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

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

2 RDCW AT A GLANCE Bathinda Cement Works Panipat Cement Works Kotputli Cement Works Aditya Cement Vikram Cement Dadri Cement Works Aligarh Cement Works 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 Terminal Ratnagiri Cement WorksRajashree Cement Works Andhra Pradesh Cement Ginigera Cement Works Mangalore Works Cement Unit BSBT- Dodballapur Arrakonam Cement Works ABG Group-Location of Integrated Plants, Grinding Units and Bulk Terminals West Bengal Cement Works Jharsuguda Cement Works Reddipalayam Cement Works Integrated plant Grinding unit Bulk terminals Units Integrated Plants Symbol Number of Units 12 Grinding Units 16 Bulk Terminals 05 Area of spread Plant capacity Area of mines Area of plant Nearest air port Trichy Units 1.6 MTPA Ha 125 Ha 75 km

3 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

4 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.

5 CEMENT MANUFACTURING PROCESS

6 Co Processing of ETP Sludge as an Alternate Raw material

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 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.

8 Co Processing of ETP Sludge as an Alternate Raw material 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 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 coprocessing of ETP sludge. Trial Run in the presence of CPCB and SPCB

10 Workshop on Co-Processing Member secretary-tnpcb addressing co processing meet at RDCW on DT

11 Co Processing of ETP Sludge as an Alternate Raw material 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

12 Co Processing of ETP Sludge as an Alternate Raw material 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) 15 YELLOW-H1 ( >1.5<4.0 SO3,>1.5<4.0%Cl, >20% CaO) 15 YELLOW-H2 ( >1.5<4.0 SO3,>1.5<4.0%Cl, < 20% CaO) 10 RED -H1 ( >4.0 SO3,>4.0%Cl, >20% CaO) 35 RED -H2 ( >4.0 SO3,>4.0%Cl, >10 < 20% CaO) 15 RED -H3 ( >4.0 SO3,>4.0%Cl, < 10% CaO) 10

13 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 GREEN YELLOW-H1 YELLOW-H2 RED-H1 RED-H2 RED-H3 UNLOADING AT APPROPRIATED LOCATION CATAGORISATION OF ETP SLUDGE AFR-LAB RECOMMENDATION SILP XRAY

14 Co Processing of ETP Sludge as an Alternate Raw material 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 Lacs Annual savings achieved: Rs 85.6 Lacs Payback : 3.5 months % % Consumption of ETP Sludge % 1.41% 1.88% Bud % 0.00% 0.50% 1.00% 1.50% 2.00%

15 Co Incineration of Industrial Waste as an Alternate Fuel

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

17 Co Incineration of Industrial Waste as an Alternate Fuel 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

18 Co Incineration of Industrial Waste as an Alternate Fuel 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.

19 Co Incineration of Industrial Waste as an Alternate Fuel 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.

20 Type of Waste as Alternate Fuel

21 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 %, 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

22 SETTING UP OF AFR 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 we have three shed of same size. Oversize material whose size is above 50 mm is shredded through the shredder machine. Shredder machine

23 Established Pre-Processing Handling System Wood Cutting machine: With the help of wood cutting machine scrap woods cut down to small pieces and fed to calciner for combustion. Chaff Cutter for Agro Waste Capacity 300 Kg / Hour. Bob Cat for AFR Feeding Shredder machine Capacity 5 TPH Multiple AFR feeding arrangement in precalciner:

24 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 Lac Savings : Rs Lac Shredder Machine ROI % Benefits : Size reduction from 500 MM to 50 MM (Plastic, HDPE bags, Tarpaulin, Foot wear waste, Agro waste, wood and other miscellaneous waste. Shredded HDPE bags & Tarpaulin

25 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

26 AFR LAB-Instrument Details 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. CHNS Analyser GC-FID&ECD TGA Analyser ICP-OES Bomb calorimeter 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. We can analyses all types of metal and heavy metals in PPB range by using ICP- OES.

27 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 27

28 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 are underway to overcome the challenges; some of the key challenges are as follows. Challenges Issue related to Size and flowability of solid AFR Flowability was a bigger issue during AFR feeding,duetobiggersizeinsolidafrupto 400 mm and high moisture content (25%- 30%)the material frequently stuck up at the hopper discharge chute. 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. Action taken 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 50MTto90MT 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.

29 Benefits & Savings Alternate fuel Usage % on TSR Basis TSR % Bud 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 Annual savings achieved Payback : Rs 77 Lacs : Rs Lacs : 4 months

30 Award & Accolades NationalEnergyEfficientUnitAwardbyCII(2004&2006,2007,2008,2012&2013) NationalExcellentEnergyEfficientUnitAwardbyCII (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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