundary layer disruption, and accelerated thermal oxidation of bulk particles, eliminating mechanical shredding.

2. The method as claimed in claim 1, wherein the preheated air is diverted from a tertiary air duct or clinker cooler to initiate rapid pyrolysis and gasification.

3. The method as claimed in claim 1, wherein the air is optionally enriched with oxygen to compensate for high moisture and low calorific value (1500-2500 kcal/kg) of the MSW.

4. The method as claimed in claim 1, wherein MSW ash is mineralogically incorporated into clinker, contributing SiO2 (15-45%), Al2O3 (5-15%), Fe2O3 (2-10%), and CaO (10-30%).

5. The method as claimed in claim 1, wherein chlorine content (0.5-1.5%) is managed to prevent preheater blockages via dissociation or alkali bypass.

6. A cement kiln system for direct utilization of unshredded MSW, comprising a WTE Plant, and waste feeding assembly, characterized in that the system includes a high-velocity air injection manifold with tapered nozzles positioned at the feeding assembly discharge, configured for air delivery at 20-80 m/s to prevent reducing atmospheres around large particles (up to 2 m).

7. The system as claimed in claim 6, integrated with the tertiary air duct for dispersion of waste volatiles using kinetic energy.

8. The system as claimed in claim 6, wherein the kiln operates at 1400-1500°C and calciner at 800-1200°C, ensuring dioxin destruction and heavy metal capture.

9. The method as claimed in claim 1, wherein unshredded MSW has particle sizes >200 mm, reducing energy costs to <5 kWh/t compared to shredded RDF.

Description:OBJECT OF THE INVENTION
The primary object of the present invention is to provide a method and system for the direct utilization of unshredded municipal solid waste (MSW) as an alternative fuel in cement kilns, eliminating the need for mechanical shredding and reducing associated costs.
A further object is to enhance combustion efficiency of bulk MSW through high-velocity preheated air injection, ensuring complete burnout, boundary layer disruption, and integration of ash into clinker.
Another object is to align with circular economy principles, reduce fossil fuel dependency, minimize emissions (e.g., dioxins destroyed at >850°C), and comply with International regulatory frameworks

SUMMARY OF THE INVENTION
The present invention discloses a method and system for using unshredded municipal solid waste (MSW) in cement kiln systems (calciner or other entry points in the cement klin) for clinker synthesis. A high velocity pre-heated air (>800) generated from Unshredded MSW is introduced directly into a high-temperature zone (e.g., claciner or any other suitable kiln inlet). A high-velocity preheated air injection manifold, integrated with the tertiary air duct or clinker cooler, delivers air at 20-80 m/s and ≥800°C to induce turbulent mixing, disrupt gas blankets around particles, and facilitate rapid pyrolysis, gasification, and oxidation. This eliminates mechanical shredding, reduces energy costs (<5 kWh/t vs. 30 kWh/t for RDF), and subsequently MSW ash can be mineralogically incorporated into clinker (e.g., SiO2, Al2O3, Fe2O3, CaO forming alite, belite, etc.).
The system optionally includes oxygen enrichment for high moisture waste and active controls to mitigate chlorine cycles or phosphorus effects. This invention provides economic significance by lowering preparation costs, enabling higher Thermal Substitution Rates (TSR, e.g., >10%), and addressing waste management challenges.
In an aspect of this invention provides a method for utilizing unshredded Refuse-Derived Fuel (RDF) in a cement manufacturing facility during clinker production, comprising: (a) Directly feeding hot air generated from unshredded RDF into a cement kiln without pre-processing steps including fine shredding or homogenization; (b) Combusting the unshredded RDF in an incinerator configured to operate at high temperatures sufficient for complete combustion of waste materials, wherein the incinerator functions as a hot air generator; (c) Transferring the hot air generated in the incinerator to the cement kiln to supply thermal energy at temperatures necessary for klin operation formation; (d) Operating the cement kiln as both a high-temperature processing chamber for clinker production in association with a waste-to-energy conversion system; (e) Reducing overall energy consumption and equipment costs associated with conventional RDF processing by eliminating fine shredding and other pre-treatment steps.

