Cement Energy and Environment

- 9. First presentation was made by Dr. Mukesh Kumar, President. Head Group Technology, Vedanta Ltd., on "Spent Pot Lining -Alternative Fuel & Raw Material for Cement Industry". In his presentation he shared the challenges faced by the both Aluminium and Cement Sector in the area of raw material and energy availability, disposal of waste and stringent environmental norms. He highlighted that how the waste from Aluminium Industry, such as SPL can be useful for Cement industry. The availability of SPL in Vedanta Group is expected to increase from a present level of 21,000 TPA to 52,000 TPA in future. He mentioned that there are two types of SPL treatment; Disposal and Recycling techniques; Recycling is an attractive and proven option and can be best if its use in Cement Industry. Dr. Mukesh Kumar concluded his presentation with a remark that "Aluminium is a green metal and Cement is the necessity for overall development. By utilizing wastes of Aluminium Industry as an alternative Fuel/ Raw material in Cement industry, both the Industries can ensure Sustainable Development" 10. Second presentation was made by Mr. Akhileshwar Nath Upadhyay, Manager Sustainability and Environment, Hindalco Group. He informed the participants that on an average SPL generation is about 15kg per ton of aluminium production in smelter plants. Presently SPL availability from three plants of Hindalco (Hirakud, Aditya and Mahan) in FY 2016 will be about 12,000 Ton per annum (TPA) which may marginally increase to 13,800 TPA by 2020. SPL generation of 6021 TPA in Renukoot plant is being reprocessed in cryolite recovery plant to recover Cryolite for its recycling in smelter pots. He informed that SPL is a mixed hazardous waste including first cut carbonaceous materials and second cut refractories. SPL (1st cut and 2nd cut) may be used as fuel supplement with raw materials additives properties. Limited time of about 3 Months is allowed for storage of SPL within plant premises and it is not possible for a new smelter plant to have cryolite recovery as this requires alumina refinery. He said that, SPL after its detoxification can be co-processed in cement kilns. This may involve inter-state movement of hazardous waste and need to be addressed in the context of CPCB rules on movement of hazardous waste . 11. Third presentation was made by Team Vedanta Group (BALCO, Lanjigarh and Jharsuguda). Brief about SPL, its availability in Vedanta plants and its various characteristics were shared by Team Vedanta . Gross Calorific Value (GCV) of first cut material varies from 3200 to 4500 kcal/kg (without wash) and Hardgrov Grindability Index (HGI) is 39 un its. Cement Industries like Rishi Cement, UltraTech Cement and Subhra Chemical have tried Vedanta's SPL for use in their plants. Tearn also shared some global experience on usage of SPL, such as in ALBA (Aluminium Bahrainm, one of the largest industrial companies in the Middle East), ALCOA (Aluminum Company of America), EGA (Emirates Global Aluminium) and RUSAL (World's second largest aluminium company, with headquarter at Moscow). 12. Next presentation was made by NALCO, represented by Ms. Binuta Patra, AGM (Chern) R&D department and Mr. Abhijit Sinha, AGM (Met) SHE department. The annual quantity of SPL available at NALCO for disposal is approx. 4500- 5000 TPA. The major issues involved in the use of SPL were explained in the presentation, which included, non-availability of a cost effective technology for SPL treatment and disposal , regulations involved for transportation of the material to outside parties and storage of this material at their sites, reservations shown by other industries for acceptance of this hazardous and heterogeneous material and very high cost for co-processing in cement industries. NALCO Smelter has been issued Hazardous Waste Authorization, which allows them to co-incinerate carbon portion of SPL in their Captive Power Plant (CPP), but approval for trial run from CPCB and Odisha State Pollution Control Board is awaited since 2012. Issues associated with co-processing of SPL in Cement industry was also touched upon which mainly revolved around segregation , detoxification, high treatment cost, transportation etc. 13. Starting with the cement sector representatives, first presentation was made by Mr. Sanjay Jain, Asst. Executive Director, Dalmia Cement(Bharat) Limited , where he discussed the issues and constraints facing the co-processing of SPL in cement Industry. While highlighting the major challenges with regard to SPL co– processing , Mr. Jain mentioned that hardness and