Cement, Energy & Environment

• No idea about tests required and facilities required at site for testing Hazardous waste. • Storage of multi-grade/type solvent in single tank causing chemical reaction inside tank and increase in the tank pressure, resulting in venting of volatiles . • Re-cycling of spills-out material is a problem. • Spent solvents from different units have different organic contents . So storage at MF Station at Firing End limited tank space is a problem . Firing through Burner exposed. There is a separate firefighting system installed for this liquid wastes handling system. Commissioning and Operations Commissioning of system was successfully done in March'12. Study was carried out for emissions by third party (Vimta Labs) and samples were also sent to APPCB as per guidelines of CPCB, in addition to operational stabilization. During the trial run, the quality of clinker produced was monitored which was found to be unchanged, and tested for heavy metals, minor constituents that were found to be very well within limits. Problems Faced in Hazardous waste Co– processing: During the operation of the system, technical problems like pump failures with high viscosity solvents and seals failures, damage of burner lancers due to corrosion caused by solvents, hoses failure. Presently the system is operating smoothly and consistently. Other problems being faced are: • Solidification of solvent in storage tank. • No identification of types , grade, COD of solvents reaching the site by tankers. No details available in manifesto. • Low calorific value HW firing causing operational disturbance in burners and kilns. • Availability of solvent is irregular. • Problems with transporters regarding tanker condition, compatibility with system installed, and mixing and adulteration while transportation. • Odour at times from storage tank vent. Present Thermal Substitution & Achievments Presently the liquid wastes are consumed at the rate of around 900 MT per month. The average CV has been around 3500 Kcai/Kg . The maximum designed thermal substitution is 4%. During the year 2012 -13 , we had consumed 4290 Tons of solvents at a rate of 0.93% thermal substitution and it was equivalent to 3515 tons of coal. For the Year, 2013-14, we hope for a better TSR. WAY Forward The system is operated taking care of occupational health & safety of the employees and all interested parties. Safety systems are installed and are in place. Being a responsible and pro– active organization, we are exploring better systems through discussions with experts from Pharmaceutical industries and other suppliers for better odor control and to reduce hazards. The systems under consideration for better odor control are Activated Carbon Filters, Condenser with chiller Plant and scrubbers along with existing Nitrogen blanketing system. 2