Cement Energy and Environment

.. Usage of Coal Tar as AFR in Sanghi Industries has made aNew Mile stone for Cement Industry K. K Vasavada Sr. Vice President - Operations Sanghi Industries Limited, P.O : Sanghipuram, Kutch, Gujarat, Pin.: 370511 1.0 Introduction Figure-1: View of Cement Plant- Sanghi Industries Limited is operating a 3.5 MTPA Cement Plant, 60 MW Captive Thermal Power Plant, 5500 M3/day MED Plant and Captive Port facilities in Kutch District of Gujarat. The Brand is well recognized as premium in National as well as International Markets. The company has become pioneer to initiate use of AFR in general and Coal Tar in particular in cement kiln under due compliance of Environmental Standards. Morbi contributes 85% of ceramic production in India. Many ceramic industrial units in Morbi and Wankaner were facing closure threat after Gujarat high court ordered strict implementation of the guidelines issued by the Central Pollution Control Board (CPCB). The order came in response to a PIL alleging the use of Tar in coal gas furnaces (gasifiers) in more than 200 ceramic units and 15 silicate industries in and around Morbi without adopting appropriate I proper pollution control system. The byproduct of coal gas furnaces (gasifiers) is Coal Tar. Proper disposal of coal tar was a big issue, it cost the industries heavily (14500 Rs/Mt approx.), as earlier they use to send Coal Tar to TSDF site at Mota Katariya, Bhachau. Few industries may had earlier adopted easy method like disposal in open field and drainage which led to soil degradation and water pollution. Sanghi Industries has been able to sort out this issue of Coal Tar disposal by co-processing in their cement kiln . 2.0 What is Co-Processing Co-processing is an authorized form of waste management that recovers energy and mineral content of waste for converting to value added product, to save conventional energy resources Sanghi Industries Ltd at Kutch, Gujarat. and consequently reduce C02 emission in manufacturing processes. Thus co-processing is an efficient operational technique which minimizes the requirement of waste materials to be dumped in landfill area or incinerated at high temperature while reducing impact on environment. It conserves fossil fuels and natural mineral resources. 2.1 Characteristics of coal tar : • • • • • • Liquid in nature. Black in colour. Highly viscous. Contains 30% to 40% moisture. If kept stagnent for long duration seggrigation of heavier and lighter particals takes place, leaving water content at the bottom. Calorific value of Coal Tar varies from 6000 to 7000 Kcal/kg which mainly depends upon the quality of coal used in gasifiers. • Material is having oder of oil like LDO, furnase oil etc. • If spilled over cloth, it is hard to remove the stain. • Need spicial pumping arrangements to unload and load Coal Tar due to high viscosity. II