BRIEF DESCRIPTION OF DRAWINGS
It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present invention and are therefore not to be considered for limiting its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference features and components. Some embodiments of systems or methods in accordance with embodiments of the present invention are now described, by way of example, and with reference to the accompanying figures, in which:

Fig. 1 illustrates a diagrammatic representation of method of processing of municipal solid waste (MSW) into an alternative fuel suitable for use in high-temperature industrial furnaces employed in the synthesis of cement clinker, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a novel method and system for utilizing unshredded municipal solid waste (MSW) as an alternative fuel in cement kilns, bypassing traditional mechanical shredding through innovative aerodynamic and thermal interventions.
Thermodynamic and Process Overview
Cement clinker production involves heating raw meal (limestone, clay, iron ore) to >1450°C for calcination and sintering. MSW, with net calorific value 1500-2500 kcal/kg, moisture 30-55%, and ash 20-40%, is heterogeneous and bulky. Conventional use requires shredding to <50 mm for RDF. The present invention introduces unshredded MSW (up to 2 m length) into the WTE inlet, where a high-velocity injection manifold uses preheated air (from tertiary duct or clinker cooler, 200-300°C) at 20-80 m/s which is furher heated to 800-1200°C and injected into cement klin at calciner or any other entry points to:
Accelerate drying via convective heat transfer.
Disrupt volatile gas blankets for oxygen penetration.
prevent reducing zones, ensuring complete burnout and avoiding sulfur volatilization or clinker build-ups.
Numerical simulations confirm that this velocity ensures turbulent mixing and boundary layer penetration, unlike passive systems in prior art (e.g., HotDisc). The resulting gases burn in the calciner, char oxidizes in the kiln bed, and ash integrates into clinker minerals (alite: 3CaO·SiO2; belite: 2CaO·SiO2; etc.). Chlorine management prevents preheater blockages via dissociation or alkali bypass.
The system comprises: A WTE Plant and precalciner, Waste feeding assembly for unshredded MSW High-velocity injection manifold with tapered nozzles for jet penetration, Optional oxygen enrichment to maintain flame temperatures for high-moisture MSW (12-25 MJ/kg calorific value).
Integration with tertiary air duct utilizes existing infrastructure, reducing modifications. Kiln operates at 1400-1500°C and calciner at 800-1200°C, with hot air from RDF introduced via secondary/tertiary firing. Emissions (dioxins, heavy metals) are controlled by alkaline environment and high residence times (>2 seconds at >850°C).
This invention eliminates shredding, reducing energy (from 30 kWh/t to <5 kWh/t) and maintenance costs. It handles bulky waste, increasing TSR (e.g., 10-15% as per Indian mandates) and reducing CO2 emissions (e.g., 50,000 tons avoided at 10% TSR). Compared to prior art:
Unlike US20230302510A1 or CN103396021A, no shredding or off-line furnaces are needed.
Over CN101633569A, the high-velocity injection provides active kinetic energy for non-obvious combustion enhancement.

The exemplary embodiments described herein detail for illustrative purposes are subject to many variations in structure and design. It should be emphasized, however, that the present invention is not limited to a system for enabling access control of physical documents as described. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the present invention.

To serve the various objectives described hereinabove, the present invention provides an advanced

There is a pressing need for an effective, safe, and economically viable method to transform MSW into a usable fuel that meets environmental regulations and can be readily utilized in cement kilns and other industrial furnaces. The present invention enables the direct utilization of un shredded RDF, which may contain heterogeneous and bulky materials, by bypassing energy-intensive pre-treatment processes typically required for uniform fuel input. The RDF is combusted in a dedicated high-temperature incinerator, which serves as a hot air generator. The resultant hot gases are introduced into the cement kiln to support the endothermic clinker formation reactions. By integrating waste-to-energy conversion directly into the cement manufacturing process, this approach increases operational efficiency, reduces the carbon footprint, and minimizes capital investment in shredding and material handling systems.

In an embodiment this invention provides a method for utilizing unshredded Refuse-Derived Fuel (RDF) in a cement manufacturing facility during clinker production, comprising:(a) Directly feeding hot air generated unshredded RDF into a cement kiln without pre-processing steps including fine shredding or homogenization;(b) Combusting the unshredded RDF in an incinerator configured to operate at high temperatures sufficient for complete combustion of waste materials, wherein the incinerator functions as a hot air generator;(c) Transferring the hot air generated in the incinerator to the cement kiln to supply thermal energy at temperatures necessary for klin operation;(d) Operating the cement kiln as both a high-temperature processing chamber for clinker production and a waste-to-energy conversion system;(e) Reducing overall energy consumption and equipment costs associated with conventional RDF processing by eliminating fine shredding and other pre-treatment steps.
In an embodiment of this invention the RDF comprises a heterogeneous mixture of non-hazardous municipal solid waste components, selected from plastics, paper, textiles, wood, and non-recyclable packaging materials.

