Integrated plant, process and product understanding in the high temperature mineral processing industry: An in progress case study of synthetic aggregate

The processing of mineral materials at high temperatures produce some very important materials for use by society and represent an important part of regional and national economies. Examples of these materials are bricks, cement, refractories, and various ceramics. Such industries are energy intensive and often use non-renewable resources. This paper outlines an integrated approach to R & D in product manufacture. An in progress case study is used of the manufacture of synthetic aggregate using waste materials in a novel design rotary kiln. The paper describes an integrated approach. Life Cycle Analysis (LCA) scoping methodology is used to help inform theR & D to help meet BAT requirements. By understanding 'waste' feedstock materials and modelling process and plant it is possible to tailor product properties and therefore performance. This then allows feedback to plant design and control. This approach conducted at the R & D scale suggests steps on the move toward more sustainable modes of resources utilisation.