PROCESS // AFR

INDIA SPECIAL
ISSUE 1 Destruction of hazardous
Cement Lime Gypsum chemicals and POPs
2014
Zement Kalk Gips in cement kilns

www.zkg.de 26

Excellent
Dosing EVENTS // Company anniversary
Strong development over 150 years 06

PLANT REPORT // Grinding

Substantial gain in cement mill output
with minor investment a case study 08

ENGINEERING // Plant performance

Trends in the performance management of cement plants 12

PROCESS // AFR
Proven experiences with alternative
fuels in the cement kiln process 20
Three guarantees ensuring your success in
the worlds comminution markets:
Outstanding in competence, technology, flexibility
and reliable service.
Sensitive about the needs of our customers to
whom we carefully listen and for whom we develop
smart solutions.
Key competence and creative advice that give
you confidence.

LOESCHE GmbH
Hansaallee 243
D-40549 Dsseldorf, Germany
www.loesche.com
TURNING IDEAS INTO
TECHNOLOGY
CONTENT Clinker
hopper

Fly
ash Trommel screen
- 4mm silo (-4mm)
Clinker bin
Gypsum
hopper Fly ash bin
Cyclone
Vibrating Solid flow
screen meter
Separator
Mill vent BF
Weigh
feeder
Weigh
SPECIAL INDIA feeder Cement mill

Cement Lime Gypsum VSI

Crusher
Mill vent
fan

Silo 3 Silo 2 Silo 1

Vertical
Packer pneumatic
conveyor

COMPANY PROFILES
3 Kppern Page 8
Substantial gain in cement mill output with minor investment
4 SICIT Group a case study
5 Siemens

PROJECTS AND ACTIVITIES

6 Gebr. Pfeiffer SE
Strong development over 150 years

8 UltraTech Cement Ltd.

Substantial gain in cement mill output with minor investment
a case study
Shyamal Roy, Sanjeev Srivastava and L. Rajasekar, T
echnical Research Centre, UltraTech Cement Ltd., Mumbai/India

12 OneStone Consulting
Trends in the performance management of cement plants
Dr. Joachim Harder, OneStone Consulting S.L., Barcelona/Spain
Page 12
20 ZKG International Trends in the performance management of cement plants
Proven experiences with alternative fuels
in the cement kiln process
Dr. Hubert Baier, ZKG International, Gtersloh/Germany

26 SINTEF
Destruction of hazardous chemicals and POPs in cement kilns
Dr. Kre Helge Karstensen, Chief Scientist,
Foundation for Scientific and Industrial Research SINTEF, Oslo/Norway

32 IMPRINT

32 ADVERTISER INDEX

32 EVENT PREVIEW

Page 20
Proven experiences with alternative fuels in the cement kiln process

PROCESS // AFR
INDIA SPECIAL
ISSUE 1 Destruction of hazardous
Cement Lime Gypsum chemicals and POPs
2014
Zement Kalk Gips in cement kilns

www.zkg.de 26

The strength of worldwide operating

FLSmidth Pfister GmbH is development
and manufacturing of sophisticated
Excellent continuous weighing and dosing systems
Dosing EVENTS // Company anniversary
Strong development over 150 years 06

PLANT REPORT // Grinding

for all stages of cement production.
Thismonths cover shows rotor weigh
Substantial gain in cement mill output
with minor investment a case study 08

ENGINEERING // Plant performance

feeder Pfister DRW for dosing pulverized
Trends in the performance management of cement plant 12

PROCESS // AFR
Proven experiences with alternative
fuels in the cement kiln process 20
fuels such as petrolcoke, lignite or coal
dust. More than 2.500 installations in
cement plants have proved its accuracy
and constancy. Many features like inline
blending of different fuels and the power
ful dosing strategy ProsCon support its
reliable performance.
www.flsmidthpfister.com Page 26
Destruction of hazardous chemicals and POPs in cement kilns

2 ZKG India Special ZKGwww.zkg.de

1 2013 2

KPPERN
Specialists in engineering,
manufacturing and technical services for
roll presses and HPGRs worldwide
Maschinenfabrik Kppern in Germany
Founded in 1898 and headquartered with its main
manufacturing facilities in Hattingen, Germany,
Maschinenfabrik Kppern remains a family-run
enterprise reflecting its traditional values of tech-
nology leadership, highly dependable manufactur-
ing quality and a unique regard for the individual
needs of its customers. Kpperns worldwide
network of subsidiaries, including manufacturing
plants and engineering offices, provides customer-
focused service on all continents.
Kpperns history is linked to the utilization
of roll presses for briquetting hard coal. Over the
years the briquetting process has been extended
to the agglomeration process, which is relevant
for a variety of materials including refractories,
Company profile//INDIA SPECIAL
Kppern Maco Services
fertilizers, chemical products, metallurgical fines
and direct reduced iron.
Further progress came with the introduction
of high-pressure comminution in the mid-1980s.
This innovative application for the cement and
minerals processing industries required a com-
pletely new approach to the question of wear
protection systems for HPGRs. To meet the new
requirements, Kppern developed unique wear
protection systems patented under the HEXADUR
brand. Moving to a new production facility in 2002
has enabled Kppern to manufacture even the very
largest roll presses required by the industry.
One of the youngest Kppern installations in the
cement industry operates satisfactory at Chettinad
Cement, Kallur, where Kppern
HPGRs are installed in the raw
grinding section as well as for
cement grinding. All grinding
units have been commissioned
in 2012.
Local customer support is
offered by Kpperns subsidi-
ary, Koppern Maco Services
Pvt. Ltd, which was incorpo-
rated in1997. Koppern Maco
Services has a team of project
and service engineers who had
been extensively trained at the
Germany HQ in installation,
commissioning and trouble
shooting of all Kppern sup-
plied equipments. Latest Installation
www.koeppern.de in India
ZKG India Special 3
INDIA SPECIAL//Company profile
SICIT
SICIT Group the worldwide leader in manufacturing
aminoacids & peptides based products
Plast Retard
Aerial view of our newest plant opened in 2004
SICIT Group structure
SICIT S.p.A.: is the holding company founded
in 1960. In over 50 years we have built two
manufacturing plants located in Chiampo and
Arzignano (Vicenza).
SICIT 2000 S.p.A.: the production and market-
ing Company in charge of the management of
the plants where raw material is treated to pro-
duce amino acids, peptides and their deriva-
tives. The plants work under HACCP control.
HPLC to determine the molecular weight distribution of hydrolyzed proteins in our
products
4 ZKG India Special
SICIT CHEMITECH S.p.A.: is the engineering
company also in charge of the R&D and Quality
Control, which ensures safe and reliable manu-
facturing process through its quality control
labs for chemical and bacteriological analysis.
It also develops new products and engineering
technologies.
The amino acids based products manufactured by
SICIT 2000 found their use in the following sectors:
Agriculture (special fertilizers & plant growth
regulator),
Building industry (multifunctional additives
for gypsum),
Cosmetic;
Detergency.
SICIT GROUP has 100 workers, whos efforts permit
to manufacture high quality products distributed
in over 70 countries through worldwide collabo-
ration with Multinational Companies and a large
distribution network. We mainly manufacture high
quality products for Multinational Companies that
guarantee the packaging and distribution under
their own trademark.
Building Sector
Plast Retard are nowadays the most used and
efficient multifunctional additives in the gypsum
industry thanks to their standardized quality.
Moreover, because of their natural origin they are
not hazardous for the workers and eco-friendly.
www.zkg.de
 Company profile//INDIA SPECIAL

SIEMENS

For highest plant availability

Integrated solutions for the cement industry power transmission technology is an in-
Whether crusher, roller press, tube mill, verti- tegral part of IDS. FLENDER drive com-
cal roller grinding mill, rotary kiln, or separator ponents convince due to highest prod-
drives each application is in safe hands with uct and manufacturing
Siemens. We provide the entire product range in quality, fast availability
the highest quality, starting with controls, fre- worldwide, and
quency inverters, motors, couplings and clutches, an attractive
progressing through helical, bevel-helical and price level.
planetary gear units, and continuing with add- With
on pieces. a global
With the highest product and application ex- workforce
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one overall solution, based on the Integrated ployees, Sie-
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Technologies Bucket elevator drive:
Divsion ensures integrated standard-
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the highest produc-
bucket elevators in-
tivity due to maximum verter, motor, coupling,
machine uptime. auxiliary motor and
The widely diversified portfolio sup- gear unit from a single
source
plies comprehensive solutions as well as standard
products that meet exactly Siemens customers re-
quirements. Siemens is the worlds leading sup-
plier of innovative and environ-mentally friendly
automation and drive technology, industrial soft-
ware and technology-based services.

For more information and technical descriptions,

click on the Support navigation point on our
Website.
www.siemens.com/flenderapplications or
www.siemens.com/cement
Contact: cement@siemens.com

FLENDER MultipleDrive: the new drive concept unites the benefits of a variable-
speed drive with the modularity of a multi-stage drive that enables the system to be
continuously available. It opens up new dimensions for power transmission up to
16.5megawatt

ZKG India Special 5

SPECIAL//India

GEBR. PFEIFFER SE

Strong development over 150years

1 In its 60-page catalog Gebr. Pfeiffer was founded in 1864 as a small ma-
dating from 1892, chine factory in Kaiserslautern/Germany. Today, it
Gebr. Pfeiffer presents
machines and plants for
is a globally active company with subsidiaries in
hard comminution India, in the United States and China and about
500employees worldwide. In the founding years
steam engines, mills for food production and malt-
ing equipment were the main products of the com-
pany, but the focus very soon turned to machines
and plants for the basic materials industry as we
learn from an exhibition catalog Machines for
Hard Comminution published in 1892 (Fig.1).
Gebr. Pfeiffer GPSE today has always strived
to supply its customers with particularly efficient
and reliable machines. In retrospect, it is not sur-
prising that you find superlatives again and again
like the first mill, the largest mill, the best
workmanship, the longest durability (Fig. 2).
True to his motto that If you rest you rust! the
company founder Jacob Pfeiffer motivated his em-
ployees time and time again to perform to their
utmost ability. The first air separators for the ce-
ment industry (1890) were manufactured during
his active business life. Before the beginning of
World War 1 in 1914, Gebr. Pfeiffer already em- the worlds largest cement mill, an MVR6700 C-6
ployed 500people in Kaiserslautern and exported with an 11,500 kW MultiDrive, currently under
75 % of its machines. erection in Barroso, Minas Gerais/Brazil for Holcim
The two World Wars (1914-1918 and 1939- Brazil.
1945) saw Gebr. Pfeiffer, which was an interna- Gebr. Pfeiffer sold its first own vertical mill in
tional and export-oriented company, suffer serious the year of 1956, which has become a success story
setbacks, in its entrepreneurial development: Sales under the name of the MPS mill. It was a signifi-
2 In 1925 the biggest markets were no longer accessible, and production cant contributing factor to the companys current
cement mill in the world plants were destroyed by the war and disassembled success and the mill has been sold several thousand
during this time left the afterwards as reparations. Yet, after each setback times over the years by GPSE and its licensees. The
companys premises a
challenge for the work-
Gebr. Pfeiffer recovered quickly and today in the MPS mill was also the worlds first vertical mill for
ers and exciting event 150th year of its company history Gebr. Pfeiffer cement grinding that was installed in Germany in
for onlookers demonstrates its technological leadership through 1979.

