Cement Energy and Environment

and wastes, Shri Saxena highlighted the major issues facing the industry, one of which is to drive further Energy Efficiency through the ongoing implementation of the BEE's PAT Scheme in its PAT Cycle II too in which the Cement Plants identified as Designated Consumers (DCs) have to further meet the Government assigned Targets for Reduction in Energy Consumption, after demonstrating exemplary performances in PAT Cycle I. He informed, the current average thermal energy consumption in the Indian cement industry is 725 kcal/kg of clinker and the average electrical energy consumption level is 85 kWh/t of cement. The average thermal energy consumption is targeted to be 709 by 2020 and further reduced to 694 kcal/kg of clinker by 2030. The electrical energy consumption is further targeted to reduce to 76 by 2020 and to 73 kWh/t of cement by the end of 2030. On the ongoing PAT implementation, Shri Saxena cited that, PAT Cycle II has 111 DC's pertaining to cement sector as compared to 85 DC's during PAT Cycle I. The average target assigned to cement sector during PAT Cycle II is 5.23 % which corresponds to energy reduction of 1.117 million toe (tonnes of oil equivalent). Since low hanging fruits have already been tapped by Indian cement plants during PAT Cycle I, plants have to opt for other conventional as well as innovative measures involving high capital investment to achieve PAT Cycle II targets. Moreover, policy initiatives by the Government in the form of subsidies and favourable normalization factors are the need of the hour to give further boost to energy conservation objectives of the country, he mentioned. Shri Sanjay Jain, Asst Executive Director– Technical Services, Dalmia Cement (Bharat) Ltd, chaired this session. 2.4 a) Pollution Monitoring & Control Equipment Shri Subroto Roy, Chemtrols Industries Ltd, Mumbai, made a presentation on Monitoring, Reporting & Control Protocols for cement plant pollutants, namely, DusUsoot, SOx, NOx, and now Mercury. He mentioned about the Primary Measures, as well as Secondary Measures in Emission Control. He then focussed on the Secondary Measures, i.e., the established systems viz. Installing bag filters, Dust suppressors, SNCR/SCR, FGD. In his presentation on Evaluation of a NOx emission problem, he drew attention of the participants to the following challenges: • Ensuring monitoring instrument accuracy, regular maintenance & calibration, • Selecting/budgeting for systems with the right technology towards abatement- NOx, SOx, • Meeting the implementation deadlines, • Concerns of accommodating the new system– a Space , 0 Capacity, 0 Sourcing & logistics 0 Safety - reagent 0 Staff training. On the choice of a NOx emission control system out of the two options available, namely, SCR {Selective Catalytic Reaction), and SNCR (Selective Non-Catalytic Reaction), Shri Roy first ruled out the choice of applying an SCR system in cement plants owing to the following reasons : As the flue gases pass through a honeycomb structure of catalyst (V205, or Ti02), dust in the flue gases clog it, that has to be washed off intermittently, which involves much cost and hence is not recommended. Highlighting on the application of SNCR System in Cement Process, he brought out the following aspects of such a system: • Placed between Kiln Inlet and Lower Cyclone, • Stable Calcination Temperature, • CO competes with NH3 for OH, • Inject NH3 after most CO burnout, • Good Efficiency at High Molar Ratios. 2.4 b) Environmental Standards & Regulatory Measures A brief presentation on the Topic was made by Dr K V Reddy, Vice President & Corporate Head Environment, Ultratech Cement Ltd. He highlighted the process of the evolution of the Emission Standards for Cement Plants, as summarised in the Table below. 27