UltraTech Cement, Reddipalayam - GreenCo_Reddipalayam.pdfPanipat Cement Works Dadri Cement Works ... •Lifeline for the textile industry to survive ... Installed shredding machine

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STRIDEABG

RDCW AT A GLANCE

Hirmi Cement Works

Jafrabad Cement Works

Magdalla Cement Works

Ratnagiri Cement Works

Andhra Pradesh Cement Works

Arrakonam Cement Works

Awarpur Cement Works

Jharsuguda Cement Works

West Bengal Cement Works

Bathinda Cement Works

Aditya Cement

Vikram Cement

Gujarat Cement Works

Kotputli Cement Works

Hotgi Cement Works

Rajashree Cement Works

Ginigera Cement Works

Panipat Cement Works Dadri Cement

WorksAligarh Cement

Works

ABG Group- Location of

Integrated Plants,

Grinding Units and

Bulk Terminals

RWCW

Reddipalayam Cement Works

Integrated plant

Grinding unit

Bulk terminalsMangalore Cement Unit

BSBT-Dodballapur

Shankarapally Bulk Terminal

Navi Mumbai Cement Unit

Units Symbol Number of Units

IntegratedPlants

12

Grinding Units 16

Bulk Terminals 05

Area of spread Units

Plant capacity 1.6 MTPA

Area of mines 188.62 Ha

Area of plant 125 Ha

Nearest air port Trichy 75 km

Plant Unique Features

� State of the art Cement Plant commissioned in the millennium year

� Designed for using multiple fuels.

� Pioneer in using alternate fuel with pre-processing system

� Pioneer in Using alternate raw material (ETP Sludge)

� First Plant in the World to get CDM credit for use of Agro waste alternate fuel

� Robolab for total quality control from sampling to analysis.

� No Fatal Accidents since Twelve years

� State of art testing laboratory for Alternative fuels

Green Co Journey

•June’2015 started Green Co journey

•July 2015 conducted training and hand holding programme

• September 2015 submission of documents

• October 2015 Preliminary assessment and site visit

• December 2015 Detailed on-site assessment by Green Co assessor team.

• December 2015 Certification

Based on site visit and the data submitted by RDCW, the assessor’s team reviewed. The

assessor’s panel has rated RDCW as Green Co Gold.

CEMENT – MANUFACTURING PROCESS

Co Processing of ETP Sludge as

an Alternate Raw material

Co Processing of ETP Sludge as an Alternate Raw mat erial

Background

• RDCW has embarked wholeheartedly on a new path of promoting the use of alternate fuel and alternate raw

material.

• We have made a strategic priority to conserve earth’s mineral resources through waste management

solutions.

•ETP sludge generated from Common Effluent Treatment Plants (CETPs) for textile dyeing wastewater a

major challenge for environment management due to its volume, toxic nature and restricted land for disposal.

•This sludge is classified as hazardous waste as per CPCB rules, uncontrolled disposal of this waste poses

significant risk and adverse impact on health, aesthetics and the environment.

•A suitable management option requires an extensive characterization for all physico-chemical parameters and

heavy metals so that a suitable solution can be selected for the disposal.

• Presently huge quantity of sludge is dumped in the treatment plant premises and awaiting for a suitable

disposal method. The conventional disposal method like land filling may not be suitable because the leachate

from the land filling sites induces secondary pollution.


• As TNPCB record approximately more than 2 LMT of Textile ETP sludge available around Tirupur/Erode

.

•The use of alternative materials in cement plants increases the environmental footprint.

•The hazardous wastes of defined characteristics can be utilized as alternate fuel or raw material for clinker

in cement kilns i.e. “co-processing of hazardous wastes in cement kilns” is a proven, legally acceptable and

environmentally safe procedure for destruction of hazardous wastes.

