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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

WorksDadri 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 SymbolNumber

of Units

Integrated

Plants12

Grinding Units 12

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

CEMENT – MANUFACTURING PROCESS

State of art AFR Laboratory Established

AFR Laboratory Inaugurated by

TNPCB Member Secretary

Laboratory is well equipped with all sophisticated

and imported instruments like -

Gas Chromatography with FID & ECD

ICP-OES

UV vis spectrophotometer

CHNS-O analyser

TGA Analyser

Automatic Bomb Calorimeter

Auto Flash Point Tester

Karl Fischer Titrator

Ion Selective Electrodes etc.

CHNS-O ANALYSER GAS CHROMATOGRAPHY WITH

FID AND ECD DETECTORSINDUCTIVE COUPLED PLASMA

SPECTROPHOTOMETER

We can analyze 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 &

Oxygen

By using GC-FID/ECD, we can find

out all types of organics like VOC’s,

PCB’s, PAH’s, Pesticides etc.

PLANT UNIQUE FEATURES

State of the art Cement Plant commissioned in the millennium year

Modified Design for multiple fuels.

Pioneer in using alternate fuel with pre-processing system

Leader in using alternate raw material (ETP Sludge)

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

Robo lab for total quality control from sampling to analysis.

Excellent Safety record- No Fatal Accidents since Twelve years

State of art testing laboratory for Alternative fuels

ALTERNATE RAW MATERIAL (ETP SLUDGE)

Co Processing of ETP Sludge as an

Alternate Raw material

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 is 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.

• Extensive characterization for all physio-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.

Co Processing of ETP Sludge as an

Alternate Raw material

Approach:

• As per TNPCB record(2012) approximately more 2 LMT of Textile ETP sludge available around

Tirupur / Erode .

• The use of alternative materials in cement plants to replace the traditional raw materials also

reduces the exploitation of natural resources and 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 Al2O3 Fe2O3 CaO MgO SO3 K2O Na2O TiO2 P2O5 Cl F

35.25 11.15 2.5 8.65 21 2.96 8.5 0.58 4.85 0.21 0.8 2.58 0

Co Processing of ETP Sludge as an

Alternate Raw material

• 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

Process Flow chart - ETP Sludge Handling

ETP RECEIPTSAMPLE COLLECTION AT

AFR LAB

SAMPLE PREPARATION

AND FPA AT AFR LAB

ELEMENTAL ANALYSIS

IN X-RAY

CATAGORISATION OF

ETP SLUDGEUNLOADING AT

APPROPRIATED

LOCATION

GREEN

YELLOW-H1

YELLOW-H2

RED-H1

RED-H2

RED-H3

AFR-LAB RECOMMENDATION

SILP

X-RAY

Co Processing of ETP Sludge as an

Alternate Raw material

Deployment:

• Finger Print analysis will be done for every truck.

• Parameters analyzed in FPA like all Proximate

analysis, major oxides and Chloride etc.

• Unloading & Storage of ETP sludge as per

categorization (Green, Yellow & Red) in the ETP

Sludge storage Shed.

• Feeding of the ETP Sludge to LS pile as per the below

blending ratio.

Classification of ETP sludge

CATEGORY Usage %

GREEN ( <1.5 % SO3 , <1.5%Cl) 15

YELLOW-H1 ( >1.5%<4.0% SO3 & Cl, >20%

CaO) 15

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

RED -H1 ( >4.0% & > 20% Cao) 35

RED -H2 ( >4.0% & <20% & >10% Cao) 15

RED -H3 ( >4.0% & < 10% Cao) 10

Co Processing of ETP Sludge as an

Alternate Raw material

Major 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 15.05 %).

• 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 (40% to 70%) of ETP sludge

Co Processing of ETP Sludge as an

Alternate Raw material

RESULT:

• This project helps to reduce the consumption of natural resources and extend the life of

the quarries.

• Reduction in green house gas emission: 23 MT CO2/year. Conservation of

limestone by 2% (approx 1 lakh MT).

Consumption of ETP Sludge %

Co Processing of ETP Sludge as an

Alternate Raw material

ALTERNATE FUELS

Co Processing of Industrial Waste

as an Alternate Fuel

Background:

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

• Fuel constitutes 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 fuel price 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.

Co Processing of Industrial Waste

as an Alternate Fuel

Approach:

• 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 our

senior executives and immediately a decision was taken that same concept can be applied in

our unit.

Country or Region % Substitution

(as per CII data)

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 scenario that 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.