6 ZKG India Special www.zkg.de


3 The largest cement mill in Australia has been operating
since 2014
Today, in terms of reliability and cost efficien-
cy, the MPS mill is worldwide considered the best
solution for small and medium capacities in the
field of raw material, coal and cement grinding. For
large and extra large capacities, starting with an
installed power of 5000kW, the MPS mill acquired
a big sister, the MVR mill, which was put on line
for the first time in 2008. Nowadays, MVR mills for
raw material and cement grinding are operating to
the entire satisfaction of Gebr. Pfeiffers custom-
ers in Europe, Asia and Australia (Fig.3) and more
MVR mills will go onstream shortly in North and
South America and in more countries in Asia.
In addition to the technically excellent prod-
uct range, Gebr. Pfeiffers endeavour is always to
render the very best services concerning the mill
to its customers. This starts with the planning and
construction of complete grinding plants, reaching
India // SPECIAL
from training programmes and plant optimisa-
tions through to repairs, modernisations and up-
grades. Moreover, the portfolio includes the supply
of spare parts which for mill components can be
made available 40, 50 or even 60years after their
delivery, thanks to GPSEs own flexible workshops
in Kaiserslautern.
Apart from continuously working on innova-
tions to the benefit of the customers and true to its
companys motto Progress is our tradition, an-
other success factor of Gebr. Pfeiffer has been con-
tinuity free from management fads of staff and
management. Many staff members at Gebr. Pfeiffer
celebrate their 25th, 40th or even 50thanniversary
with the company. Staff fluctuations are not an is-
sue and over the 150years of the companys his-
tory the average employment period of the execu-
tive board members is 18years.
The customers. however, who decide over and
over again in favour of Gebr. Pfeiffers machines
and plants, sharing their positive experience with
other customers, are the most important factor for
the companys success. On May8th/9th, 2014 Gebr.
Pfeiffer will celebrate the companys 150th anni-
versary with these faithful customers and thereby
not only look back on past achievements but also
make plans for the future true to the company
founders motto If you rest you rust!.
www.gpse.de
textile packaging | consumer bags | |
SPECIAL//India

ULTRATECH

Substantial gain in cement mill output

with minor investment a case study
TEXT Shyamal Roy, Sanjeev Srivastava and L. Rajasekar, Technical Research Centre, UltraTech Cement Ltd., Mumbai/India

Clinker
hopper

Fly
ash Trommel screen
- 4mm silo (-4mm)
Clinker bin
Gypsum
hopper Fly ash bin
Cyclone
Vibrating Solid flow
screen meter
Separator
Mill vent BF
Weigh
feeder
Weigh
feeder Cement mill

VSI
Crusher
Mill vent
fan
1 Flow sheet of mill circuit

1 Introduction
The manufacturing process of cement is a highly
electrical energy intensive process. Size reduction Silo 3 Silo 2 Silo 1
in a plant consumes 55-65% of the total electrical
energy consumption accounting for 30-40% of the
total production costs. So, a ball mill used for ce-
Vertical
ment production consumes nearly 30-35% of total Packer pneumatic
power consumption of the plant. Hence the impact conveyor
of ball mill productivity enhancement has substan-
tial influence on manufacturing cost reduction.
In our group, the ball mill output ranges from as condition. In this article, substantial increase in ce-
low as 52tph to as high as 290tph with power con- ment mill output (~20%) and reduction in specific
sumption ranging from as low as 20kWh/mt to as power consumption of one of the ball mills with
high as 36kWh/mt. The large difference in mill TPH minor investment has been discussed.
and specific power consumption is dependent on
many factors starting from selection of equipment, 2 Observation and analysis during study
grinding media distribution, liner condition, sepa- The cement mill is a closed circuit ball mill (3.2m
rator condition, process flow sheet, input material diameter and 12.07m length) with installed mo-
granulometry, material hardness, material fine- tor power of 1680kW and supported on trunnion
ness, input moisture, clinker microstructure, clinker bearings. The separator has horizontal guide vanes.
chemistry and most importantly process operating The feeding of the material to the separator is from

160
60
Sp. surface area in m2/mt

140 1st Chamber 2nd Chamber

Percentage retained

2nd Chamber 47,2 46,7 47,1

120 50 45,8
1st Chamber 42,8
100 40 38,0
34,0 34,2
80 30,0
60 30 25,0
22,2
2 Graph showing resi- 40 20
due and Blaine along 20
10
the mill length 0
0.5 M 1.5 M 2.5 M 0.5 M 1.5 M 2.5 M 3.5 M 4.5 M 5.5 M 6.5 M 0
0.5 M

1.5 M

2.5 M

0.5 M

1.5 M

2.5 M

3.5 M

4.5 M

5.5 M

6.5 M

7.5 M

3 Specific surface area 1st Chamber

of grinding media along + 45 mic + 90 mic +210 mic Blaine Distance from mill inlet in m
the mill length

8 ZKG India Special www.zkg.de

 India // SPECIAL

the top and split into two different locations. The mill is used
to produce PPC with Blaine ~330-340m2/kg. The clinker
is preground in a vertical shaft impactor (VSI), followed by
screening through a deck screen with 4mm mesh.
The undersized clinker material from the deck screen plus
gypsum is fed together into the mill inlet and dry fly ash is
fed directly at the separator inlet. The coarse material from
the separator is also fed to the mill inlet. The capacity of the
mill was 62tph, with 336m2/kg Blaine with specific power
at 32.5 kWh/mt for grinding. Looking at mill dimensions
and present output figure, it was felt that there is a scope
of improvement in output with reduction of specific power
consumption. Hence, a technical evaluation study was con-
ducted to find out the scope for improvement with minimum
investment. Mill and separator performance data, circuit and
chamber samples were collected and then analysis was car-
ried out to indentify the cause of poor productivity. Mill pro-
cess flow chart is given in Figure 1.
Table 1 and 2 give the information on the ball mill and
separator section collected during performance evaluation.
Circuit samples were also drawn from the mill outlet, fly
ash, separator inlet, separator fines, separator coarse, mill
ESP fines and the final product. Blaine, cumulative residue
percent on 45m for all the samples are given in Table 3.
After completion of the flow measurement and sampling,
the mill was crash stopped to do the chamber sampling and
checking of the internal condition of the mill as well as the

Comminuting
separator. The axial trend of cumulative percentage retained
on 210, 90 and 45m plus the Blaine value are graphically
shown in Figure 2.
Sampling for grinding media (more than 200 numbers)
were collected from every meter separately to check the clas- your maintenance
expenditure
sification of media across the length. Based on weight and
number of balls from each meter, specific surface area of
media along the length was calculated, which is graphically
represented in Figure 3.
Based on the result of particle size distribution of three
samples (separator feed, separator fines and separator coarse),
the tromp curve was plotted, which is given in Figure4.
The tromp curve analysis confirms that the apparent by-
pass (ABP) was 26%, which is high. The reason for a high
bypass may be due to agglomeration of fine particles, a high Kppern roller presses have been proven successful all
rotor seal gap and improper feed distribution. This resulted
over the world in plants for the energy-saving high
into low separator efficiency.
pressure comminution of cement clinker, limestone and

3 Action plan blast furnace slag as well as various ores and minerals.
Based on the analysis of information collected during the For the comminution of abrasive materials the patented
study, the following actionable points were indentified for im- Hexadur wear protection of rollers is available.
provement in the mill productivity. Kppern Quality made in Germany.
The screen size of the vibrating deck screen after the VSI
crusher has to be changed from 4mm to 3mm to reduce
the feed size of material into the mill. State of the art technology
Grinding media pattern re-distribution in the 1st chamber Process technology know-how
for increasing the specific surface area in view of maxi- High plant availability
mum 3mm material input size and low residue of mate- Quick roller replacement
rial near the intermediate diaphragm.
Re-distribution of grinding media pattern in the 2nd
chamberto increase its specific surface area in order
to improve the fine generation in the 2nd chamber par-
www.koeppern.de

ZKG India Special 9

SPECIAL//India

Tab. 1 Details of mill parameters Material level in 2nd chamber was ~15-20mm
below the grinding media, which indicates that
Particulars Unit Data
the mill has the potential for increasing the feed
Production rate TPH 62
until the material filling level in the 2nd cham-
Fineness Blaine m2/kg 336 ber will be ~50mm above the grinding media
Mill water spray m3/hr Nil in crash stop condition. This will reduce the mill
Grinding media filling degree in 1st chamber % 31.5
main motor power consumption as well as im-
Grinding media size used in 1st chamber mm 40 & 30
prove the production.
Sp. surface area of media in 1st chamber m2/mt 22.46
The air velocity of the mill is too low (0.26m/s),
Grinding media filling degree in 2nd chamber % 30.9
which is to be increased in steps up to the level
Grinding media size used in 2nd chamber mm 25, 20 & 17
of 0.8-1.2m/s to remove generated fines from
Sp. surface area of media in 2nd chamber m2/mt 41.66
the system and avoid over grinding.
Mill inlet draft mmwg -2
The separator efficiency needs to be improved
Mill outlet draft mmwg -26
by reducing a rotor seal gap to optimum value
Mill discharge material temp. C 103
of 6-8 mm and through even distribution of
Mill velocity m/s 0.26
Sp. power of mill main motor kWh/mt 21.93
feed material. Feed material to the separator
should be distributed in four locations instead
of two locations.
Tab. 2 Details of separator parameters

