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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.
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.
Co Processing of ETP Sludge as an Alternate Raw mat erial
• 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
Co Processing of ETP Sludge as an Alternate Raw mat erial
• 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
Co Processing of ETP Sludge as an Alternate Raw mat erial
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
Co Processing of ETP Sludge as an Alternate Raw mat erial
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
Co Processing of ETP Sludge as an Alternate Raw mat erial
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
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.
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
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.
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.
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)