WASTES UTILIZATION in cement
industry
Cement Production India
year Capacity Mn T
2010 228.3
2022 605.8
2027 975.6
Coal requirement for cement plant -2030- 150 Mn T
The availability of linkage coal a major concern for the cement industry.
Even importing coal is not the best option . Will have to compete with power plants .
The industry has no choice but to use waste derived fuels
Linkage coal for Cement sector
No new Coal allotment to Cement industry . Coal materialization thru
linkage has come down from 14. 8 mill T in FY 06 to 11.9 in FY 11
Data based on CMA member companies
Alternate fuel use in Cement kilns
Country % TSR by AFR Country % TSR by AFR
Netherlands 83 Sweden 29
Switzerland 48 Luxemburg 25
Austria 46 Czech Republic 24
Norway 35 Japan 10
France 34 United states 25
Belgium 30 India Less than 1
Germany 42
Source: CEMBUREAU
Waste generation in India
Type of waste Quantity Mil T Quantity Mil T
Municipal waste 58. 4
Hazardous waste A+B+C 6.21
A recyclable 3.08 3.08
B Land fillable 2.72 2.72
C Incinerable 0.41 0.41
Total 64.61
National Inventory of Hazardous Wastes Generating Industries &
Hazardous Waste Management in India February 2009, CPCB
Municipal waste alone can generate 9 mil T of RDF to replace 4. 5 Mil T of coal Equivalent to
22 % of current coal requirement for cement plant operation . Does not include other non
hazardous waste
Incinerable waste generation in India
State
Hazardous waste incinerable
Maharashtra 36.75%
Gujarat 26.12%
AP 7.61%
Rajasthan 5.54%
U.P 3.78%
Punjab 3.57%
WB 3.03%
TN 2.68%
Total Incinerable waste generation 0.41MTA
Total Incinerable waste capacity 0.32 MTA
Deficit of Incineration capacities 0.09MTA
UltraTech - Leading Indian Cement Manufacturer
has taken this Challenge as Technology Mission.
The advantages of co processing of
alternate fuel in cement plant
• Co processing ranks higher in the waste processing hierarchy .
• High flame temperature (2000°C) – ensures complete destruction
of harmful pollutants
• Residence time of combustion gases above 1000°C in excess of 3-4
seconds – ensures complete destruction of pollutants.
• Complete destruction of organic compounds.
• Total neutralization of acid gases, sulphur oxides and hydrogen
chloride, by the active lime in the kiln load, in large excess to the
stoichiometry.
• Embedding of the traces of heavy metals in the clinker structure
with very stable links (metallic silicates formation).
• No production of by-products such as ash or liquid residue from gas
cleaning.
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The advantages of co processing of
alternate fuel in cement plant
• Produces overall environmental benefits by reducing releases to air,
water and land.
• Maximizes the recovery of energy while ensuring their safe disposal
• Saving of non renewable fossil fuels. Substitution of coal with
waste. Savings are made through resource conservation and
associated CO2 emissions.
• Reduced burden on TSDF
• Immobilization of toxic and heavy material
• Reduced NOx emissions when using certain types of waste
UltraTech Cement in India
• Rajasthan- Three Integrated Units( Aditya Cement works, Kotputli cement works and
Birla white cement plant)
• Chhattisgarh- ( Hirmi Cement Works, Rawan Cement Works)
• Maharashtra- (Awarpur Cement Works, Hotgi cement Works, Ratnagiri Cement Works)
• Madhya Pradesh- ( Vikram Cement Works)
• Karnataka- (Rajshree Cement Works, Ginigera Cement Works)
• Tamil Nadu – (Reddipalayam Cement Works, Arakkonam Cement Works)
• Gujarat - Gujarat Cement Works , Narmada Cement Jafrabad Works, Magdalla Cement
Works
• Andhra Pradesh – ( Andhra Pradesh Cement Works)
• Uttar Pradesh- ( Dadari Cement Works, Aligarh Cement Works)
• Haryana- ( Panipat Cement Works)
• Punjab- ( Bathinda Cement Works
• West Bengal ( West Bengal Cement Works)
• Orissa – ( Jharsuguda Cement Works)
India UAE-
Integrated Units-12 Clinkerisation Units-1
Grinding Units -11 Grinding Units -3
Bulk terminal -4 Grinding Units Bangladesh -1
Bulk terminal Sri lanka -1
Industrial Wastes We Co-Process
Automobile Industry ( Paint Sludge, Phosphate Sludge, ETP Sludge, Spent
Catalyst, Waste Oil)
Textile Industry ( ETP Sludge, Waste Oil)
Pharmaceutical & Bulk Drug Industry (Spent Carbon, ETP Sludge, Spent
Catalyst, Mother Liquor, Waste Oil, Still Bottom Residue, Spent and
distillation Residue)
Soft Drink Industry ( ETP Sludge, Spent Carbon)
Petroleum Refinery
Pesticide Industry
Paint and Dyes Industries
Agro Waste and Biomass ( Rice Husk, Soya Husk, Mustard Husk, Ground Nut
Husk, Saw Dust etc)
Tyre Chips, Rubbers, Plastics and polythene
MSW/RDF
Overall AF Consumption
2.50
2.28 2010-11 2011-12 2012-13…
2.00 Targeted % TSR for FY 2012-13
2.00
1.80 1.84
1.57
1.50
1.26
1.13
1.00
0.68 0.71
0.50
0.15
0.00
% AF Weight % TSR Qty (in Lac MT)
Overview of AF Usage in UltraTech
(Based on Material)
Hazardous waste 43% ,Non Hazardous waste 15%
Biomass fuel 42%
Alternative Raw Material
Utilization of Fly ash, Slag as Substitute materials for Cement
Production . Potential to use LD slag , spent pot liners , lime sludge .
16.81 million tonnes of recycled material used during Fy-10-11 and
Fy-11-12.
Alternative Raw Materials Rate (% total raw materials for cement
production) 14.10 and 13.75 during Fy-10-11 and Fy-11-12.
Storage Yard & Feeding System at RDCW
We have a well covered storage yard with good
ventilation, concrete floor and leachate collection
drainage system.
A special and fully mechanized feeding system with
hopper, belt conveyor, weigh feeder etc.
Fully dedicated handling vehicle like dozer.
Special manpower for pre-processing, handling and
monitoring of waste fuel feeding.
Pump for feeding liquid/semi solid material like sludge.
Plastic and wood shredding machine for size reduction.
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Alternate Fuel Feeding System at RDCW
BUCKET
ELEVATOR
TRANSFER UNLOADING
TOWER AREA
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Alternate Fuel Feeding System at RDCW
17
Storage Yard at RDCW With Different Wastes
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Municipal Solid Waste Plant at Jaipur ( Rajasthan)
(Future plan and Support required )
• Policy to encourage waste generators to divert incinerable
waste to cement plant.
• To include “co processing ”in Hazardous wastes
(Management, Handling, and Trans boundary Movement )
Rules,2008 and place it above incineration .
• To Create a class of Waste processing facilities for fuel
homogenization and preparation for Industry .
• Polluters pay principle to be enforced .
• Need for better coordination between regulatory authority,
TSDF operators and cement industry.
• Inter States movement permission.
• Permit import of non hazardous waste such as Tyres and RDF
.
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