Particulars Unit Data 4 Result obtained after implementation

Separator rotor diameter m 1.95 Result obtained after implementation: All the
Separator rotor height m 0.96
above actionable points have been implemented.
Air flow through separator m3/hr 90291 Results obtained after the implementation of all
Separator feed TPH 129 actionable points are as follows:
Separator fines TPH 62 The mill TPH has been improved by ~12mt/h
Velocity through separator cage m/s 4.26 (current TPH of mill is ~74)
Specific air load wrt feed kg/m3 of air 1.43 Separator efficiency has been improved up to
Specific air load wrt fines kg/m3 of air 0.69 71%
Specific rotor load TPH/m2 10.54 Specific power of the grinding section has been
Separator efficiency based on 45 m % 52.2 decreased by ~2 kWh/mt (current sp. power is
Circulating factor based on 45 m 2.5 ~30.5kWh/mt).
Measured horizontal seal gap of rotor mm 1216
5 Conclusion
Tab. 3 Blaine and resi- An holistic approach is necessary for improving
Blaine m2/kg +45 m
due of circuit sample the productivity of any process section. In the case
Mill outlet 178 39.28 of ball mill operation, grinding and classification
Input fly ash 372 16.66 is interlinked. Once the separator efficiency drops
Separator inlet 223 35.50 down, then the grinding efficiency will also be af-
Separator fines 315 8.56 fected and vice versa. By improving the efficiency
Separator coarse 98 53.50 of both sections simultaneously, it is possible to
Mill ESP fines 458 3.10 improve the output by 10-15% with minor invest-
Final product fed to silo 336 8.30 ments. This will not only improve the capacity of
the plant, but also save lot of precious power for
4 Tromp curve based on
ticularly <45m and also optimized grinding grinding. The cement mill output for this particular
circuit samples of PPC media filling level from 30 to 29% for lower- plant has been increased from 62TPH to 74TPH
grinding ing power consumption. with specific power reduction of 2kWh/mt.

P30/P70 : 0.36 ; P50 : 43 ; ABP : 26 %

ACKNOWLEDGEMENTS
100
Incremental Recovery [%]

90
80 The authors are grateful to the management team
70 at M/s. UltraTech Cement Ltd. for their permission
60
50
to publish this paper. The authors are also thankful
40 to the respective unit head for giving his input and
30 implementing the entire action plan to achieve the
20
10
result. The authors would also like to thank to Mr.
0 Shrikrishna Herwadkar for his valuable suggestion in
1 10 100 1000
Avg Particle Size [ ] finalizing this paper.

10 ZKG India Special www.zkg.de

 PFEIFFER.
SETTING BENCHMARKS.
SINCE 1864.

From one mans idea to the largest mill in the world

When industrialization began in Europe, Jacob Pfeiffer had a vision: the grinding of
mineral raw materials on a large scale. As a family-owned company, inspired by his
energy and enthusiasm, we carry on his idea and have been doing so for 150 years.
And still today, as a technology leader operating worldwide, we continue to set bench-
marks for the industry. Behind all this, lies state-of-the-art engineering work made
YEARS
NG
ERIN in Germany and the special quality of a manufacturer with his own manufacturing
ENGINE
GERMAN 64 facilities guaranteeing highest durability and reliability. Jacob Pfeiffer would be proud.
SINCE 188
www.gpse.de

1864 1890 1894 1925 1956 1979 1994 2006 2007 2014
Jacob and Karl The rst air The rst cement The largest The rst MPS mills The rst vertical Launch of MPS B The rst MVR The rst vertical The worlds largest
Pfeiffer founded the separator in the grinding operation cement mill for raw material mill for cement series with improved mill for cement mill with vertical mill for
Pfeiffer machine cement industry in a Pfeiffer mill in the world and coal grinding grinding performance grinding MultiDrive cement, under
factory and foundry erection

Benchmarking the performance of cement plants is the trend in the
global cement industry and is now widely used. The following article
outlines the major implications and focus areas of this approach.
TEXT Dr. Joachim Harder, OneStone Consulting S.L., Barcelona/Spain
Bearing of a rotary ONESTONE CONSULTING S.L.
cement kiln
Trends in the performance management
of cement plants
1 Introduction
Cement plants are operating continuously for 24
hours a day and when possible for about 330 days
a year without interruption. The rest of the year
the plants have their annual shutdown for major
repairs. Each day of unscheduled shutdown re-
sults in a loss of income, which can be as high as
0.3 million US$ for a standard 1.0 million tons
(Mta) capacity plant and cement prices in the range
of 100US$/t. Accordingly plant managers have to
concentrate on keeping the plant running and opti-
mising the production costs. These production costs
differ greatly depending on region, plant technol-
ogy and other parameters but are the most useful
benchmarking parameter for the comparison of in-
dividual plants [1].
For several years this kind of benchmarking has
been used by a number of cement manufacturers,
engineering consultants and organisations mainly
for cost and energy efficiency comparisons. For
example the Cement Association of Canada (CAC)
used this method to compare the specific thermal
energy demand of Canadian cement plants (Fig.1).
With support from Natural Resources Canada (NR-
12 ZKG India Special
Thyssen Krupp Industrial Solutions
Can), the CAC commissioned the benchmarking
study of Canadas Portland grey cement industry
in 2007. The study determined that the overall
energy efficiency of the 15 plants was relatively
good, with a median energy efficiency index (EEI)
of 76, compared with a theoretical best practice
plant value of 100 [2].
In an international benchmark comparison the
Canadian cement plants will most likely be at the
lower end, because the average energy demand of
the plants was 4.2GJ/t of cement and 4.5GJ/t of
clinker, when compared with 3.0GJ/t of clinker or
less, which is possible today with modern plants.
Accordingly when using benchmark methods for
the comparison of actual cement production costs
it will be best if the latest energy and other produc-
tion costs of other cement plants in the same region
are known. If not, average cost breakdowns could
help. The average Lafarge 2012 production cost for
cement is (before distribution and administration):
33 % energy, 29 % for raw materials and consum-
ables, 26 % other costs and 12 % depreciation.
The benchmarking of cement plants should
take into account that each plant is unique in terms
www.zkg.de
 India//SPECIAL

of its raw materials, fuel types and cements pro-

duced, beside plant capacity, technology used and
the status of the plant (age, condition, automation),
management and human resources. So for example
with an advanced control and automation system
the plant can be run much more smoothly with a
stable kiln condition at lower burning zone tem-
peratures which can result in reducing fuel con-
sumption by up to 5 %.

2 Performance management and benchmarking

Cement Association of Canada

In the last decade cement kiln lines became larg-
er because of the economies of scale that can be
achieved with high capacity plants. Globally there
are more than 20 additional kiln lines operating
today with a capacity of 10 000tpd or more, com-
pared to 10 years ago. Beside the very large plants
there is a trend for kiln capacities in the capacity
range of 5000 to 6000 tpd [3]. Nevertheless the index indicates that with better or higher main- 1 Energy efficiency
drawback of this approach is that if these kilns are tenance the targeted high production capacity and benchmarks
not run close to optimum, the losses are bigger than lower production costs could be achieved. In ther-
with small plants. When the benefits of the econo- mal energy consumption, only a small effect can
mies of scale shrink it becomes more difficult to be seen. Thermal energy consumption is fixed with
achieve the desired return on plant investment. So the plant design and the type of pyroprocessing
with larger plants the needs of optimization sig- system (Fig. 3). It is also interesting to note that the
nificantly increase. cement quality was not compromised.
In larger cement groups auditing has become In practice if cement plants (Fig. 4) want to start
a part of the normal routine of performance man- with a performance audit, normally a longer time
agement in cement plants and individual kiln lines. span is necessary to achieve significant improve-
A professional plant audit is a powerful tool in ments. Such an audit begins with a historic evalu-
analyzing current plant performance, identifying ation of plant operation and stoppage data being
current limitations on the productivity of the plant, collected for the past two or more years. Data for
developing improvement measures and eventual- fuel consumption, power consumption, output and
ly justifying necessary modernizations and plant product quality will also be analyzed. In a more
upgrades. When the audit is properly conducted detailed analysis, the frequency, durations and
the cost drivers that have the greatest influence on reasons for kiln stoppages will be analyzed and
the profitability of the plant can also be identi- categorized (mechanical, electrical, refractory, in-
fied. Other performance indicators include train- strumentation/plant control, environmental, hu-
ing, environmental issues and occupational health man errors, etc.) in order to identify performance
& safety (OH&S). gaps in key technical or other areas.
Figure2 shows an example of the overall per- From such an analysis the potential for plant
formance index of a cement plant, benchmarked performance improvements can be derived. Mak- 2 Overall performance
against other plants [4]. The benchmark index is ing adjustments or improvements to the plant op- index (OPI) chart
given as 100 for each parameter and includes as-
pects such as production capacity, product qual-
ity, thermal energy, electrical energy, production,
maintenance costs and OH&S. While the rated
production capacity of the kiln is mostly indexed
at 100, the thermal energy consumption index
can be 3.0GJ/t of clinker and the electricity de-
mand index can be 100kWh/t of cement. More
specifically the indexes can also be based on the
best practices which are possible for a specific kiln
size [5].
In the example on the chart the plant was able
to keep or improve its performance in practically
all aspects close to the benchmark from one year
to the other, with the one exception of the main-
Holcim

tenance index. The decrease in the maintenance

ZKG India Special 13

SPECIAL//India
3 Advanced dry pyro-
processing at Akcansa
in Turkey
eration often needs only a little capital investment
but issues such as operator training and fixed op-
eration procedures are very important. If it comes
to a de-bottlenecking of the plant or the upgrade/
modernization of single equipment usually mi-
nor capital investments with a payback time of
<24 months are necessary. For an upgrade of the
preheater, kiln and cooler system or new cement
grinding equipment (Fig. 5) or new storage and
dispatch facilities, major capital investments with
3-5years payback can be feasible.
4 Benchmark 3 Mta
Rewa cement plant in
India
14 ZKG India Special
HeidelbergCement
3 Process optimisation and production consistency
The performance of a cement plant depends on a
large number of parameters. An optimization of
the plants throughput must not be the energy op-
timum or vice versa. And there are a lot of other
parameters, which could have their own optimum,
such as the cement quality, maximum availability,
maximum use of alternative fuels, lowest main-
tenance or the environmental impact of the plant
at the rated or other given capacity. Furthermore
an individual optimization can be achieved for the
JALINDIA
www.zkg.de
 India//SPECIAL

5 State-of-the-art verti-
cal roller mill (VRM)

Loesche
different plant sections from quarry to cement dis-
tribution. It is important to find the right mix.
Another important point is that kiln lines tend
to become unstable or unbalanced over time. When
the plant is commissioned and the guarantee pa-
rameters are fulfilled the individual set points for
the plant are installed. But when the plant ages, the
raw material composition changes, the fuel chang-
es and mills throughputs or fineness change due
to wear and the set points have to be adjusted. If
for example the fineness of the raw material has to
be reduced due to throughput constraints, then the
fuel consumption of the kiln will increase. Empiri-
cal studies show that each additional 1 % residue
of raw material fineness above the target of 12 %
on the 90m screen will result in 5-10 extra kcal/t
clinker in fuel demand [6].

