Section Opener 3 Font: Verdana Size: 30 pt. ABG STRIDE

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1 Section Opener 3 Font: Verdana Size: 30 pt. ABG STRIDE

2 RDCW AT A GLANCE Bathinda Cement Works Panipat Cement Works Kotputli Cement Works Dadri Cement Works Aligarh Cement Works ABG Group- Location of Integrated Plants, Grinding Units and Bulk Terminals Units Integrated Plants Symbol Number of Units 12 Grinding Units 12 Aditya Cement Vikram Cement Hirmi Cement Works Gujarat Cement Magdalla Cement Works Works Awarpur Cement Jafrabad Cement Works RWCW Works Navi Mumbai Cement Unit Hotgi Cement Works Shankarapally Bulk Ratnagiri Cement Terminal WorksRajashree Cement Works Andhra Pradesh Cement Ginigera Cement Works Mangalore Works Cement Unit BSBT- Dodballapur Arrakonam Cement Works West Bengal Cement Works Jharsuguda Cement Works Reddipalayam Cement Works Integrated plant Grinding unit Bulk terminals Bulk Terminals 05 Area of spread Units Plant capacity 1.6 MTPA Area of mines Ha Area of plant 125 Ha Nearest air port Trichy 75 km

3 CEMENT MANUFACTURING PROCESS

4 State of art AFR Laboratory Established AFR Laboratory Inaugurated by TNPCB Member Secretary CHNS-O ANALYSER 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. GAS CHROMATOGRAPHY WITH FID AND ECD DETECTORS INDUCTIVE COUPLED PLASMA SPECTROPHOTOMETER 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. We can analyze all types of metal and heavy metals in PPB range by using ICP-OES.

5 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

6 ALTERNATE RAW MATERIAL (ETP SLUDGE)

7 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.

8 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 SiO 2 Al 2 O 3 Fe 2 O 3 CaO MgO SO 3 K 2 O Na 2 O TiO 2 P 2 O 5 Cl F

9 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

10 Process Flow chart - ETP Sludge Handling ETP RECEIPT SAMPLE COLLECTION AT AFR LAB SAMPLE PREPARATION AND FPA AT AFR LAB ELEMENTAL ANALYSIS IN X-RAY GREEN YELLOW-H1 YELLOW-H2 RED-H1 RED-H2 RED-H3 UNLOADING AT APPROPRIATED LOCATION CATAGORISATION OF ETP SLUDGE AFR-LAB RECOMMENDATION SILP X-RAY

11 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

12 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 %). 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

13 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 CO 2 /year. Conservation of limestone by 2% (approx 1 lakh MT). Consumption of ETP Sludge %

14 Co Processing of ETP Sludge as an Alternate Raw material

15 ALTERNATE FUELS

16 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.

17 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.

18 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.

19 Established Pre-Processing & Handling System 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.

20 Alternate Fuel Feeding System 3 rd Stage Cyclone FLAP VALVES 4 TH Stage Cyclone HOPPER-1 HOPPER-2 BAG FILTER FAN Bucket Elevator BAG FILTER FAN PRECALCINER KILN 20

21 Co Processing of Industrial Waste as an Alternate Fuel Alternate fuel Activities Flow Chart

22 Type of Waste as Alternate Fuels

23 Co Processing of Industrial Waste as an Alternate Fuel Deployment: 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.

24 Type of Waste as Alternate Fuels Deployment: Plastic waste It is mainly sourced from plastic industries/municipality and consists of CV around 2500 kcal/kg. The moisture content is about %, 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 %, 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

25 Type of Waste as Alternate Fuels Deployment: FMCG Waste It is mainly sourced from FMCG manufacturing industries and consists of CV around 2500 kcal/kg. The moisture content is about %, 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. 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.

26 Key Challenges and Action Taken Process Challenges: 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 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. Action taken 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

27 Key Challenges and Action Taken Process Challenges: Challenges 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. Action taken 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 C. 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.

28 Co Processing of Industrial Waste as an Alternate Fuel Alternate fuel Usage % on TSR Basis

29 Co Processing of Industrial Waste as an Alternate Fuel Alternate fuel Quantity (MT) till Feb

30 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.

31 Storage Facilities Hazardous wastes storage area has been earmarked separately

32 Storage Area Safety Measures

33 Safety Measures Periodical medical check up Every 3 months Leachate collection tank Flame proof electrical fittings in AF Yard Full Body suit for hazardous waste handling

34 International Expert AFR visiting our Plant

35 Co Incineration of Plastic waste from near by municipality

36 Award & Accolades TNPCB Green award by Hon ble CM

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

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