INNOVATIVE INITIATIVES FOR SUSTAINABLE DEVELOPMENT IN THE CEMENT INDUSTRY

M.K.Singhi* Avinash Mathur**

Shree Cement, India

ABSTRACT For sustainable development triple bottom line of economic prosperity, environment quality and social equity are to be addressed. These can be achieved by improving business results focusing on People , Process and Technology. Paper recommends many innovative ideas, based on their own experience and results of various applied research and development projects carried out by cement and non-cement industries worldwide. INTRODUCTION For meeting business goals, People, Process and Technology be reviewed and revalidated in today's and future context. It is to be seen that whether the present job holders are competent to meet the requirement ? Whether the process and the technology is meeting the requirement of continual improvement in productivity, decrease in energy consumption and reduction in GHG emissions ? Professional vision and creative thinking be blended to chalk out strategic plan for the development, motivation and satisfaction of people, adoption of new processes and application of the emerging technologies. Change Management should become way of life. Shree Cement Ltd was incorporated in 1979. It is a ISO-14001 company and is the largest cement plant in northern India at single location, Beawar, with a production capacity of over 2.6 million tonnes per annum across two plants. It prides itself as India's lowest cost cement manufacturer. In the Cement Factory Performance Review-2002 conducted by Whitehopleman UK for 235 kilns and 167 factories, Shree Cement was accredited with four star status. No cement company has achieved five star status. Heat consumption which was 795 in 1996-97 is at 690 kcal/kg clinker in 2002-03. Similarly power consumption which was 90 in 1996-97 is at 76 kwh/ton cement in 2002-03. Initiatives which were taken over these years (2003>1996) for sustainablity are as follows: 1. Installed first pet coke based 36 MW captive power plant at a cost of Rs 970 million (US$ 21 million) within 16 months. Generation cost Rs 1.79 / kwh (US$ 0.04) against state grid cost of Rs 4.20/kwh (US$ 0.09). Pay back < 2 years. 2. Zero Waste in power plant as fly ash is used in cement plant. 3. Use of Rock Breaker to avoid drilling, blasting and noise pollution in mining. 4. Installed high efficiency process fans in place of low efficiency fans. 5. Installation of PyroTop in KHD kiln for productivity enhancement. 6. Installed automatic process control system. 7. Balancing of equipment and optimization of plant operation. 8. Installed Variable Voltage Variable Frequency (VVVF) drive for process fans. 9. Installation of Sewage Treatment Plant.

10. Installed Ramco's expert system for kilns. 11. Installed VVVF drive in compressor room to save 10% power. Pay < 3 years. 12. Conversion of high pressure pre heater cyclones into low pressure. 13. Use of single Roll Press as pre grinder for two cement ball mills. Saving of over 2 kwh / tonne cement. It is the first such RP application in the world. 14. Close circuiting of cement ball mills. 15. Installation of Electro-static Air Filter in DG Sets in place of Dry Filter, saving 2 - 4% fuel oil. This innovative application is the first in the World. 16. Used cooler hot air to 3 MW power plant reducing fuel & 9000 metric tonne CO 2 . 17. Installed multi-channel burner in place of Uni- flow burner. 17. Installed Refractory Bricks Management System. 18. Up gradation of drives for increasing kiln speed from 3.6 RPM. to 4.75 RPM. 19. Installed high dynamic separator in place of low separator in coal mill. 20. Achieved unity power factor to avoid Transmission & Distribution losses. 21. Use of 100 % pet coke as a fuel in the kiln. 22. Enlarged Tertiary Air Duct size to reduce air velocity. 23. Installed KIDS in clinker cooler-I. 24. Installed Calcium Silicate Insulation in calciners , ducts and cyclones etc. 25. Reduction of false air leakages . 26. Installation of efficient inlet & outlet kiln seals. Besides above , there are more initiatives with respect to People, Process and Technology which are as follows for sustainable development in the cement industry.