In a modern dry processing cement plant there
are a large number of inter-relationships in the
many process parameters. Without a good under-
standing of the different processes it will become
difficult to adequately optimize the cement pro-
duction process. Today, various expert systems are
available which are specifically designed for ce-
ment plants and supplement advanced automation
and control systems of the cement plant from the
central control room (Fig.6). The expert systems
approach is to model the behaviour of the best kiln
operators by means of neural networks, soft sen-
sors and model predictive control (MPC). MPC aims
to integrate self-learning and auto-adjusting
modules [7].
MPC systems have become especially useful
for cement mill control. There are many plants in
Europe where mills have to be operated when there
are low electricity tariffs and at least a daily start-
up and shutdown becomes necessary. So for night
shift operations, which have a reduced staff level,
TKIS
the MPC shortens the mill start-up phase and al- 6 State-of-the-art
central control room
lows the mill to be operated at stable conditions.
Such systems require comprehensive and reliable
instrumentation (Fig. 7), including, for example,
vibration sensors for the mill. When MPC systems
are used for kiln control, it is very important that
process alarms are carefully monitored, because
any drift to extreme or dangerous conditions has
to be avoided.
The biggest challenge for a cement plant com-
pared with a specific chemical plant is that the raw
materials differ widely and the production of con-
stant quality cement needs several stages of blend-
ing and homogenization in the process flow.
Figure8 illustrates the complexity of the raw
material variation. The first step is to employ a
blending bed to even out the quality fluctuations
in raw materials coming from the quarry. Other
components are added in the raw mill in order to

ZKG India Special 15

SPECIAL//India
Siemens
7 Condition monitoring of VRM mills
TKIS
8 Blending and attain the constant cement moduli for the burning
homogenisation of raw process. Complete homogenization takes place in
materials the raw meal blending silo.
The control system for the material handling
starting with the receipt of raw material from
the quarry to the kiln feed has to be designed to
achieve the required level of material homogeneity.
Figure9 shows the qualitative result for the fluc-
tuation in lime standard arising from the raw meal
analysis method. The greatest range of fluctuation
occurs in offline operation with manual sampling.
In the case of inline operation with automatic sam-
pling and automatic sample preparation there is
only slight fluctuation that also depends on the
number of samples per hour. More than two sam-
ples per hour bring no further improvement [8].
The best means of achieving process optimiza-
tion is generally a combination of online and inline
analysis with two control loops. As depicted in Fig-
ure10, for the raw meal analysis the inner control
loop is formed by an online analysis and the belt
feed material is used as the manipulated variable.
16 ZKG India Special
The outer control loop consists of inline labora-
tory analysis. Such a configuration can be used for
the implementation of various cascade solutions,
which can also include the raw meal blending silo
to achieve an optimal raw meal consistency. How-
ever, such methods also involve a significant in-
crease in the amount of equipment and the com-
plexity of the control system.
4 Maintenance strategies
In a cement plant which is continuously operating
not all components are necessarily running for 24
hours a day as is the case for the pyroprocessing
equipment. There are some buffer functions, for
example, in the raw material processing and clink-
er storage, which allow the raw material handling
system or the cement grinding system to be active
for only 8 hours a day. Accordingly some cement
plants have such high clinker storage and cement
storage volumes that they can even produce and
sell cements when the pyroprocessing line is in the
annual shutdown.
So, critical equipment which is running
around the clock needs different maintenance cri-
teria than non-critical equipment which runs for
8 hours. In many cement plants the maintenance
concept for the latter equipment is reactive or as
needed, while for the critical equipment more
proactive tools such as predictive and preventive
maintenance are used. Figure11 gives an idea of
how the concept is applied to cement plants, with
measures that can be installed in parallel, depend-
ing on how critical the equipment is. The meas-
ures adopted will depend on the cement producers
philosophy, the age of the plant and budget con-
straints.
Reactive or corrective maintenance allows the
plant sections or components to operate until a
fault or equipment failure occurs. These faults can
usually be solved or repaired without requiring a
plant stoppage. The situation is different in the
case of critical components like large drive motors,
large bearings for mills and gear units. To avoid the
replacement of such components before they reach
the end of their planned service life, the condition
of the units is monitored. Condition monitoring
can be implemented by recording different param-
eters and interpreting them in order to assess the
possibility of failure.
In recent years condition monitoring has experi-
enced a real boom, due to the advance in automation
solutions. Condition monitoring of plant compo-
nents is supported by active maintenance concepts
that are aimed at identifying fault mechanisms and
consequential damage and determining the possible
effects of, for example, operating errors or incorrect
maintenance. One of the most widely established
processes in the cement industry is computer-aided
thermal imaging of rotary kilns. The latest processes
www.zkg.de
 India//SPECIAL

make use of infrared sensors that scan the entire 10 9 Lime standard as a
length of the kiln and supply three-dimensional pic- 9 function of material
analysis

LSF (Standard Deviation)

tures and evaluations (Fig. 13). 8
7
Preventive maintenance is primarily employed
6
for critical plant components that involve lengthy
5
stoppages. It comprises a planned maintenance
4
programme and regular inspections (Fig. 12) to en-

OneStone Research
3
sure high availability of the respective plant com- 2
ponents. The inspection results determine whether 1
the required maintenance can be carried out dur- 0
Offline 1/h Inline 1/h Inline 2/h Inline 4/h
ing the annual plant stoppage or need to be per-
formed earlier. This particularly serves the purpose
of avoiding expensive scheduled replacement of
Customer Plant ountry Contract Status
systems and equipment that are still in fully func-
ACC Ramliya I Egypt 2007 in production
tional condition and have a lengthy residual ser-
AUCC Zliten Libya 07/2009 in production
vice life expectation.

FLSmidth, OneStone Research

FCK Sumbe Angola 04/2010 start-up 2014
Preventive maintenance is essential to mini-
Jovein Cement Mashad Iran 05/2010 in production
mize the number of unplanned plant shutdowns. Wadi El Nile Wadi Egypt 05/2010 in production
Shutdowns are always problematic because of the NCC I & II Egypt 10/2010 in production
length of time involved and have a decisive effect ACC Ramliya II Egypt 05/2011 in production
on the cost-effectiveness of the plant. The mainte- Carthage Cement Djebel Ressas Tunesia 10/2012 in production
nance concept is simple: solve problems before they Dangote Cement 5 lines Nigeria 11/2013 start-up 2014
happen. These requirements are met by inspecting
critical plant components, such as the kiln, cooler, dustry. These systems are based on predictive and Tab. 1 O&M contracts
mills, large fans etc. to determine how smoothly the proactive tools and are a major part of the so-called
machines are running, whether vibrations or high reliability centred maintenance programs. CMMS
surface temperatures occur, whether there is corro- use sophisticated failure mode and effect analy-
sion etc., and by checking oil levels and lubricant sis (FMEA) and root cause failure analysis (RCFA)
conditions. Another purpose of regular inspections tools. So for example the RCFA is used to conduct
is to check that all plant safety issues are assured. an investigation into every kiln stoppage in order
In the last few years computerized maintenance to find out and determine the true cause of failure
management systems (CMMS) have been more and to prevent the same problem occurring in the
widely accepted and established in the cement in- future [9].

10 Process optimisa-
tion with online/inline
control loop
FLSmidth

ZKG India Special 17

SPECIAL//India

is reduced, because the service provider takes the

Cement Plant Maintenance Concept risk. Plant owners keep the responsibility for the
raw material, utilities, offices, security and plant
Reactive Preventive Predictive Proactive property.
At the moment in the cement industry there are
Small items Critical components Critical components Human factor / plant
Unlikely to fail Subject to wear-out Subject to wear/no wear Subject to wear/no wear a handful of providers for O&M contracts includ-
Non-critical Failure pattern known Random failure patterns RCFA ing engineering consultants such as Holtec Con-
Redundant Long downtime Condition based FMEA
Spares in stock Spares on schedule Spares on demand Age Exploration sulting in India and Cemex Global Solutions. Other

Run-to-failure Component exchange
Abbreviations:
RCFA Root Cause Failure Analysis
FMEA Failure Modes Effects Analysis
11 Mixture of different
maintenance concepts
12 Inspection of a ce-
ment grinding plant in
Morocco
OneStone Research
Repair / exchange Acceptance testing
5 Outsourcing
In Africa, the Middle East and Asia there is a clear
trend to outsource plant operation and mainte-
nance (O&M) as well as other services such as per-
formance audits. Probably the market leader in the
sector is FLSmidth (FLS), who were awarded almost
10O&M contracts in the last few years (Table 1).
In such projects FLS is contracted to operate and
maintain the cement kiln line or plant over a spe-
cific period of time such as 5-7years. FLS guar-
antees a specific cement output of the plant for an
agreed price per ton. The fee of the O&M services
are performance based and FLS is committed not
only to operating the plant efficiently, but to main-
taining it in premium condition.
The benefit for the cement plant owner of this
kind of outsourcing is that the fixed production
costs are significantly reduced, while variable
(performance based) costs will probably increase
and at the end there is a net and significant saving
in costs (Fig. 14). Such an approach is especially
useful for new investors and cement plant owners
who have a problem finding experienced personal
to operate and maintain the plant. Furthermore
for the plant owner the risk of operating a plant
services such as those offered by ASEC Cement in
Egypt include an investment in the plant which can
be a minor or major stake in the plant assets. So
the full spectrum of contracts which are possible
today include:
BOT models, this is the build, operate and trans-
fer concept as known by other industries such
as power plants and other utilities, sometimes
referred to as DBO (Design, build, operate with
later transfer).
BOO models (Build, Own, Operate) according to
ASEC approach.
DUO/DDO models (Design, upgrade, operate
and Due diligence, operate), such as the one of-
fered by FLS for older plants requiring an up-
grade or performance optimisation.
It should be noted that some of the cement majors
also provide O&M services to internal and exter-
nal customers. TECHPORT for instance is a Holcim
Group company that is looking at developing a
synergistic collaboration among Holcim and In-
dian group companies ACC and ACL. At the mo-
ment the primary objective is to contribute to the
performance improvement of ACC and ACL plants.
Cemex Global Solutions also has experience in
practically all O&M issues and other customized
services which it offers to external customers.
Even more suppliers exist for cement plant op-
timisation, benchmarking and plant audits. Among
Italcementi

