Design and operation of a demonstration plant for fluidized bed low-temperature gasification of alternative fuels applied to cement production

•An integrated system of fluidized bed gasifier coupled with calciner was constructed.•The commissioning and operation data of the gasification plant were obtained.•Gasification performance of alternative fuels in the gasification plant is obtained.•The stable operation and profitability of the gasification plant was realized.•The thermal substitution rate of the calciner in cement production reached 53.10%. A fluidized bed low-temperature gasification technology for solid waste treatment is proposed, which provides an effective solution for energy saving and carbon reduction in the cement industry. A demonstration plant was designed and constructed, which is a fluidized bed low-temperature gasifier coupled to the calciner, capable of treating more than 4,000 kg/h of solid waste. The project involved detailed equipment configuration to ensure stable operation. Commissioning tests for rice husk and textile waste gasification assessed system reliability and gasification performance, with a thermal substitution rate (TSR) of 53.10 % for the calciner. At the same time, targeting a clinker production capacity of 2500 t/d, the gasification plant could achieve an annual net profit of at least 753,100 USD. The fluidized bed low-temperature gasification technology not only has a good economic and environmental value for the use of alternative fuels in the cement production process, but also is important for the design and operation of industrial-scale gasifiers and for numerical modeling.