Chemical Analysis of ETP Sludge:

LOI SiO2 Al 2O3 Fe2O3 CaO MgO SO3 K2O Na2O TiO2 P2O5 Cl F

35.25 13.12 3.25 14.55 28 2.98 3.05 0.62 2.56 0.23 0.6 0.91 0


• RDCW has discussed with Textile Industries of Tamil Nadu state and TNPCB. After having discussion, it

was agreed upon for the environmental friendly disposal of CETP/IETP Sludge from textile industries in kiln

by co-processing at Reddipalayam Cement Works of UltraTech Cement Limited.

• The Unit has conducted the Trial Run successfully in the presence of CPCB and SPCB and has

presented the study reports. RDCW has received CPCB permission and SPCB permission for regular co-

processing of ETP sludge.

Trial Run in the presence of CPCB and SPCB

Member secretary-TNPCB addressing co processing meet at RDCW on DT.21.01.2015

Workshop on Co-Processing


Technical Challenges

• Huge variation in chemical properties of ETP sludge Cl (0.16% to 13.65%) , Na2O (0.8% to 9.3%) and

SO3 (0.3 %to 6%).

• High chloride, alkali and SO3 has tendency of ring formation in rotary kiln due to adhesion of alkali melt at

pre burning zone .

• Handling of high moisture of ETP sludge


Classification of ET P Sludge

• Storage of ETP sludge as per categorization (Green, Yellow, Red) and

process flow chart from receipt to disposal.

• This material is meticulously blended in the ratio as mentioned below &

spread across the pile

Classification of ETP sludge

CATEGORY Usage %

GREEN ( <1.5 % SO3 , <1.5%Cl) 15YELLOW-H1 ( >1.5<4.0 SO3,>1.5<4.0%Cl, >20% CaO) 15YELLOW-H2( >1.5<4.0 SO3,>1.5<4.0%Cl, < 20% CaO) 10

RED -H1 ( >4.0 SO3,>4.0%Cl, >20% CaO) 35RED -H2( >4.0 SO3,>4.0%Cl, >10 < 20% CaO) 15RED -H3 ( >4.0 SO3,>4.0%Cl, < 10% CaO) 10

Process Flow chart - ETP Sludge Handling

AUTHORIZED VEHICLE -ETP RECEIPT

SAMPLE COLLECTION AT AFR LAB

SAMPLE PREPARATION AND FPA AT AFR LAB

ELEMENTAL ANALYSIS IN XRAY

CATAGORISATION OF ETP SLUDGE

UNLOADING AT APPROPRIATED LOCATION

AFR-LAB RECOMMENDATION SILP

XRAY

GREENYELLOW-H1YELLOW-H2RED-H1RED-H2RED-H3


Benefits/ Savings of ET P Sludge

• Elimination of legal & illegal land filling concept & there by giving a big boost for environment

management.

• Lifeline for the textile industry to survive

• Reduction in green house gas emission: 23 MT CO 2/year.

•Conservation of limestone by 2% (25707 MT/year)

• Cost economics for the implementation of the project

Investment made : Rs 24 LacsAnnual savings achieved: Rs 85.6 LacsPayback : 3.5 months

1.52%

1.88%

1.41%

0.38%

0.00% 0.50% 1.00% 1.50% 2.00%

Bud 15-16

15-16

14-15

13-14

%

Consumption of ETP Sludge %

Co Incineration of Industrial Waste as

an Alternate Fuel

Co Incineration of Industrial Waste as an Alternate Fuel

Background:

• The major cost drivers for cement manufacturing are raw material, fuel and power. .

• Fuel constitutes approximately 24% of the total cost of production, the cost of fuel at RDCW was very

high compared to other cement plants because of its location and high logistic cost

• Continuous increase of price of coal as fuel price was increasing at very fast pace and to cut down the

production cost, a petroleum refinery by-product known as petroleum coke was used 100% as fuel in

RDCW.

• Price of pet coke gradually started increasing and availability reduced and it was not economically much

viable.

• It was felt that other innovative measures were required to be taken to sustain low fuel cost for a longer

period of time.

• Hence, the distinct focus was on reduction of fuel cost, either by improving the operational efficiency or

by adopting other innovative measures like utilizing industrial waste as fuel, through installation of a tailor-

made pre-processing (handling & feeding) and co-processing system.