18 ZKG India Special www.zkg.de

 India//SPECIAL

the leading engineering consultants are Holtec cash-flow fixed industry. Accordingly it is forecast
Consulting, PEC Consulting, PEG Engineering, that the trends will continue in this decade and
Penta Engineering, JAMCEM Consulting, CemCon might even accelerate in the next decade. On the
AG, Cement Performance International (CPI) and other hand more service providers will enter the
Whitehopleman as well as the major equipment market and the services will become more competi-
suppliers and equipment specialists such as FLS- tive while margins shrink.
midth, Thyssen Krupp Industrial Solutions, KHD
Humbold Wedag, Siemens and ABB to name a few.
The concepts for plant optimization of the dif-
ferent suppliers seem to be very similar, although
the tools may differ significantly. Such an opti-
misation always starts with a plant audit to get
an independent assessment of the plant condition,
identifying bottlenecks [10, 11]. In a second step
opportunities for improvement are derived from
benchmarking methods. In the final step a report is
prepared in which measures are outlined as to how
the gap can be closed and how the opportunities
can be taken advantage of.
Other services that are offered include:

HGH Systems Infrarouges

Energy optimisation
Product quality enhancement
Remote plant operations & efficiency monitor-
ing
Capacity balancing & enhancement
Productivity improvements
13 Display of a kiln scanning system
6 Outlook
The cement services sector generates higher mar-
gins for suppliers than the equipment supply sec-
tor. This was true in the past and will probably
continue to be true in the future. Suppliers like
FLSmidth already generate higher revenues in the
cement business from cement services than from
equipment supply. At the moment, especially, the
demand for outsourcing is fast growing due to the
needs of larger cement plants for adequate perfor-
mance management and reduced personal in the
plants.

FLSmidth
With O&M services from third parties, cement
plant owners are able to reduce their fixed costs
which today become more and more important in a 14 Financial benefits of O&M outsourcing

REFERENCES

[1] Harder, J.: Current Modernisation and Maintenance Concepts in the Cement Industry. ZKG International, 5/2010, pp. 24-38
[2] CIPEC: Energy Performance Benchmarking and Best Practices in Canadian Cement Manufacturing Sector. Canadian Industry Program
for Energy Conservation (CIPEC). ISBN 978-1-100-14036-0, Ottawa, Ontario/Canada 2009
[3] Harder, J.: Trends in Cement Kiln Pyroprocessing. ZKG International, 2/2012, pp. 22-32
[4] Aebischer. T.: Performance Measurement at Holcim, Presentation at Swiss CFO Day 2014, 22.01.2014, Zug/Switzerland
[5] Harder, J.: Trends in Kiln Systems for the Cement Industry. ZKG International, 7/2007, pp. 38-49
[6] Mutter, M.: Finding the Balance. World Cement, March 2012, pp. 73-76
[7] Alsop, P.A.: The Cement Plant Operations Handbook The Concise Guide to Cement Manufacture. Sixth Edition January 2014. Trade-
ship Publications Ltd., Dorking, Surrey/UK.
[8] Harder, J.: Material Analysis for Process Control in Cement Plants. ZKG International, 7-6-7/2009, pp. 58-71
[9] Mutter, M.: Managing for Reliability. World Cement, September 2013, pp. 95-98
[10] Boon, B.: All about Audits, World Cement, September 2010, pp 139-141
[11] Rudd, K.: Mechanical Integrity and Reliability, World Cement, September 2013, pp. 91-94

ZKG India Special 19

SPECIAL // India

In times of increasing energy costs, it is of vital interest for any company to save energy.
To cut the energy costs for clinker production, the German cement industry started substitution
of primary fuels with Alternative Fuels (AF) such as used oil or tyres after the first oil crisis
of 1973. Today, alternative fuels and raw materials (AFR) include a wide range of types of
hazardous and non-hazardous waste, as well as solid and liquid, organic and mineral waste.

TEXT Dr. Hubert Baier, ZKG International, Gtersloh/Germany

Co-processing of SRF SPECIAL AFR

Proven experience with alternative fuels in

the cement kiln process
1 Introduction
To cut the energy cost for clinker production, the
German cement industry started substitution of
primary fuels with Alternative Fuels (AF) such as
used oil or tyres after the first oil shock in the early
1970s. Today, at more than 2/GJ energy costs and
after establishing a reliable disposal management,
alternative fuels and raw materials (AFR) include a
wide range of types of hazardous and non-hazard-
ous waste, as well as solid and liquid, organic and
mineral waste, which have to be pre-processed,
quality-monitored and tailor-made for existing
kilns or newly-installed kilns and its chemistry of
geological survey and products.
For example in Germany the ban on landfill
in 2005 pushed the development of technologies
for co-processing in the electricity and cement in-
dustry. Based on 30 years of proven experience,
co-processing is assuming an important role for
integrated waste and energy concepts, however in
that reduction target on emission of greenhouse
gases (GHG).

20 ZKG India Special www.zkg.de

 India//SPECIAL

Therefore almost 50 Mechanical-Biological Parameter %

Treatment (MBT) public plants were installed with CV 21 800 kJ/kg
an annual input of approx. 6million tons of mu- C 25.2 28.8
nicipal solid waste (MSW) and hundreds of small, H 2
privately owned plants preselect feasible com- O 10 11.5
mercial & industrial waste (C&IW), which have N 0.2
to be subsequently processed into tailor-made S 0.1 0.5
residue derived fuels (RDF, <80mm) for calciners Volatiles 46 48
and quality-monitored solid recovered fuel (SRF, Ash 2 20
<25mm) for main burners. CaO 1.6 2
Realizing in some cases ~100% thermal sub- SiO2 0.3 0.4
stitution rates (TSR), the German cement indus- Al2O3 0.5 0.6
try reached a high level of more than 60% of its Fe2O3 1 1.4
thermal demand of about 92 million GJ, which
correspond totally with approx. 2million tons of Trace elements ppm
alternative fuels. Solid, liquid or pasty from haz- As 0.2 2.5
ardous or non-hazardous sources, the feedstock for Be 0.04 0.4
alternative fuels is different like tyres, meat & bone Pb < 0.01 2.2
meal, waste oil or solvents, or production residues Cd 0.01 1.5
(textiles, paper, wrappings, cuts etc.) and biomass Cr 0.01 15
have to be pre-treated to meet the requirements Ni 1 9.3
regarding handling, dosage, feeding, combustion, Hg 0.11 0.9
process, air pollution and product performance. Tl 0.027 0.2
The article will focus on the main aspects of pre- V 1 13
Table 1 Parameter of
processing of waste and co-processing of AF in ce- Zn 3.9 22 German lignite
ment kilns, by identification, waste management,
pre-treating and utilization in the cement clinker After the first oil crisis in the early 1970s, in
process with sophisticated processing techniques. order to cut costs a switch was made first from gas
The process of clinker burning has to be as- and oil to hard coal and lignite, and, due to their
sessed with regard to its technical options and de- high energy content and relatively easy handling,
faults. The pre-processing and handling concept to waste oil and used tyres. Later, this was fol-
within the cement plant as well as the impact of AF lowed by solvents, oil sludge, wrappings, cuttings
on the manufacturing process will be emphasised. and others coming from identified industrial pro-
Of major importance in this context are pyropro- cesses.
cessing as well as combustion at its point of en- Single streams of lignite-like (Table1) solid
trance, impact on product and emission. alternative fuels of preselected, production-specif-
ic (so called cherry-picked) commercial wastes and
2 Initial positions biomass and that mentioned liquids were processed
Due to the continuing energy cost fluctuations and to fuel for the main burner, the kiln inlet or if
the discussions on the sustainable protection of re- installed the calciner. Additionally mineral based
sources, the German cement industry was able to residues like filter cake, foundry sand, mill scale or
achieve a continual reduction of its entire power contaminated soil are used for blending to Alter-
requirement by changing from the wet process to native Raw Materials (ARM) which replaces virgin
the dry process inclusive preheater tower. mineral compounds.

1 Simplified operational
sequence of drying,
pyrolysis and ignition
regarding the conver-
sion of fuels with sub-
sequent coke burnout
All by H. Baier (WLTP)

ZKG India Special 21

SPECIAL//India
2 Clinker as an inter-
mediate product of
cement production.
Right: under normal
conditions, left:
burnt under reductive
conditions, bottom:
reductively burnt with a
so-called brown core
Table 2 Average param-
eter of SRF (preselected
industrial waste com-
ponents)
1
The distinction between the
share of biogenic carbon and
fossil carbon is important for
the GHG approval.
22 ZKG India Special
or stand-alone municipal waste incinerators. In or-
der to implement such concepts, naturally also ce-
ment plants come into focus. Frequently, however,
this makes us forget that cement is a standardised
mass product of a highly energy-efficient produc-
tion process.
The general opinion is that alternative fuel
still implies cheap disposal to the extent that
even legislation talks about co-combustion. But
actually, these are highly complex physical-chem-
ical conversion processes, which have not yet been
entirely clarified even with regard to the combus-
tion of coal.
Simplifying combustion as a diffusion con-
trolled combustion process (Fig.1) it can be de-
scribed as drying, pyrolysis, ignition and coke
burnout in a decreasing oxygen atmosphere. With
an increasing TSR, this sequence dominates the
combustion and in consequent the entire cement-
Since it was proved that the use of individually clinker process.
processed wastes had no effect on the emission bal- Usually, commercial wastes and fractions of
ance of the plant or on the clinker burning process high calorific value are separately or jointly pre-
or the product quality, the wastes may now also be processed while removing water, metals, glass, ash
manufactured as blends and used for the energy or other harmful constituents from the fuel.
content as well as the ash content to create clinker, Therefore, solid alternative fuels with an aver-
shortly co-processing. age lump size of dmax. 300mm to be fed via kiln
In the meantime, the alternative fuel produc- inlet or a calciner to the rotary kiln are subject
tion and use have been established to the point that to a different sample preparation procedure and
especially countries, which are extremely depend- quality management than those fuels, which must
ent on external energy resources increasingly take be fed via main burner. For a better burnout, these
into account the integration of waste management compounds must be comminuted into pieces (dmax.
into a country-wide energy concept to avoid high 25 mm or finer) and sifted to avoid reductive
public investments into large sanitary landfillings burning conditions in the kilns sinter zone and
still coming to several powers of ten compared to
Parameter % coal dust. If the processing should be finer still,
CV 21 800 32 200 kJ/kg the processing increasingly reaches technical and
C1 n.d. economic limits.
H n.d. Normally, in the cement plant, ready to be
O n.d. burnt fuels are transported pneumatically to the
N n.d. respective firing point. Especially, if they are fed
S 0.1 0.8 via the main burner, the recent inhomogeneous
Volatiles n.d. alternative fuel mixtures are differentiated again
Ash 9 39 into individual particle fractions burning at dif-
CaO n.d. ferent levels: While thin, large-area particles (e.g.
SiO2 n.d.
Al2O3 n.d.
Fe2O3 n.d.
Cl 0.39 2.2
F 0.1 1.7
Trace elements ppm
As 0.68 15.32
Pb 27 4.406
Cd 0.75 162
Cr 19.10 187
Ni 5.41 1.622
Hg 0.09 1.62
Tl 0.23 1.96
3 Sifted SRF (<30mm) matching the requirements for
V 2.17 164 combustion in a sinter zone burner
www.zkg.de
 India//SPECIAL

