Cement Energy and Environment

S.No. Equipment Number Lcoatiou Cost/Rs. Crore I. Electrostatic 4 Clinker 10 precipatators cooler (ESP) 2. Bag houses 7 Kiln. coal 35 mill and cement mill 3. Dust 15 Unit I 10 collectors 45 Units ll and II I The ESP's are fitted with semi-pulse type micro-processor based controllers. They are of a very high efficiency and designed for an emission level below 50 mg/Nm 3 . The bags, made of imported fibre glass, homopolymer and polyester, in the bag houses. have an efficiency close to I 00 per cent. In addition to the 60 dust collectors at Units I, II and III, cassette-type single-point suction- type dust collectors are installed at various material transfer points in the plant. For co~1t ro l li ng fugitive dust emi ss ions due to wind, all conveyor belts are covered as is also the coal stacking yard wh ich is provided with wind guard. At material handling and storage yards. water spray system is used for suppressing dust. Atomised water spray is provided at different locations of crusher and material handling circuit. Dust num itorillf: The level of SPM is automotically monitored continuously bymeans ofopacity monitor installed at 9 major stacks. These give on-line SPM emission concentration at the control room; wh ich, in turn , helps detect any increase in emissionand alert the central control for immediate checking of the process equipment, etc. SO 2 Emission (from coal) Fibre glass bag houses downstream kilns greatly reduce the SO 2 content in kiln exit gases to maintain SO 2 concentration below detectable limits. Cost The plant 's total investment on the po ll ut ion contro l equipment is about Rs. 65 crore which works out to about I0 per cent of the project cost of Rs. 650 crore for Units II and 111.Thf rewrrl~~ ~o~t of [\r ~ollu!ion wntrol m~a!ur~~ i~ about Rs. 1.5 crore per year. 2 Colon~ Waste Water Treatment For the treatment of domestic sewage from colony, standard oxidation ponds on the lines recommended by National Environmental Engineering Research Institute (NEERJ) have been laid out. The treated water is used for watering the plantation around the plant. This has cost Rs. 30 lac and the recurring cost is about Rs.6 lac/annum. Ecological Balance After mining, mined-out areas are reclaimed in a planned manner and plantations created upon them. Thus, a wide variety ofplants like Cassia seamia, Pongomia uerigado, Cajurina, Poly althia pendu/a, Azadirachta indica, Delonix regia and other ornamental and fruit plants have been planted in and around the plant and colony. The lush green plantations created act as "Carbon sinks" and also help in attenuation of plant noise. !\lining and Rtlatcd Areas For minimi s ing fug itive emi ss ion during dril ling operations, drilling machines used are fitted with cyclone and bag filter. Water is spraye d on haul roads fo r suppressing dust. Conservation of Natural Resources The plant produces about 75000 tonnes of PPC every year, utilising flyash procured from Ahmedabad Electric ity Company. At a 12 - 15 per cent fly ash content, this co nsumes approximately I 0 ,000 tonne s of flyash which would otherwise be adding to the problem of its disposal. Abu Road, situated at Rajasthan's Border with Gujarat, has deposits of marble and has a good a number of stone cutting/polishing industries in the industrial area. The plant purchases and consumes waste marble chips which are otherwise abandoned in the open. Annually, about 6000 tonnes of this waste are so consumed. Likewise, the plant uses chemical gypsum, which is a solid waste generated from dye units in Gujarat, to the tune of 5000 tonnes per annum. Lakshmi Cement has installed fibre glass bag houses in quantities of water in conditioningtower for bringing ..