Background:

• The concept of utilization of industrial waste as fuel is conceived because of huge availability, which

otherwise is being dumped as land-filling, burning in unauthorized & unorganized way thereby creating high

level of pollution in atmosphere & water.

• The developed countries in Europe and USA, where utilization of waste fuels was very high quantity and

in a very organized and environment-friendly way, got the attention of UltraTech Management and a

decision was taken that same concept can be applied at RDCW.

Country or Region % Substitution

Netherland 83

Switzerland 47.8

Austria 46

Norway 35

France 34.1

Belgium 30

Germany 42

Sweden 29

Czech Republic 24

EU (prior to expansion in 2004) 12

Japan 10


• It was in this backdrop unit took the challenge to

install an alternate fuel feeding system in plant. The

strategic decision for co- processing of AF at RDCW

was taken because of the availability of industrial

waste in the surrounding areas.

•At the initial period surrounding agro waste were

targeted for usage but the availability of agro waste

became difficult, so the unit shifted towards industrial

waste usage.

•Alternate fuel are collected from different locations

through different suppliers, and stored as per allotted

space in closed yard of size 25X36 square meters.

Presently the unit has three shed of same size.


The initiatives was taken by RDCW both at unit and corporate level were of multi dimensional few initiatives as

follows.

�Explored the availability of different type of alternate

fuel.

� Setting up waste fuel handling system inside plant.

� Obtained clearance from TNPCB & CPCB for usage of

various AFR.

� Installed shredding machine for plastic, paint sludge

� Installed wood cutting machine

Established state of art AFR laboratory for detailed

analysis of alternate fuel.

Type of Waste as Alternate Fuel

Type of Waste as Alternate Fuel

Plastic waste – It is mainly sourced from plastic industries / municipality

and consists of CV around 4500 kcal/kg. The moisture content is about 10-

12 %, due to light in weight, it cannot flow properly from the hopper so it

is blended with other alternate fuel

Paint Sludge- it is from Automobile industries and having CV around 3500

Kcal/Kg. it will be in sticky in nature and lumps form. Hence shredding will

be done and made into powder form. Then blended with other material

and fed to Calciner

Oily cotton waste: it is from automobile industry, which was used for

cleaning for oil/grease is having CV around 4500 Kcal/Kg. Size of the

material is big. Hence shredding will be done before feeding.

� De-Oiled Rice Bran (DORB)

� Shredded Tyres

� De-oiled Cashew nut shell (DOCS)

� Saw Dust

� Refinery Sludge

� Groundnut shell

� Coconut shell

� Match stick waste

� Wood strips

� Leco fines

� Municipal waste

(RDF Fluff)

� Coir waste/dust

� Corn waste

� Rice Husk

� Rubber trimmings/liquid

� Chilly stump

� Bio-compost

� Banana waste

� Wood char coal

� Tyres powder

SETTING UP OF AFR HANDLING SYSTEM

Alternate fuel are collected from differentlocations through different suppliers, andstored as per allotted space in closed yard.size 25X36 square meters. Presently the unithas three shed of same size.

Size 25X36 square meters. Presently we have three shed of same size.

Shredder machine

Oversize material whose size is above 50 mm is shredded through the shredder machine.

Established Pre-Processing Handling System

Wood Cutting machine:With the help of wood cutting machinescrap woods cut down to small pieces andfed to calciner for combustion.

Capacity 300 Kg / Hour.

Multiple AFR feeding arrangement in precalciner:

Chaff Cutter for Agro Waste

Bob Cat for AFR Feeding

Shredder machineCapacity – 5 TPH

Established Pre-Processing Handling System

Purpose:

Capacity enhancement of Alternate fuel feeding system through size reduction.

Technical Approach:� Installed Multi-purpose shredding machine� Double shredding of Alternate fuels

Investment: Rs.77.05 Lac

Savings : Rs. 158.37 Lac

ROI - 205.54 %

Benefits :

Size reduction from 500 MM to 50 MM(Plastic, HDPE bags, Tarpaulin, Foot wearwaste, Agro waste, wood and othermiscellaneous waste.