Parameter % 30.0 0.45

CV 16 700 25 700 kJ/kg
0.4
C1 48.2 54.1 25.0
H 7.3 8.5 0.35

O 32.5 34.1 20.0 0.3

N 0.76 1.35

Mass wt.%

Dichte t/m3
0.25
S 0.1 1 15.0
0.2
Volatiles n.d.
Ash 13.6 46.7 10.0 0.15
CaO 26 32.1 0.1 density: 0.145 t/m3
SiO2 22.6 30.5 5.0
0.05 density: 0.085 t/m3
Al2O3 7.82 60
Fe2O3 4.26 6.75 0.0 0
<1.5 1.5 2 3 4 5 6 7 8 9
Cl 0.8 4.3 rate of descent m/s
F 0.02 0.09 mass distribution % SRF (30 mm, shreddered)

mass distribution % SBS sifted (30 mm, heavy body cleaned, 10 mm pellet)

Trace elements ppm
As 0.48 7.33
Pb 131 30.176
Cd 2.1 55
Cr 82.73 3.029
Ni 14.19 3.658
Hg 0.28 3.39
Tl 0.18 5.90
V 5.19 135
Table 3 Average parameter of SRF (out of municipal waste)
packaging film with a size of 2-500m thickness)
are consumed by the flame floating, three-dimen-
sional particles (e.g. hard plastic, rubber, wood,
etc.), form the tip of the flame or even fly through
its ending into the clinker bed or inlet and leading
to reductive clinker burning conditions, hot inlet
temperature and forming sulphuric cycles.
For these reasons fuel mixtures from
dmax.<25mm up to 80mm can be processed me-
chanically, while large and very large-sized alterna-
tive fuels up to 250mm can be processed thermally.
3 Optimised clinkering zone firing system
If alternative fuels are to be fed via the so-called
clinkering zone burner, they must be comminuted
to dmax. 25mm without heavy and 3-D bodies, to-
tally removed for an improved burnout. In order
to react appropriately to different fuel properties,
the burner must also be designed according to the
physical requirements.
An adopted clinkering zone burner is designed
to burn primary fuels as well as SRF with a ther-
mal output of 10 MW to 300 MW and has been
especially designed for the use of solid and liquid
alternative fuels (Fig.3). Thus, with a blend of liq-
uid and solid alternative fuels and an average SRF
grain size of dmax.<25mm it has already been pos-
sible to achieve thermal substitution rates of al-
most 100 %.
During operation, primary air nozzles are se-
lectively adjustable so that any random swirl and
divergence are possible and can be adjusted to the
density t/m3 of fraction SBS sifted (30 mm, heavy body cleaned, 10 mm pellet)
density t/m3 of fraction SRF (30 mm, shreddered)
flow path of the trajectories of the AF particles. An 4 SRF particles after
adapted particle size and intense mixing of fuel analytical wind sifting.
Fractions with equal
and combustion air ensures a quick and complete
ballistical properties
conversion and significantly shortens the combus- will finally take the
tion and conversion time in the reaction zone. This same trajectories burn-
behaviour is especially important for hard burning ing in abeyance or rain-
ing into the clinker bed
petrol coke or blends of low calorific fuels.
In order to be able to design the burner opti-
mally, the multi-component mixtures of the solid
alternative fuels must first be analysed in a clas-
sifier and chemically. In the process, the fuel par-
ticles separate into particle fractions (Fig.3, 4), in
which the same properties result from equivalent
solids of revolution, densities or grain shapes, i.e.
the particles move on identical trajectories and will
not rain incompletely burnt like falling stars
into the clinker bed.
Now, this method results in statements regard-
ing the flight behaviour or the quality of pre-pro-
cessing, the former composition of the waste sin-
gle components become clearly perceptible and
the suitability of the fuels particles for the advised
feeding point at the rotary kiln. At relevant indi-
vidual particle fractions, it is now also possible to
determine the oxygen requirement or the ignition
behaviour at the highest TSR.
4 Mechanical processing
for use in a clinkering zone burner
Regarding the insulating effect, geometry and
other surface effects, the diffusions in fuel parti-
cles and the combustion speed proceed at differ-
ent speeds. Mechanically, the diffusion path can be
shortened by decreasing the particle size, respec-
tively to enlarge the surface of the fuel particles.
For this reason a certain windsifting technology is
recommended in the pre-treating process of waste
as well, where the SRF will be optimized due to
the retention time in the individual body of flame
when leaving the mouth of the burner.

ZKG India Special 23

5 RDF (< 80 mm) for the calciner requires a long retention time

This process is perfectly applicable to particles, tion of the clinker cooler to the firing points inside
which are three-dimensional, hard or brittle and so the calciner. With regard to reaction, the calciner
far have led to reductive burning conditions in kiln requires only a temperature of 850-900C to cal-
material. They are separated quickly and effective- cinate the limestone fraction. Inside the calciner,
ly, whereby large, but thin two-dimensional flat the 1000-1200C hot flue gases of the rotary kiln
particles are mostly obtained, which do not affect and the 800-1000C hot tertiary air mix, whereby
the combustion with regard to the burnout behav- safe ignition and burning are also ensured by slow-
iour. While the amount of heavy, water containing reacting, large-sized alternative fuels.
and three-dimensional particles are reduced, the However, especially the burning of various and
chemical properties of the alternative fuel compo- slow-reacting fuels takes significantly longer time
nents remain unchanged. than the preheating and calcining of the raw meal
and is consequently the determining factor for the
5 Use of alternative fuels at the calciner calciners dimension. For this reason, various tech-
In modern plants with calciners only 40% of the nical solutions for calciners are available. These
thermal output is covered by the clinkering zone will allow a control of the combustion temperature
burner, while 60% of the thermal heat demand is and atmosphere so that it is also possible to reduce
covered by one or more firing points at the calciner. the NOx emissions.
In the process, the necessary combustion air is fed In order to ensure the burnout of slow-reacting
via the tertiary air duct from the recuperation sec- alternative or primary fuels it is not only necessary
to support the retension time inside the calciner
Table 4 Indication for Element Concentration with a suitable distance required for calcination
input criteria of AFR CaO in ash and burnout but if necessary, by using an addi-
for valorization in a dry
system with preheater
SiO2 in ash single or in total tional burning chamber.
and calciner Al2O3 in ash > 50 wt.-% For coarse fuels with a very long retention
Fe2O3 in ash time (Fig. 5), such as biomass, petroleum coke or
Mercury (Hg) < 2 ppm dry substance anthracite, the precombustion chamber is used,
Cadmium (Cd) < 50 ppm dry substance where in the centre of a vortex flow and with an
Thallium (Tl) < 45 ppm dry substance initial supply of pure tertiary air high tempera-
other trace elements < 20 000 ppm dry substance tures develop starting drying, pyroprocessing, ig-

24 ZKG India Special www.zkg.de

 India // SPECIAL

nition and burnout. For the use of low

calorific, large-sized alternative fuels the
retention time in the short hot zone is
insufficient. Therefore, a precombustion
chamber has been especially developed
for the high feed rate of low calorific,
large-sized alternative fuels.
The typical retention time of 4-8 sec-
onds in a calciner is sometimes grossly
insufficient for the safe burnout of such
slow-reacting alternative fuels like high
calorific fraction (HCF) with a diameter
approx. <300mm. Therefore, FLSmidth
developed its Hot Disk as a turning ta-
ble integrated with the preheater and cal-
ciner systems. It has proven its feasibility
for coarse alternative mono fraction fuels
made as for truck tires or biomass in sizes
up to approx. one metre in diameter.
ThyssenKrupp Industrial Solution de-
veloped its Step Combustor also added
on to the calciner but capable of burning
different alternative fuel qualities be-
cause the transport and discharge rates
are separately controlled by air blast
nozzles and no mechanical internal fit-
tings are necessary inside to push over
the edge into calciner.