1. PEOPLE
Identify and enhance manpower competencies to increase performance and bridge gaps between existing and desired competencies to achieve winning performance from the employees. High investment be earmarked for employees development. They be developed in the area of their choice which meets the business goal. It will enable them to become most productive , innovative , effective and successful. Idea is to build a meritocratic organization producing cost leaders. Also , they be motivated to further the mutual trust and sense of ownership. Employees be involved at all levels . Implement SA8000 , a social accountability system, for assuring humane workplace throughout the supply chain.

2. PROCESS
2.1 BY PASS EXISTING SUSPENSION PRE HEATER CYCLONES AND INSTALL WASTE HEAT POWER RECOVERY SYSTEM Electrical energy is many times costlier than thermal energy. A cement plant in China is generating 196 kwh per tonne clinker from 550 TPD long dry kiln . After the calciner , a power recovery potential from 65 to130 kwh / ton clinker is possible in million tonne plant i.e 9-18 MW. Investment Rs 46-55 millions / MW ( US$ 1000-1200 / KW). Construction 16-18 months. Generation cost Rs 1-1.50 / kwh. Return Rs 3-4 / kwh. Pay back less than 3 years. World cement industry contributes 3 % of total global CO2 emissions. Waste heat power recovery system assures 10-15 % CO2 reduction. Considering world's cement production 1700 million tonnes, there is a potential of 150-225 million tonnes CO 2 reduction. It will boost the economic prosperity besides improvement in the environment. Hence, WHPRS is ideal for sustainable development in the cement industry. Considering that 10 cement majors who accounts for over 1/3 rd world's cement production adopt waste heat power recovery system , then 50 - 75 million tonnes of CO2 can be reduced. Also, they would be recovering over 5000 MW. This will avoid generation of fly ash & use of 8oo hectares land for ash ponds typically required for each million tonnes fly ash.

Waste Heat Power Recovery System 2.2 REVIVE WET & SICK PLANTS WITH POWER RECOVERYSYSTEM As power recovery in these cases would be more than 65 kwh / ton clinker. These be dedicated to manufacture innovative cements like Ultra- fine Cements, Quick Setting Cements, High Alumina Cements with an almost ten times higher resistance to acid corrosion, and enviro- friendly Spray Cements for rapid hardening sprayed concrete e.g. for tunnel constructions. 2.3. USE MODELLING TO OPTIMISE COMBUSTION IN THE KILNS. A cement plant in Australia was able to save 10 % fuel consumption. Pay back < a year.

2.4. FEED KILN FROM BOTH SIDES Tried successfully in Russia, saving 8% fuel in dry and 20% in wet process cement kiln. 2.5. OXYGEN ENRICHED COMBUSTION (OEC) Undershot Oxygen Enrichment to the kiln flame results into 10- 20 % increase in production. In California many plants are using OEC for increasing production. CEMEX USA consider OEC in calciner as their technology . 2.6. INSTALLTUMBLER LINING IN KILNS To eliminate Calcining Zone Rings which results into unexpected kilns shutdowns causing losses of millions of dollars each year. It also reduces fuel consumption & improves clinker quality . 2.7 PRODUCE MINERALISED CLINKER For CO2 reduction and increase in production .High % of fly ash and slag can be added in Blended Cement . A cement plant in China has used gypsum & Ca F2 for mineralized clinker & got remarkably increase in 28 days strength 60 MPa . Clinker output increased & Coal consumption reduced by 5-15 %.. 2.8 ACTIVATE FLY ASH BEFORE USE Under hydro thermal treatment at 100C by CaOH2. In this, Calcium Silicate Hydrate is formed which increases the surface area by more than 25 times. Fly ash addition can be further maximized in Blended Cement . It will boost the economic prosperity with huge CO 2 reduction. 2.9 FOCUS ON PSD ANALYSIS Whether it is raw meal , coal meal or cement , what matters as per chemistry of clinker and cement is Particle Size Distribution. Besides quality control it conserves energy in mills. As per Dr Alan Rawle, Malvern Instruments, UK pay back on On-Line Control , have been achieved in just 18 to 20 days. 2.10 ADOPT XRD FOR ON_LINE CONTROL On-line XRD can analyse clinker phases for strength prediction, gypsum hydration states (di-hydrate, hemi-hydrate and anhydrite) to predict setting times, be used for cement mill weighfeeder control, identify cement pre- hydration (portlandite), measure free lime in clinker, for kiln control, can identify phase analysis in clinker for kiln control etc. This instrument is an exciting development for cement plant operators , who have seen the potential of XRD but not yet been able to reap the potential benefits. A cement plant in Australia has already installed it. 2.11 ADOPT NEW FLYASH CONCRETE Manufacture Ecocrete which is earthquake resistant construction material using fly ash. Ecocrete cellular lightweight concrete ( CLC) blocks are pre fabricated reinforced building elements. Ecocrete ensures cost effective , comfortable and safe housing for rural and urban population. DLF India, has constructed 15 high rise towers. Double storey demonstration house for slum rehabilitation can be inspected at Narela. Capital cost for 500m3 CLC batching plant: Rs 10 millions. ( US$ 220,000). Raw materials shall be cement , sand, fly ash and stable foam. 2.12 MAKE AGGREGATES FROM FLY ASH To eliminate alkali- silica- reaction (ASR) in concrete, synthetic light weight aggregates (LWA) be manufactured from fly ash. One cubic meter concrete will utilize about 1.3 ton of fly ash aggregate as against 100 kgs of fly ash used either as an

