Cement Manufacturers Association (CMA)

63 Cost Economics Concrete is the second most consumed substance on Earth after water. Cement production is growing by 2.5% annually, and is expected to rise from 2.55 billion usages to 3.7- 4.4 billion tons by 2050. The production of cement releases greenhouse gas emissions both directly and indirectly and another major problem is dumping of fly ash and pond ash. Coal ash represents a major environmental problem. There has been steady rise in the production of fly ash over the years due to increased demand for power and the dependence on coal for producing electricity. Fly ash landing cost is 1100-1200 Rs/Tons, whereas Pond Ash cost is 600-700 Rs/Tons. Thus, using pond ash is much better and sustainable option to reduce the manufacturing cost of cement and increase profitability, by employing effective POND ASH Drying Combustion chamber. Advantages of using Pond-Ash V/s Dry Fly-Ash S. No. Parameters Unit Values 1 Cost of Dry Fly-Ash Rs/Tonne 1100 2 Cost of Pond-Ash Rs/Tonne 700 3 Cost of Drying Pond-Ash (As per basis of Coal) Rs/Tonne 50 4 Processing cost of 1 Tonne of Pond-Ash (Removal of Moisture) Rs 750 5 Moisture in 1 Tonne Pond Ash % 15 6 Finished product after drying in furnace (Convert into Dry Fly-Ash) Tonne 0.85 7 So Total Cost of Pond-Ash after processing Rs/Tonne 882.35 8 Cost Difference of Dry Fly-ash & Pond-Ash Rs/Tonne 217.65 9 For 100 TPH Mill, Fly-Ash used (PPC) % 35 10 Pond-Ash used Tonne 18 11 Benefit of using processed Pond-Ash Rs Per Hour 3,918 12 Benefit of using processed Pond-Ash Rs Per Day@20 Hrs 78,353 13 Benefit of using processed Pond-Ash Rs Per Month@25 Days 19,58,824 14 Benefit of using processed Pond-Ash Rs Per Year@300 Days 2,35,05,882 2008-09 2010-11 2012-13 2014-15 2016-17 2018-19 2020-21 2022-23 2024-25 1500 1200 900 600 300 0 Coal CO Emissions (mt co ) 2 2 492.41 533.73 557.18 605.64 693.72 742.85 823.75 884.63 931.21 902 1020.96 964.03 979.01 1057.15 1662.32 1259.89 1299.22 1259.92