REFERENCES

[1] Baier, H. (2006): Ersatzbrennstoffe fr den Einsatz in Mitverbrennungsanlagen

(Alternative fuels to be used in co-combustion), in Zement-Kalk-Gips International,
Bauverlag BV Springer BauMedien Gtersloh, No.3-2006, Volume 59, pp. 7885
[2] Baier, H. (2009): Erzeugung von Ersatzbrennstoffen fr die deutsche Zementindustrie
Rahmenbedingungen, Herkunft, Aufwand und Realisierung- (Production of second-
ary fuels for the German cement industry Basic conditions, origin, expense and
implementation), Berliner Energiekonferenz Erneuerbare Energien (Energy Conference
Renewable Energies in Berlin) 10./11. November 2009 in Berlin, TK Publishing House
Neuruppin 2009, pp. 7588

Kiln Shell
[3] Baier, H. (2010): Disruptive substances and the burning behavior of solid alternative
fuels, in Zement-Kalk-Gips International, Bauverlag BV Springer BauMedien Gters-
loh, No. 6-2010, Volume 63, pp. 5867
[4] FLSmidth One Source product prospectuous: HOTDISCTM combustion device
[5] Mass, U., Frie, Sebastian (2013): Proceedings -Special Lectures and Extended Ab-
stracts, 13th NCB International Seminar on Cement Building Materials 1922 Novem-
ber 2013, New Delhi, India, p. 175ff, published by National Council for Cement and
Thermal
Monitoring
Building Materials 34km Stone, Delhi-Mathura Road (NH-2), Ballabgarh 121004,
Haryana/India
[6] Menzel, K., Maas, U., Lampe, K. (2009) Technologies for Alternative Fuel Enhance-
ment in Clinker Production Lines, 2009 IEEE Cement Industry Technical Conference
Record
[7] N.N. (2005): Leitfaden zur energetischen Verwertung von Abfllen in Zement-, Kalk-
und Kraftwerken in Nordrhein-Westfalen (Guideline for thermal valorization of waste
in cement and lime works, power plants in Northrhine-Westphalia), 2. Circulation,
Ministry of Environment and Conservation of Nature, Agriculture and Consumer
Protection of Northrhine-Westphalia
[8] Reznichenko, A. (2009): Welcome to a new dimension, Burner Technology, Interna-
tional Cement Review, Tradeship Publications Ltd. Dorking, June 2009, pp. 9698

www.hgh.fr
ZKG India Special 25 hgh@hgh.fr
 SINTEF
Hazardous chemicals and persistent organic pollutants constitute a threat to health
and environment, both locally and globally. Many developing countries have no destruction
options available and export is usually too costly. Cement kilns can be found in virtually
every country and might constitute a sound treatment option if found feasible.

TEXT Dr. Kre Helge Karstensen, Chief Scientist, Foundation for Scientific and Industrial Research SINTEF, Oslo/Norway

Inspection tour along SINTEF

the kiln during the test
run

Destruction of hazardous chemicals

andPOPs in cement kilns
1 Introduction
Several international conventions aim to protect
human health and the environment by requir-
ing parties to take measures to reduce or elimi-
nate releases of hazardous chemicals like obso-
lete pesticides and persistent organic pollutants
(POPs) from intentional production and use, from
stockpiles and wastes and from unintentional re-
lease. The Aarhus Protocol covers 16 POPs and
the Stockholm Convention on POPs covers for
the time being 21compounds or groups of com-
pounds.
There is currently no reliable information
available regarding what quantities these POPs
constitute on a global level but these conventions
acknowledge that there is an urgent need for en-
vironmentally sound disposal and that developing
countries and countries with economies in transi-
tion need to strengthen their national capabilities
on sound management of hazardous chemicals.
The intention of the Basel Convention, ratified in
1989, is to control shipment of hazardous wastes
across borders, to avoid dumping in developing
countries and to stimulate local treatment.
Environmentally sound disposal of hazardous
chemicals and POPs is however costly and compli-
cated, and export may not be affordable to many
developing countries. In contrast to incinerators
and other treatment techniques, cement kilns al-
ready exist in virtually every country and resorting
to them may be feasible and cost-efficient for the
treatment of POPs wastes and other types of haz-
ardous wastes.
2 Cement kilns
Co-processing of alternative fuels and resources
in the cement industry should primarily be about
energy recovery and material recycling. In special
cases however, where hazardous chemicals are
posing an imminent threat to health and environ-

26 ZKG India Special www.zkg.de


ment and where no other disposal option exist, the
feasibility of using a local cement kiln for destruc-
tion could be investigated.
A BAT/BEP cement kiln has many inherent fea-
tures which makes it ideal for organic hazardous
waste treatment: high temperatures, long residence
time, surplus oxygen during and after combustion,
good turbulence and mixing conditions, thermal
buffer capacity, dry scrubbing of the exit gas by
alkaline raw material (neutralises acid gases like
hydrogen chloride), fixation of traces of heavy met-
als in the clinker structure, no production of by-
products such as slag, ashes or liquid residues and
complete recovery of energy and raw material com-
ponents in the waste (Karstensen, 1998 and 2006).
Comprehensive test burns with hazardous
chemicals and POPs have been conducted in sev-
eral developing countries (Fig. 1), demonstrating
in most cases that local cement kilns can destroy
hazardous chemicals including POPs, in a safe and
environmentally sound manner, and irreversibly
without generating new POPs (Karstensen, 2006
and 2008).
A stable cement kiln will comply with the US
TSCA PCB incineration criteria which require a
temperature of 1200 C and 2 seconds retention
time at 3 % oxygen or the EU Directive 2000/76/
EU, requiring a temperature of 850 C for at least
2seconds for the incineration of non-chlorinated
hazardous waste and 1100 C and 2seconds reten-
tion time for organic substances containing more
than 1 % halogen at 2 % oxygen. Another impor-
tant criterion for environmentally sound destruc-
tion and irreversible transformation is to achieve a
sufficient destruction efficiency (DE) or destruction
and removal efficiency (DRE). The DRE consider
emissions to air only while the more comprehen-
sive DE is also taking into account all other out-
streams, i.e. products and liquid and solid residues.
A DRE value greater than 99.9999% is required for
disposal of POPs in the US (see Karstensen et al.,
2010 for further references).
2.1 General requirements and prerequisites
The following minimum requirements and pre-
requisites should be in place to prevent and reduce
the risks to the greatest extent possible prior to
commencing with destruction of hazardous wastes
in cement kilns on a routine basis (Karstensen,
2009a and 2009b):
An approved environmental impact assessment
EIA and all necessary national/local licences;
Compliance with all relevant national and local
regulations;
BAT/BEP performance and compliance with the
Basel, the Stockholm Convention and the Mon-
treal Protocol;
Approved location, technical infrastructure and
processing equipment;
India//SPECIAL
Reliable and adequate power and water supply;
Adequate air pollution control devices and
continuous emission monitoring ensuring
compliance with regulations and permits;
needs to be verified through regular baseline
monitoring;
Exit gas conditioning/cooling and low tem-
peratures in the air pollution control device to
prevent dioxin formation;
Clear management and organisational struc-
ture with unambiguous responsibilities, report-
ing lines and feedback mechanism;
An error reporting system for employees;
Qualified and skilled employees to manage
hazardous wastes and health, safety and envi-
ronmental issues;
Adequate emergency and safety equipment and
procedures, and regular training;
Authorised and licensed collection, transport
and handling of hazardous wastes;
Safe and sound receiving, storage, preparation
and feeding of hazardous wastes;
Adequate laboratory facilities and equipment
for hazardous waste acceptance and feeding
control;
Demonstration of hazardous waste destruction
performance through performance verification
and test burns;
Adequate record keeping of hazardous wastes
and emissions;
Adequate product quality control routines;
An environmental management and continu-
ous improvement system certified according to
ISO 14001, EMAS or similar;
Regular independent audits, emission monitor-
ing and reporting;
Regular stakeholder dialogues with local com-
munity and authorities, and for responding to
1 Comprehensive test
comments and complaints; burns with hazardous
Open disclosure of performance reports on a chemicals and POPs
regular basis. have been conducted
SINTEF
ZKG India Special 27
SPECIAL//India
2 Management of
obsolete pesticides
and other hazardous
chemicals
3 Obsolete pesticides
The accumulation and inadequate management
of obsolete pesticides and other hazardous chemi-
cals constitute a threat to health and environment,
locally, regionally and globally (see Karstensen et
al., 2006 for further references). Estimates indicate
that more than 500 000 tons of obsolete pesticides
are accumulated globally, especially in developing
countries (Fig.2).
3.1 Toxic insecticides in Vietnam
A test burn with two obsolete and toxic insecti-
cides was conducted in a cement kiln in Vietnam
in 2003 (Karstensen et al., 2006). The solvent-
based insecticide mix had two active ingredients,
18.8 % Fenobucarb and 2.4 % Fipronil. It had ex-
pired and was deemed unusable; approximately
40 000 litres was stored in 200 steel drums wait-
ing for a suitable treatment option to become
available. The active ingredients of the insecti-
cide were solved in cyclohexanone and aromatic
solvents.
The two toxic insecticides were fed through
the main burner and the destruction efficiency
was measured to be better than 99.9999969 %
for Fenobucarb and better than 99.9999832 %
for Fipronil and demonstrated that the hazard-
ous chemicals had been destroyed in an irrevers-
ible and environmentally sound manner. All the
test results, except for the NOx, were in compliance
with the most stringent regulations. This was the
first time PCDD/PCDFs, PCBs and HCB were meas-
ured in an industrial facility in Vietnam and all
the results were below the detection limits. This
proved that the destruction had been complete and
irreversible and not causing any new formation of
PCDD/PCDFs, HCB or PCBs.
28 ZKG India Special
SINTEF
4 PCBs
Commercial production of PCB started in the US,
Germany and France in the 1930s and ceased
when the production in Russia ended in 1993 (see
Karstensen et al., 2010 for references). The total
volumes produced are uncertain; estimates vary
from 60 000 tons to about two million tonnes. PCB
production was banned and phased out in the US
and European countries during the 1970s and it
can be anticipated that most developed countries
now have disposed of their stocks, primarily by us-
ing thermal techniques.
4.1 PCB destruction in Sri Lanka
PCB-oil had been stored in a warehouse in Colom-
bo for more than 20 years, waiting for a disposal
solution to emerge (Karstensen et al., 2006). High
concentration PCB-oil was kept in 60 l stainless
steel drums; as well as diesel washings from the
transformers cleaning, in 200l steel drums. The
PCB-oil was confirmed to be pyralene with an av-
erage concentration of 59 % of PCB, 36 % trichlo-
robenzene and 5 % tetrachlorobenzene.
The mix of PCB-oil and diesel-washings from
Colombo was further blended to a total of 10 000l
with diesel oil in a steel feeding tank at the cement
plant; the final PCB-diesel oil mix was homog-
enised and fed directly to the main burner flame
of the cement kiln during two consecutive days of
testing with various feeding rates and PCB-con-
centration.
The test burn started with emission measure-
ments when no PCB was fed to the kiln, followed
by Test day 1 with a feed rate of 500l/h of PCB-
diesel oil mix with 14.000mg PCB/l and Test day
2 with a feed rate of 1000 l/h of PCB-diesel oil
mix with 10.050mg PCB/l. The feeding system was
calibrated and tested before start up.
www.zkg.de