admixture or pozzolona. Since production of 1 tonne of fly ash aggregate will require more than 1 tonne of fly ash , this will result in Bulk Disposal of fly ash and will help in reducing the pressure on agriculture land being used for bricks making. Also , heavy air pollution would be reduced through bricks chimneys. Typically aggregates requirement is 5 to 10 times of cement. Global potential requirement of aggregates would be 8500 17000 million tonnes. Light Weight Aggregates business industry potential US$ 60-120 billion dollars. 2.13 S AVE POWER IN CEMENT BALL MILLS By installing Electronic Device which eliminates the electrostatic charges from the process and transfer them to earth. Successfully tested in Egypt, Greece, & Oman. Potential power savings 12 to 25 % . 2.14 INSTALL VVVF DRIVES IN BALL MILLS TO SAVE ENERGY & COST Ball mill's speed can safely be reduced to 65% of critical speed. Pay back < 3 year. 2.15 REDUCE FEED SIZE TO MILLS Since crushing is cheaper than grinding, feed size be reduced to 0-5 mm for limestone, coal and clinker irrespective whether it is Ball Mill , Vertical Roller Mill or Roll Press etc. 2.16 ACHIEVE UNITY POWER FACTOR Unity Power factor saves transmission & distribution losses , results in CO2. reduction and brings economic prosperity. 2.17 EXPLORE NEW CO2 TECHNOLOGY South Korea has commercialized to recover and reuse high purity CO2 which can be used as raw material gas for producing fertilizers, dry ice, carbonates and caprolactum. 2.18 MANUFACTURE COLOURED CLINKER Presently for meeting the requirement of coloured cements, white cement is used. White cement clinker is difficult to burn as there is no iron as flux. It's heat consumption is also very high with respect to Portland grey clinker. It would be easier to manufacture coloured clinker in old low TPD plants.It would enhance the economic prosperity as it would be cost effective than Coloured Cement being made out of the white cement & costly pigments addition. 2.19 USE SHOTCRETING FOR REFRACTORYLINING IN KILNS. It is to be used for speedy installation of refractory linings in kilns, pre-heater cyclones, calciners and clinker coolers . Shotcreting lining rate is 8-12 tonnes per hour which is three times that of conventional lining rate 2-4 tonnes / hour. Switching to shotcreting will bring economic prosperity because of high uptime of the kilns.

3.0 TECHNOLOGY
3.1 MINING Consider SURFACE MINERS. They cut , crush and load hard rock in one single pass without drilling and blasting thus considerably increasing the utilization factor of the deposits. Limestone having compressive strength up to 1000 kg/ cm2 can be mined .Mining below water table possible without blasting. 45 tonne pay loader can be loaded in 4 minutes. These are successfully working in many cement quarries including 2 in India. Power consumption less than 1 kwh / tonne material. In case of Cement cum Power Plant, electrically operated mining vehicles can be considered in place of HSD driven vehicles.

