Cement Energy and Environment

ENERGY CONSERVATION AND ENVIRONMENTAL IMPACT ABATEMENT AT VASAVADATTA CEMENT P.K.Goyenka, B.L.Saini &. A.K.Deshpande ABSTRACT: C ement industry is highly energy intensive with energy accounting for about 40 per cent of the total manufacturing cost. From the environmental viewpoint. the cement manufacturing process causes dust emissions. C0 1 emission, etc., leading to environmental pollution. This paper describes measures adopted at M/s. Vasavadatta Cement, Sedam, for energy conservation and improving the performance of pollution control equipment. These measures have led to 120 per cent capacity utilisation in both Units I and II and a lowest energy consumption of 81 I<Wh/ tonne of cement in Unit II and 87 kWh/ tonne of cement in Unit I. Introduction Vasavadatta Cement is the second green field project of Kesoram Industries, located in the Gulbarga District of Karnataka, 3 km away from Sedam town . It has two units whose main features are summarised in Table 1. Table l Main features of Units I and II Feature Unit I Unit II Year of commissioning 1986 1997 Capacity TPD 1500 2000 Crusher Hazemag, impact, single stage (Common to both units) Raw meal grinding Vertical roller mill (VRM) VRM with dynamic separator RM 43/21/65 RM 51/26/40 Coal grinding VRM RMK 21/10 VRM with static separator RMK 23/11 Raw meal blending Single continuous blending silo Single continuous blending silo Preheater 5-stage suspension 1528-AS 5-stage suspension - D0pol - 90 Precalciner In-line In-line Clinker cooler RS-2421/11 jet ring RS-3121/11 Cement grinding Open-circuit Combi-circuit (Roller press with 4.4 m<t> x 16 ML, 115 TPH tube mill) Appreciating the importance of energy efficiency and productivity. the plant management set up an energy conse rvation cell which has laid down the methodology of measurement of parameters, logical approach to and implementation of modifications/ innovative ideas. Likewise a full-fledged environmental wing also has been established for monitoring fugitive emissions, suspended particulate matter (SPM), noise level and other related parameters. It aids the 14 4.6 m<t> x 16 ML, 225 TPH management to continuously improve pollution control equipment by upgrading existing ones where feasible , and retrofitting those based on latest technology in other cases. Major Modifications and Improvements The major modifications carried out to make up for the deficiencies noticed or problems met with in the operation of various equipment and systems are summarised in Table 2. >