In an embodiment of this invention, the unshredded RDF has an average particle size greater than 200 mm and upto 2000-3000 mm.

In an embodiment of this invention,the RDF is introduced into the kiln via a secondary or tertiary firing system.

In an embodiment of this invention, the kiln operates at a temperature range of 1,400°C to 1,500°C during clinker formation and calciner at 800-1200°C.

In an embodiment of this invention, the calorific value of the RDF is between 12 MJ/kg and 25 MJ/kg.
In an embodiment of this invention, feeding unshredded RDF reduces overall carbon emissions compared to conventional fossil fuels.

In an embodiment of this invention, the RDF feeding process is monitored and controlled to ensure stable combustion and clinker quality.

In an embodiment of this invention, the method further includes collecting and analyzing emission data to comply with environmental regulations.

In an embodiment of this invention, the cement kiln is modified with a reinforced feeding mechanism to handle unshredded RDF without clogging or material backflow.

Detailed Description of the Process Steps:
Municipal Refuse Supply and Handling: Original ecological municipal refuse (unshredded or coarsely sorted) is collected and optionally passed through a coarse separator to remove large metal items or oversized inert objects. In an embodiment no shredding or homogenization is required.

Feeding into the System:The unprocessed refuse is fed into the hot air generator for complete combustion and the hot air generated is fed at the rear end of the cement kiln via a mechanical or pneumatic feeding system.

In an embodiment an outside pre-processing or decomposition chamber can be employed for partial drying or incineration of refuse before kiln entry.

Fuel Combustion at Kiln Head:The kiln head generally uses traditional coal, alternative fuels, or even refined portions of refuse to maintain the high-temperature zone needed for clinker production. In an embodiment the hot air generated after the combustion of the un shredded waste is directly used as fuel in the cement industry.

Clinker Formation:Inside the kiln, the mineral and organic content is subjected to high temperatures and Organic components combust to provide additional energy. In an embodiment the inorganic components (such as Ca, Si, Al, Fe compounds) integrate into the clinker-forming reactions.

Emission Control:the usage of hot gases generated from the hot air generator reduces the emissions and in turn comply with environmental regulations.

Clinker Cooling and Collection:The formed clinker is cooled, collected, and stored for further grinding into cement.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the spirit or scope of the present invention.
, Claims:I/we Claim
1. A method for using unshredded municipal solid waste (MSW) in a cement kiln system for clinker synthesis, comprising;
introducing hot air generated from unshredded MSW into a high-temperature zone of the kiln system, characterized:
in that a high-velocity preheated air injection manifold delivers air at 20-80 m/s and ≥800°C at the MSW entry point to induce turbulent mixing, boundary layer disruption, and accelerated thermal oxidation of bulk particles, eliminating mechanical shredding.
2. The method as claimed in claim 1, wherein the preheated air is diverted from a tertiary air duct or clinker cooler to initiate rapid pyrolysis and gasification.
3. The method as claimed in claim 1, wherein the air is optionally enriched with oxygen to compensate for high moisture and low calorific value (1500-2500 kcal/kg) of the MSW.
4. The method as claimed in claim 1, wherein MSW ash is mineralogically incorporated into clinker, contributing SiO2 (15-45%), Al2O3 (5-15%), Fe2O3 (2-10%), and CaO (10-30%).
5. The method as claimed in claim 1, wherein chlorine content (0.5-1.5%) is managed to prevent preheater blockages via dissociation or alkali bypass.
6. A cement kiln system for direct utilization of unshredded MSW, comprising a WTE Plant, and waste feeding assembly, characterized in that the system includes a high-velocity air injection manifold with tapered nozzles positioned at the feeding assembly discharge, configured for air delivery at 20-80 m/s to prevent reducing atmospheres around large particles (up to 2 m).
7. The system as claimed in claim 6, integrated with the tertiary air duct for dispersion of waste volatiles using kinetic energy.
8. The system as claimed in claim 6, wherein the kiln operates at 1400-1500°C and calciner at 800-1200°C, ensuring dioxin destruction and heavy metal capture.
9. The method as claimed in claim 1, wherein unshredded MSW has particle sizes >200 mm, reducing energy costs to <5 kWh/t compared to shredded RDF.