Co Processing of Industrial Waste

as an Alternate Fuel

Approach:

• 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 sheds of same size.

Alternate fuel are collected from

different locations through different

suppliers, and stored as per allotted

space in closed yard. size 25X36

square meters. Presently the unit has

three shed of same size.

Size 25x36 square meters. Presently

the unit has three shed of same size.

New shredder machine

Oversize material whose size is

above 50 mm is shredded through

the shredder machine.

Established Pre-Processing & Handling System

20

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

Co Processing of Industrial Waste as an Alternate Fuel

Alternate fuel Activities Flow Chart

Type of Waste as Alternate Fuels

Co Processing of Industrial Waste

as an Alternate Fuel

The initiatives was taken by RDCW both at unit

and corporate level were of multi dimensional

nature as follows.

• Explored the availability of different type of

alternate fuel.

• Obtained clearance from TNPCB & CPCB for

usage of various AFR.

• Established waste fuel handling system in plant.

• Installed shredding machine for plastic, paint

sludge

• Installed wood cutting machine

• Established state of art AFR laboratory for

detailed analysis of hazardous AFR.

Deployment:

Type of Waste as Alternate Fuels

Plastic waste – It is mainly sourced from plastic

industries/municipality and consists of CV around 2500

kcal/kg. The moisture content is about 10-12 %, due to

light in weight, it can flow properly from the hopper so it

is used with other alternate fuel it comes with free of cost

so it is on another advantage to use.

Paint Sludge – It is mainly sourced from Automobile

industries and consists of CV around 3500 kcal/kg. The

moisture content is about 20-50 %, due to high moisture

and sticky nature of the material, it has to dry for

shredding properly in the shredding machine.

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

Deployment:

Type of Waste as Alternate Fuels

Foot wear waste– It is mainly sourced from Foot

wear manufacturing industry and consists of CV around

6500 kcal/kg. The moisture content is about 1-5 %, due

to long length pieces, required size not achieved with

single shredding. Double shredding is required to get

small size. It gives high calorific value for Mixed material.

FMCG Waste – It is mainly sourced from FMCG

manufacturing industries and consists of CV around

2500 kcal/kg. The moisture content is about 10-50 %,

due to high moisture and different types of material

mixed together, uniform shredding is difficult. After

shredding, mixing of this material with other material and

feeding to PC.

Deployment:

Key Challenges and Action Taken

There are several challenges associated with using industrial waste in kiln. It is a

highly heterogeneous in nature which makes difficult to maintain kiln stability. Several

efforts have been made to overcome the challenges. Some of the key challenges are

as follows:

Challenges Action taken

Issue related to size and flow-ability of

solid AFR:

Flow-ability was a bigger issue during AFR

feeding, due to bigger size in solid AFR

upto 400 mm and high moisture content

(25%-30%), the material frequently stuck

up at the hopper discharge chute.

To improve the flow-ability, 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

Process Challenges:

Key Challenges and Action Taken

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.

Variation in material flow at hopper

discharge:

Un-uniform material flow from hopper

discharge caused operational issues in

kiln.

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.

Wobbler feeder installed for smooth and

continuous flow of alternate fuel.

Process Challenges:

Alternate fuel Usage % on TSR Basis

Co Processing of Industrial Waste

as an Alternate Fuel

Co Processing of Industrial Waste

as an Alternate Fuel

0

5000

10000

15000

20000

25000

13-14 14-15 15-16 16-17 till Feb

20698

17887

21030

23499

Alternate fuel Quantity (MT)

Safety Measures

• Full Body suit for hazardous waste handling

• Flame proof cable lighting fitted in AFR Yard.

• Fire Hydrant System provided In & around AFR Yard.

• Sprinkler System provided in AFR Yard.

• Periodical health check of person working in Alternate fuel.

• Leachate collection tank provided in the storage sheds.

• Full body & Eye wash provided at AFR Yard.

• Storage of AFR material as per CPCB guidelines.

• Display of safety signs & SOP for handling Hazardous waste.

Storage Facilities

Hazardous wastes storage area has been earmarked separately

Storage Area – Safety Measures

Safety Measures

Periodical medical check up –Every 3 months

Flame proof electrical fittings in AF Yard Full Body suit for hazardous waste handling

Leachate collection tank

International Expert AFR visiting our Plant

Co Incineration of Plastic waste from

near by municipality

TNPCB Green award by Hon’ble CM

Award & Accolades

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)