Cement, Energy & Environment Jan-Mar 2002

A Section of the audience efficient combustion, low pressure-drop 5-6 stage preheaters, third-generation high-efficiency coolers and waste derived fuels (WDF) which can • significantly increase .output and cut down energy consumption. Useful presentations were made on these topics, from Australia, USA, Malaysia and India, apart from actual case studies of improved productivity through debottlenecking. Discussions on these aspects would form a vital input to the industry's modernisation programme. • Thanks to developmental efforts in plant and machinery, kilns of higher output rates and mills of larger size as well as • lower energy consumption were • becoming possible. Accordingly, many of the kilns operating in India could be upgraded with suitable modifications of upstream and downstream equipment. This was most pertinent in the current competitive market scenario where least-cost alternatives had to be found for maximizing capacities. In the coming years, cement industry's coal requirement was expected to go up considerably. This called for greater emphasis on use of alternative and waste derived fuels (WDF), such as pet-coke and combustible wastes. Efficient preparation of fuels and use of proper burning technology was the key to the effective use of all types of fuels. The various case studies presented emphasised that WDF's were perfectly suitable for replacing expensive fossil fuels. Besides reducing energy costs, they had a positive environmental impact through conservation of natural resources and reduction of green house gas emissions. The changing perspectives of Indian cement industry's environmental management were highlighted during the deliberations. Until recently the industry was mainly concerned with controlling visual dust pollution asso~iated with the manufacturing process. With the adoption of new– generation bag houses and ESPs, still lower levels of dust emissions have become possible. But fugitive dust control inside plants needed· more consideration. The concept of Environment Management Systems (EMS) was becoming increasingly. popular as reflected in the rising number of plants adopting the IS0-14001 certificatio~, their current tally being 27. At the same time the industry needed to develop a proactive strategy for new EMS initiatives encompassing the concepts of waste minimization, waste avoidance and pollution prevention through better manufacturing process and 7