APPCB

PUBLICATION 121

INFORMATION BULLETIN
October, 2004

Cleaner Production Techniques and Strategies for Cement Industry

BACKGROUND The cement industry today is on the threshold of a new era of energy efficient and pollution-free activities. The depleting energy resources clubbed with rising cost of energy have compelled the industry to develop and upgrade the modern techniques and methodologies on a continuous basis. Over the years, the industry has significantly invested in a number of technological measures to keep itself competitive in the fast changing scenario world-wide and implementation of some of these technologies have amply demonstrated their potential for minimizing energy wastage and cutting down production costs. The Indian cement industry, the 3rd largest producer in the world, comprises of medium and large capacity cement plants, ranging in unit capacity per kiln from as low as 10 TPD (Tonnes per day) to as high as 6,000 TPD. Majority of the cement capacity in the country is by large cement plants (86.76%), which are defined as having capacity of more than 600 TPD. At present, there are 59 cement companies in the country, putting up a total of 116 large rotary kiln plants. These plants fall under both public and private sector. About 90% of the total installed capacity is presently operating under private sector. The process of cement manufacturing gave way to dry process from earlier wet process, as the former is more energy efficient and lesser polluting. Cement making is highly energyintensive process. The thermal energy is obtained from coal or oil products and electrical energy is obtained either from grid or captive power plants (both coal as well as oil based) of the individual manufacturing units. At the current level of cement production, the coal consumption by the industry alone stands close to 18 million tonnes which is likely to go up to 25 million tonnes by the turn of the century. The annual power requirement, which stood over 7,000 GWh in 1994-95, is likely to go up to 14,000 GWh by the end of this century. Of the total estimated energy demand in the industrial sector, cement industry's coal consumption share works out to 18.32%, which makes it the third largest user of coal after steel and power. Electricity consumption in the sector accounts for 5.30% of the total industrial electricity consumption, which works out to be about 2% of the country's total generation. The total energy bill of the sector amounts to approximately Rs.2,000 Crore per annum. PROCESS The limestone rock is drilled, blasted, loaded and hauled from the open cut mine to a processing plant where it is crushed and then dispatched in rail trucks. The Process largely comprises of i) Crushing the limestone at mine area ii) Raw Mix preparation iii) Raw

Cleaner Production Cell, Andhra Pradesh Pollution Control Board

mix homogenization iv) Coal preparation v) Calcination and Clinkerisation vi) Cement Grinding and vii) Packing. SOURCES OF DUST GENERATION

Emissions during Mining. Emissions during unloading of mined stones at crusher site Emissions during Crushing Operations Emissions during Material Movement and Transfer Emissions from Raw Mill/Kiln Emissions from Cement Mill Emissions during Packing and Loading of the Cement Bags

Dust damages rotating parts, bearings etc Frequent breakdowns of plant & machinery Dust deposition on surface of the leaves, affects photosynthesis & plants growth Noise leads to fatigue, increased blood pressure

Energy Consumption in Cement Industries There exists a wide variation in the energy consumption pattern of different cement plants depending upon various factors. It varies by plant installed capacity, capacity utilisation, age, process of manufacture, equipment configuration, product mix, process control systems, layout/system design, general maintenance level, raw material characteristics and above all the management's attitude and operational practices of plant personnel. Besides, various external parameters like quality of coal, raw material and power supply have their own repercussions. The energy consumption norms have been developed by taking some of these factors into account.

ADVERSE IMPACTS DUE TO DUST EMISSIONS

Fugitive dust emissions pollute work environment & surroundings Adversely affects health of workers Inhalation of dust causes respiratory problems, lungs damage etc Low productivity of workers due to dusty environment Adversely affects visibility & prone for accidents

Table 1: Typical Energy Consumption Pattern by Cement Types S. No. 1 2 3 4 5 Process OPC PPC PSC SSC White cement Thermal Energy (kcal/kg clinker) 1,100 980 800 300 1,180 -1,200 Electrical Energy (kWh/t cement) 140 125 117 80 135 -140

It could, therefore, be argued that more production of blended cement would

result in lesser consumption of energy to produce it and hence lesser GHG emission would result per ton of production.