3.2 CRUSHING Consider LOW SPEED ROLL SIZER followed by Tertiary and Quaternary crushing with Vibrating Screens for producing crushed limestone of 0- 5 mm, eliminating Stacker and Re claimer. It will drastically reduce the electric power consumption in the grinding mill. Power consumption less than 1 kwh / tonne material. 3.3 RAW MATERIALGRINDING Consider Roll Press with Fluidised Bed Classifier. Power consumption less than 8 kwh / tonne material. 3.4 PRECALCINING Consider CIRCULATING FLUIDISED BED CALCINER used in a cement plant in China 3.5 PYROPROCESSING Stationary kiln is the future cement kiln because clinker chemistry wise Rapid Burning & Rapid Cooling can be achieved. Kawasaki is the pioneer in developing such kiln FAKS Fluidised Bed Advance Kiln System in 200-3000 TPD range. In Japan, it is in use for commercial production. Heat consumption 676 - 694 kcal/kg clinker which is 10-25% less than rotary kilns. Raw meal residue 25%, coal residue 20% on 90 sieve. Refractory consumption 0.2 kg / tonne clinker. Low environmental impact with 10-25% reduction in CO2 emission, 40% or more reduction in NOx Economical advantages with 10-30% of construction cost saving, around 70% reduction in installation space, lower maintenance & running cost. Power consumption less than 25 kwh / tonne clinker. 3.6 PURE OXGEN COMBUSTION ( POC) World Cement Industry has yet to use & derive benefits out of POC . Breakthrough results can be obtained for sustainable development. In an aluminum smelting rotary kiln, POC resulted into 50 % reduction in energy thermal was doubled

from 35 to 70 %, exhaust gas volume reduced by 70 % , Nox reduced by 70 %. In a glass industry it resulted into 20 % increase in production , 80 % reduction in NOx. There is no need for waste heat power recovery system with POC. An incinerator plant in Argentina has been able to reduce their fuel consumption by 95 %. Fluidised kiln with pure oxygen combustion would be ideal for Responsible Investors for sustainable development. 3.7 CLINKER GRINDING Consider ROLL PRESS in FINISHED MODE with Fluidised Bed Classifier to control cement particles.Power consumption would be less than 20 kwh / tonne cement. 3.8 DOME STORAGES Advantages: Superior protection of the stored material. Strength and durability . Low cost per ton construction cost. Excellent environment control and containment of dust. Rapid construction regardless of weather. 3.9 CLEAN & GREEN POWER

Figure of a global view of geothermal energy

Cement plants should go for geo thermal power plants where ever hottest reservoirs are existing as it conserves fossil fuels and provides clean, safe , renewable and sustainable CLEAN & GREEN POWER using little land. For sustainable development there is need not to import and burn fossil fuel to CREATE ENERGY but to MOVE ENERGY which is home grown, and available 24 hours , 365 days. It is to be noted that World's total geothermal energy resource base is more than the combined resource base of fossil fuels (coal, oil & gas) including even uranium used for nuclear energy. USA is generating around 10,000 MW . Investment US$ 1200-2000 / KW . Construction 8-2 months. Generation cost US$ 0.03-0.05 / kwh Return US$ 0.05 / kwh . Pay back 3 5 years. Besides generation of power, New Mexico's gross receipts from over 50 acres of geo thermal greenhouses exceeds $ 30 million annually. And from 6 to 12 people are employed per acre at these greenhouses. Idaho's geothermal fish farm produces 2.2 million pounds annually as well as alligator hides and meats. Receipt exceeds $ 22 millions. Typically 110 acres geothermal water greenhouse produces around 18000 metric tones fish annually. Capital investment in developing one acre geothermal greenhouse farm lies in between Rs. 2- 3 million.