Shredded HDPE bags & Tarpaulin

Shredder Machine

Established AFR LAB

On 12th Sep 2014, RDCW inaugurated UltraTech

cement Limited's first AFR (AFR) Testing Laboratory.

Inauguration of AFR lab by

Dr. Karthikeyan-Member secretary-TNPCB

� Laboratory is well equipped with

all sophisticated and imported

instruments like

� Gas Chromatography with FID &

ECD

� Inductive coupled plasma-OES

� UV-Vis spectrophotometer

� CHNS-O analyser

� TGA Analyser

� Automatic Bomb Calorimeter

� Auto Flash Point Tester

� Karl Fischer Titrator

� Ion Selective Electrodes etc.

We can analyses all types of metal and heavy metals in PPB range by using ICP-OES.

By using CHNS we can find out ultimate analysis like Carbon, Hydrogen, Nitrogen, Sulphur and Oxygen

By using GC-FID/ECD we can find out all types of organics like VOC’s, PCB’s, PAH’s, Pesticides etc.

AFR LAB-Instrument Details

TGA Analyser Bomb calorimeter

CHNS Analyser GC-FID&ECD ICP-OES

27

HOPPER-2

Bucket

Elevator

FAN

BAG

FILTER

FAN

BAG

FILTER

3rd Stage Cyclone

4TH Stage Cyclone

PRECALCINER

KILN

FLAP

VALVES

HOPPER-1

Alternate Fuel Feeding System

Key Challenges and Action Taken

There are several challenges associated with using industrial waste in kiln. It is a highly heterogeneous innature which makes difficult to maintain kiln stability. Several efforts are underway to overcome the challenges;some of the key challenges are as follows.

Challenges Action taken

Issue related to Size and flowability of solid

AFR

Flowability was a bigger issue during AFR

feeding, due to bigger size in solid AFR up to

400 mm and high moisture content (25%-

30% )the material frequently stuck up at the

hopper discharge chute.

To improve the flowability, hopper chute is

modified. Slant inclination of hopper was

modified and made vertical.

A new shredder machine with mechanised

system for feeding to shredder and

discharge from shredder is installed. This

helps to reduce the size of solid AFR less

than 50mm. This increase AFR feeding from

50 MT to 90 MT

Challenges Action taken

Calciner Temperature Fluctuation:

There was huge fluctuation in calciner

temperature followed by CO generation at

kiln inlet during AFR (industrial waste)

injection in calciner.

VFD installed in AFR feeding conveyor belt.

Interlock provided to reduce belt speed by

50% and weigh feeder set point to

minimum (i.e. 1 MT) whenever calciner

temperature exceeds 9000C. To avoid

variation in CV, to minimize CV variation

mixing of high and low CV alternate fuel

started with help of wheel loader.

11.25

10.94

9.62

9.60

8.34

8.11

6 7 8 9 10 11 12

Bud 15-16

15-16

14-15

13-14

12-13

11-12

TSR

%

Alternate fuel Usage % on TSR Basis

Benefits & Savings

• Recovery of energy from waste

• Elimination of separate incineration

• Conservation of Fossil Fuel• Environmental benefits achieved: Reduction in GHG emission 1247 MT of CO2/Year.• Fossil fuel saving 2886 MT/year

• Investment made : Rs 77 LacsAnnual savings achieved : Rs 197.54 LacsPayback : 4 months

Award & Accolades

� National Energy Efficient Unit Award by CII (2004 & 2006,2007 , 2008 ,2012 & 2013)

� National Excellent Energy Efficient Unit Award by CII – (2009 , 2010 , 2011,2014, 2015)

� NCCBM Best Electrical Energy Performance Award 2008-09

Green Co Gold awardFrost & Sullivan Leader award for Sustainability 4 (Green Manufacturing)

UltraTech Cement, Reddipalayam - GreenCo_Reddipalayam.pdfPanipat Cement Works Dadri Cement Works ... •Lifeline for the textile industry to survive ... Installed shredding machine

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