Cleaner Production Cell, Andhra Pradesh Pollution Control Board

Energy conservation options The following energy efficient technologies were identified for the cement sector: Use of high-efficiency motors Conversion of cement mills to closed circuit milling Use of variable speed drives Adoption of improved process management systems Replacement of old cyclone preheaters by new low pressure ones Adding new preheater with precalcination Improved housekeeping Grate cooler modification Installation of new burners, including dual firing system 6-stage suspension pre-heater Waste heat recovery Conversion of wet to dry process with suspension preheater systems Impact of Energy Conservation Measures

Fluidised bed furnace Roller press as pre-grinder Use of mineralisers Installation of vertical roller mills in raw-, coal-, and cement mills

Options Largely Implemented Vertical roller mills: most plants have installed it for raw meal grinding. However, a large potential for coal and cement grinding remains. Conversion from wet to dry process: most plants have already completed the conversion. The remaining wet process capacity is high unlikely to go for the conversion. Fluidised bed furnace: the option is still new to the Indian context. The target penetration potential is estimated to be 89%.

Some of the implemented schemes for energy conservation are shown at Table 2: SOME OF IMPLEMENTED SCHEMES FOR ENERGY CONSERVATION Project Lime Stone Crusher motor replacement from 220 KW to 165 KW Elimination of Raw mill pneumatic gravity conveyor blower Raw mill exhaust fan motor replacement AC to DC drive Raw mill Vertical Pneumatic pump carrying pipe Diameter change (180 to 210 mm) Stationary grill arrangement at Limestone stock yard & Feed table Invmt. (Rs.) 1,00,000 Saving (KWh) 8 Savings Rs./Annum 73,606

Nil 2,18,000 55,000 4,000

6 30 5 --

1,10,409 5,52,048 92,008 10,30,489

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Installation of Variable Frequency drive & Proportional Integral Derivation for Raw mill feed table Pre Heater fan impeller modification Elimination of kiln feed pneumatic gravity conveyor Kiln feed VP pump speed reduction from 835 to 660 RPM Heat exchanger VP pump speed reduction Removal of bricks in the waste zone of the kiln Elimination of No.2 Rotary Air Lock in the Heat exchanger circuit Elimination of Rotary Air Lock in Air separation circuit Kiln exhaust fan replaced with AC to DC motor Belt conveyor motor replaced with 18.5 to 7.5 KW Installation of high efficiency Primary Air fan in place of pedestal fan Heat exchanger return dust carrying through Raw Meal VP pump Pre heater modification twin cyclone inlet duct

1,47,000

--

5,15,244

45,000 --3,000 15,000 --2,50,000 5,000 70,000 92,000 8,000 -31,000 55,000 96,000 1,00,000 4,40,000 4,71,000

10 1.5 15.5 3 0.2 0.5 0.5 25 0.2 17.5 9.2 2 8 1 ----8

2,76,024 41,403 4,27,837 27,602 43,125 13,801 13,801 6,90,060 5,520 4,83,042 1,69,294 55,204 2,20,819 27,602 25,02,000 40,000 28,09,000 1,54,573 1,10,409

Replacement of PH fan drive from LT to HT Installation of Variable Frequency Drive at Kiln feed Installation of water spray at Pre heater down comer duct Pre heater Riser duct modification Installation of secondary firing system Introducing the air separation system to kiln feed bin New bag filter to Bypass cyclones & run with single fan

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Coal mill Combustion Air fan replaced with AC to DC motor CA fan inlet duct diameter increased from 500 to 600 mm Coal mill furnace hot air duct insulation Introducing of VFD & Proportional Integral Derivative in coal mill Cement mill exhaust fan speed reduction from 1440 to 980 Speed reduction of cement silo aeration blower Modification of cement mill dust collector Cement mill 2nd & 3rd chamber replaced with classified liners Policies to promote adoption of cleaner technologies The policy initiatives that were considered include the following: Subsidised energy audits/feasibility studies Tax credits for energy efficient investments Information centre/database of energy conservation options Subsidised demonstration plant Time-of-day tariff for electricity Subsidised training programmes Carbon dioxide tax (tax on higher energy consumption) Mandatory energy audits Agreements with industry associations to fix a certain percentage reduction in energy consumption over time

72,000 40,000 10,000 30,000 --1,84,000 5,60,000

5 0.2 --7 2 5 --

68,006 2,760 59,566 41,403 1,77,115 27,602 1,26,511 3,41,579

Policies facilitating buy-back of power by SEBs Workshop on Cleaner Production Strategies and Technologies in Cement Industries: A workshop on Cleaner Production Cleaner Production Strategies and Technologies in Cement was conducted by APPCB through Energy Conservation Mission at Hyderabad.During the workshop, Cleaner Production strategies and Technologies in Cement Industries and case studies were discussed . At the end of the Workshop it was opined that the Cleaner Production Technologies in Cement Industries is going to play a key role in the survival of Cement Industries in the existing scenario.

For further information and assistance contact : Mr. B.Madhusudhana Rao or Mr. K.Ravi Kumar or Smt.Geeta Sapare. Cleaner Production Cell, A.P.Pollution Control Board, Hyderabad
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