3.10 POTENTIAL BENEFITS TO NEW PLANTS

Clean and Green Cement cum Power Plant

3.10.1 CONCEPT TO COMMISSIONING TIME 14-15 months. 3.10.2 INSTALLATION COST

Rs 4500 - 5500 per ton of installed capacity. 3.10.3 HIGH RETURN ON INVESTMENT

Minimum 10 -15 %. 3.10.4 LOW ENERGY

Power consumption 60- 65 kwh / ton OPC. Can be set up in the remotest area where no grid pow er. Heat consumption: 690 - 770 kcal / kg clinker. 3.10.5 LOW MATERIAL Less steel consumption as highly compact design, and also as number of equipment would be reduced. Less gypsum consumption as maximum SOx would be absorbed in clinker in case of high sulphur fuel. Less refractory consumption.

3.10.6 LOW LAND 50 % reduction in area . Plant can be set up very near to the mines away from the inhabitants. 3.10.7 LOW POLLUTION Less CO2 emission as less energy would be used. Less NOx with OEC. Carbon Trading potential demonstrating that Clean & Green is profitable. In the end, I wish: May our earth with all it's beauty produce a harvest of PEACE and PROSPERITY - Rigveda. *** References: 1. A co-generation process for clinker & electricity in portland cement plants by J. Li, J. Kong, Institute of Cement, China Building Materials Academy, Beijing, R'99 Congress (Recovery, Recycling, Re-integration), February,1999. 2. Clinker formation in high- silicate low temperature melt by Vladimir D. BARBANYAGRE, The Belgorod Technological Academy of Building Materials,Russia. 10th International Congress On The Chemistry of Cement, Gothenburg , Sweden, June 1997. 3. An Innovative Cement Burning Technology FAKS- Fluidized Bed Advanced Cement Kiln System By I. Hashimoto, Y. Aranishi, T. Watanabe, Kawasaki Heavy Industries, Japan. 4. Presentation of Geothermal Education Office, USA 5. FLS -Mineralised Clinker Technology. 6. Fly Ash Activation by Ca OH2 - M.A. Weiping, Cement Concrete Research, Feb'95 25 (2), page 417 to 425. 7. Optimum Burning Condition in Kiln Using Inferior Coals by S .N.Banerjee, VDZ 8. Social Accountablity International Website. 9. Practice Application of Composite Mineralizer Technology In Precalcining Cement Kiln. By Li Peiquan and Liu Changfa, China Building Materials Academy , Beijing, China. 10. Koppern Roll Press technical brochure. 11. Towards A Sustainable Cement Industry by World Business Council for Sustainable Development. 12. Coal Ash Institute of India News Issue 24- 25 ,March/ July 2001, page 8. 13. Air Products & Chemicals Technical brochure. 14.Innovative Ideas for Sustainable Development in Cement Industry by M. K. Singhi, and Avinash Mathur, Shree Cement Ltd., India. 4th International Conference and Exhibition on Environment Protection in Cement and Building Materials IndustriesAbu Dhabi, UAE, 19-21 October 2003., organized by Arab Union for Cement and Building Materials (AUCBM) and United Nations Environment Programme(UNEP). 15. Save Fuel and Combat Pollution By Installing Electro Static Filter and Using Fuel additive in D.G. Power Generation: An Innovative Application Study of National and Global Interest by Avinash Mathur, Shree Cement Ltd. Paper presented in 3rd International Symposium On Fuels and Lubricants ( ISFL- 2002) , organized by Indian Oil 1993 page 40-46 .

Corporation, October 7-9 2002, New Delhi. 16. Address Optimum Combustion of Fuel Oil To Save Energy And Environment : An Utmost Need Of The Hour by Avinash Mathur, Shree Cement Ltd. Paper presented in 5th International Petroleum Conference and Exhibition PETROTECH- 2003, organized by ONGC, January 9-12 , 2003, New Delhi. 17 Technical Brochure of Kiln Flames System, U.K. 18. Technical Brochure of Dome Technology .

M.K. Singhi is a Graduate in Science & Law and a Chartered Accountant. He is the Executive Director of Shree Cement Ltd. He is also the leader of Cement Sector Task Force constituted by the Bureau of Energy Efficiency under the aegis of Ministry of Power, Govt. of India for Improving Energy Efficiency in Indian Cement Industry. e-mail: singhimk@shreecementltd.com

** Avinash Mathur is a graduate in mechanical engineering working as Assistant Vice President. e-mail: mathura@shreecementltd.com