Emissions study of co-firing waste carpet in a rotary kiln

Post-consumer carpet represents a high volume, high energy content waste stream. As a fuel for co-firing in cement kilns, waste carpet, like waste tires, has potential advantages. Technological challenges to be addressed include assessing potential emissions, in particular NO emissions (from nylon fiber carpets), and optimizing the carpet feed system. This paper addresses the former. Results of pilot-scale rotary kiln experiments demonstrate the potential for using post-consumer waste carpet as a fuel in cement kilns. Continuous feeding of shredded carpet fiber and ground carpet backing, at rates of up to 30% of total energy input, resulted in combustion without transient puffs and with almost no increase in CO and other products of incomplete combustion as compared to kiln firing natural gas only. NO emissions increased with carpet waste co-firing due to the nitrogen content of nylon fiber. In these experiments with shredded fiber and finely ground backing, carpet nitrogen conversion to NO ranged from 3 to 8%. Conversion increased with enhanced mixing of the carpet material and air during combustion. Carpet preparation and feeding method are controlling factors in fuel N conversion.