The three-day test burn demonstrated that it
was able to destroy PCBs in an irreversible and en-
vironmentally sound manner without causing any
new formation of PCDD/PCDF or HCB (Karstensen
et al., 2010). The destruction and removal efficien-
cy was better than 99.9999 % at the highest PCB
feeding rate.
4.2 PCB destruction in El Salvador
A test burn with TCE and PCBs was carried out in
El Salvador in 2007 and 2009; the DRE was meas-
ured to be better than six nines in both cases, i.e.
>99.9999 %. We could not detect any influence on
the emissions of PCDD/PCDFs; the average concen-
tration measured during in total seven days was
0.0398ng I-TEQ/m3.
4.3 PCB destruction in Vietnam
High strength PCB was transported to the Hon
Chong cement plant in South Vietnam in steel
drums and diluted in two 16 000l feeding tanks,
making two batches for two days testing (Fig.3).
The entire test campaign was carried out over three
days; the first day a baseline test was performed,
i.e. with stack gas sampling under normal condi-
tions with coal firing only and with the exit gas
through the raw mill in compound mode the next
two days, a mix of PCB and used oil was fed to the
main burner of the kiln; only the first test burn day
however was complete.
The destruction and removal efficiency
DRE were measured to be 99.9999 % for PCBs,
99.99999 % for dioxin-like PCBs and 99.999999 %
for Chlorobenzenes during test burn. A destruction
and removal efficiency of 100 % will never be pos-
sible to demonstrate due to detection limits in the
analytical instruments.
The test burn demonstrated that the PCB had
been destroyed in an irreversible and environmen-
tally sound manner, i.e. without new formation of
dioxins, furans or hexachlorobenzene. The result
revealed very low emissions of both I-TEQ PCDD/
PCDFs and I-TEQ PCBs and all other parameters
were in compliance with QCVN 41: 2011/BTNMT.
5 Contaminated soil
Soil and contaminated soil contains major fractions
of silica, alumina, calcium and iron oxides, all of
which are important in cement production. Cement
manufacture requires high temperatures, typi-
cally 1450 C with a residence time of 2030min
at peak temperature. It is expected that organic
contaminants will be degraded, and inorganic con-
taminants (like heavy metals) will be stabilized and
locked into the cement phases.
Soils with low concentrations of POPs con-
stitute a particular challenge as environmentally
sound destruction usually is deferred due to high
costs for excavation and subsequent decontamina-
India//SPECIAL
tion. Contaminated soil is challenging as it must
be fed to the low temperature part of the kiln
and soil-minerals must be compatible with the raw
materials.
Compared with other treatment options, a ce-
ment kiln has a huge capacity and a likely practical
replacement of 1-2 % of the total feedstock mate-
rial, considering the factors of chloride and SiO2
burning, but will also be a function of the bulk soil
chemistry and the major elemental content.
The main concerns with the feeding of POPs
contaminated soil to the kiln inlet (with the excep-
tion of handling) are the risk for strip off, or vola-
tilisation of the POPs into the preheater, and insuf-
ficient destruction.The temperature is lower at the
kiln inlet part of the process and there is a risk that
POPs are volatilised and acting as precursors in the
formation of PCDD/PCDFs in the preheater.
5.1 Dieldrin contaminated soil in Venezuela
Soil from an old pesticide formulation plant, con-
taminated with POPs, constituted a local problem
in Venezuela and it was decided to test the feasibil-
ity of using a local cement plant for safe destruc-
tion (Karstensen, 2009). Approximately 6000 m3
of contaminated soil was excavated around the
formulation plant and put into 1m3 big bags and
stored in a warehouse. 60 tons were homogenised
and transported to the San Sebastian cement plant
by truck. Samples were taken from each of the
batches and analysed (Fig.4).
A complete test burn was carried out over a
period of four days, split into two baseline meas-
urements and three contaminated soil feeding pe-
riods with a fed rate of two tons/hour lasting for a
least eight hours each. Contaminated soil with up
to 522ppm Dieldrin fed to the kiln inlet showed a 3 The entire test cam-
DRE of 99.9994 % for Dieldrin at the highest feed- paign was carried out
ing rate. over three days
SINTEF
ZKG India Special 29
SPECIAL//India
SINTEF
4 Samples were 5.2 DDT and contaminated soil in China
taken from each of the Test burns with DDT-powder and DDT contami-
batches and analysed
nated soil fed into the flue gas chamber at the
cement kiln inlet in two preheater/precalciner ce-
ment kiln systems showed that the DDT had not
been destroyed completely satisfactorily (Dahai et
al., 2014). The obsolete DDT-powder destroyed in
this study came from the Hunan Province of China
and the concentration of DDT was measured to be
10.63 %. The DDT concentration of the contami-
nated soil varied within 1352-3394mg/kg.
The DE and DRE was 99.99997 % and 99.99999 %
respectively when feeding DDT-powder to kiln A,
while the DE and DRE was in range of 99.9889-
99.9991 % and 99.9983-99.9997 % respectively
when feeding DDT-contaminated soil to kiln B.
Traces of DDT were detected under baseline
conditions in both kiln systems and needs to be
investigated further (Dahai et al., 2014). Not de-
stroyed DDT may be adsorbed on dust particles at
5 In India co-processing
the post-preheater zone, trapped in the air pollu-
of hazardous wastes has tion control equipment and recycled back through
been tested successfully the raw meal silo and to the top of the preheater,
SINTEF
30 ZKG India Special
creating an adsorption and desorption circulation
which will bleed and emit traces of DDT even when
not feeding the waste.
This study indicated that feeding of DDT and
DDT-contaminated soil to the lower temperature
part of a cement kiln system might lead to trace
emissions; best international practice is to feed
POPs to the high temperature part of the kiln, the
main burner, i.e. the technical feasibility and en-
vironmental acceptability of this Chinese practice
needs to be reassessed.
6 Chlorofluorcarbons
Chlorofluorocarbons (CFCs) and halons (brominat-
ed fluorocarbons/CFCs) are potent ozone depleting
substances (ODSs) and synthetic greenhouse gases
(GHGs) (see Karstensen et al., 2014 for further ref-
erences). All ozone depleting substances contain
either chlorine or bromine; substances containing
only fluorine do not harm the ozone layer but may
still be a GHG.
The wide use of these chemicals has caused se-
vere damage to the ozone layer and contributed
significantly to the global warming. The global
warming potential (GWP) refers to the amount of
global warming caused by a substance and is the
ratio of the warming caused by a substance to the
warming caused by a similar mass of carbon diox-
ide; thus, the GWP of CO2 is defined to be 1.
Many emerging countries, such as India, still
possess stocks of concentrated CFCs which need to
be destroyed in an environmentally sound manner
but costs are prohibitive. The UNEP Technology and
Economic Assessment Panel (TEAP) task force on
destruction technologies applied screening criteria
to 45 identified technologies, where eleven met the
qualification criteria for destruction of concentrat-
ed sources, i.e. CFCs and HCFCs (UNEP, 2002).
Despite the fact that cement kilns were among
the methods recommended by UNEP TEAP in 2002,
no study to assess their feasibility and destruction
performance under real developing country condi-
tions has been reported in the scientific literature
up to now (Karstensen et al., 2014).
6.1 Destruction of chlorofluorocarbons in India
India has the second largest cement industry in
the world, with 181 kilns, and has recently been
exploring the possibility to increase waste treat-
ment capacity through co-processing of wastes in
the cement industry and several hazardous waste
categories have been tested successfully (Fig.5).
The GWP of CFCs destroyed in this study was:
CFC-11 is 4750, CFC-12 10 890 and CFC-113 6130
over a time horizon of 100 years. The test demon-
strated that the local Indian cement kiln using high
feeding rates was able to destroy several concentrat-
ed CFC-gases effectively in an irreversible and en-
vironmentally sound manner, without causing any
www.zkg.de
 India//SPECIAL

increased release of HCl, HF or PCDD/PCDF. The DRE
was demonstrated to be >99.9999 % for all CFC-
gases, better than recommended by UNEP TEAP.
The demonstration indicated that cement kilns
have a much higher disposal capacity than previ-
ously anticipated and that such an undertaking
can contribute significantly to reduce the release of
greenhouse gases; destruction of 16.3ton of CFCs
in the Indian cement kiln is equivalent to saving
the release of 131 265ton of CO2 to the atmosphere.
7 Conclusions
A feasible cement kiln may together with envi-
ronmentally sound management and operational
procedures, adequate safety arrangements and in-
put control secure the same level of environmental
protection in developing countries as in developed
countries. As illustrated in several studies, instead
of representing a threat to the environment and
health, hazardous chemicals can in most instances
be safely destroyed in a local cement kiln. The cost
savings of using a local kiln are considerable com-
pared to other treatment options including ex-
port- and will contribute to the increase of disposal
capacity in developing countries.
Results from some limited studies indicate how-
ever that feeding of hazardous chemicals and POPs
should be restricted to the high temperature zone
of the main burner, and that feeding to other lower
temperature zones, e.g. kiln inlet or pre-calciner,
should be done only with low concentrated mate-
rial and after being proved safe and sound with
satisfactory destruction.
Treatment and destruction of hazardous chemi-
cals and POPs is controversial among some stake-
holders and one accident may under worst case
conditions undermine the acceptance in the entire
industry, i.e. all parties involved have the respon-
sibility to minimize risks and strive towards excel-
lence and best international practice.

REFERENCES

[1] Basel Convention (2007): Updated general technical guidelines for the environmentally sound management of wastes consisting of,
containing or contaminated with POPs
http://www.basel.int/meetings/sbc/workdoc/techdocs.html
[2] Basel Convention (2011): Technical guidelines on the environmentally sound co-processing of hazardous wastes in cement kilns.
http://www.basel.int/Portals/4/ download.aspx?d=UNEP-CHW-GUID-PUB-CementKilns. English.pdf
[3] Dahai Yan, Zheng Peng, Kre Helge Karstensen, Qiong Ding, Kaixiang Wang and Zuguang Wang (2014): Destruction of DDT wastes in
two preheater/precalciner cement kilns in China. Science of the Total Environment, 476-477 (2014) 250-257. ISSN No. 0048-9697
[4] Karstensen, K. H. (1998): Benefits of incinerating hazardous wastes in cement kilns. FAO Pesticide Disposal Series 6, Prevention and dis-
posal of obsolete and unwanted pesticide stocks in Africa and the Near East. 3rd Consultation Meeting. Food and Agriculture Organiza-
tion of the United Nations, Rome, 1998
[5] Karstensen, K. H. (2006): Formation and Release of POPs in the Global Cement Industry Second Edition. Report to the World Business
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