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COMPREHENSIVE INDUSTRY DOCUMENT SERIES: COIN DS/6412006-2007

COMPREHENSIVE INDUSTRY DOCUMENT ON VERTICAL SHAFT KILN BASED MINI CEMENT PLANTS

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CENTRAL POLLUTION CONTROL BOARD (MINISTRY OF ENVIRONMENT & FORESTS) e-mail: [email protected] Website: www.cpcb.nic.in February 2007

COMPREHENSIVE INDUSTRY DOCUMENT SERIES: COINDS/64/2006-07

COMPRHENSIVE INDUSTRY DOCUMENT ON VERTICAL SHAFT KILN BASED MINI CEMENT PLANTS

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CENTRAL POLLUTION CONTROL BOARD (Ministry of Environment & Forests, Govt. of India) Parivesh Bhawan, East Arjun Nagar Delhi-110032 Website : www.cpcb.nic.in e-mail : [email protected]

CPCB 200 Copies, 2007

Published By: Dr. B. Sengupta, Member Secretary, Central Pollution Control Board, Delhi - 32 Printing Supervision & Layout: P.K. Mahendru and Mrs. Anamika Sagar Composing & Laser Typesetting : Mohd. Javed Printed at: DSIIDC Ltd.

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gufgurru Central Pollution Control Board (A Govt. of India Organisation) Ministry of Environment & Forests Phone : 22304948 / 22307233

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J. M. MAUSKAR,

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Chairman

FOREWORD The Central Pollution Control Board has published several industry specific documents, called Comprehensive Industry Documents (COINDS), envisaging the environmental issues and preventive measures. The present document on vertical shaft kiln based mini cement plants is in continuation of the series of COINDS. A Study was undertaken by Central Pollution Control Board through National Council for Cement and Building Materials, in which depth examination of selected vertical shaft kiln based mini cement plants was conducted. This Report provides detailed information on number of units in the country, their locations, capacities, manufacturing process, emissions generated, present status of pollution control measures and also the recommendations for abatement and control of pollution. This will enable the vertical shaft kiln based mini cement plants need to install proper pollution control devices and to operate them to achieve the intended objective of pollution control. I would like to express my sincere appreciation for the work done by the team of NCBM, headed by Dr. L.K. Janakiraman. I also appreciate the efforts made by my colleagues Sh. P.K. Gupta, Environmental Engineer and Sh. J.S. Kamyotra, Additional Director for coordinating and finalizing the Study under the guidance of Dr. B. Sengupta, Member Secretary, CPCB. We in CPCB hope the Study will be useful to the vertical shaft kiln based mini cement plants, regulatory agencies, research organizations and to all interested in pollution control.

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February,

2007

(J. M. Mauskar)

'Parivesh Bhawan C.B.D.-cum-Office Complex, East Arjun Nagar, Delhi-110 032

Fax': 22304948 / 22307078 email : [email protected] Website : http://www.cpcb.nic.in

CONTENTS

Page No. EXECTIVE SUMMARY

i — iii

1.0 INTRODUCTION 2.0 OBJECTIVES OF THE STUDY 3.0 GROWTH OF MINI CEMENT PLANTS 4.0

WORLD SCENARIO OF MINI CEMENT

2

5.0

COMPARISION OF LARGE AND MINI CEMENT PLANTS

3

6.0

CEMENT MANUFACTURING TECHNOLOGIES

5

TO

TYPES OF MINI CEMENT PLANTS IN INDIA

16

s.0

TYPES OF MINI CEMENT PLANTS IN CHINA

27

9.0

TYPES OF MINI CEMENT PLANTS IN COUNTRIES OTHER THAN CHINA AMD INDIA

2.7

10.0

OPERATION OF A CRI -MODERN VERTICAL SHAFT KILN

29

11.0

RAW MATERIALS AND THEIR CONSUMPTION FACTOR

34

12.0

ELECTRICAL ENERGY AND THERMAL ENERGY

34

13.0

FIELD STUDIES

35

14.0

EMISSION STANDARDS FOR CEMENT SECTOR

66

15.0

DUST COLLECTION SYSTEMS

67

16.0

SOURCES OF AIR POLLUTION

77

17.0

GUIDELINES TO CONTROL THE DUST EMISSION

79

LIST OF FIGURES

Page No. 7

Fig 1:

Fluid Bed Process

Fig 2 (a):

Material flow in Reba Process

10

Fig 2 (b):

Gas Flow in Reba Process

10

Fig 3:

Lurgi Sinter Grate

II

Fig 4:

Flow Sheet of Dry Process Rotary Kiln Cement Plant

13

Fig 5:

Flow Sheet of Black Meal Vertical Shaft Kiln Cement Plant

15

Fig 6:

General Arrangement - CRI Modem Vertical Kiln

17

Fig 7:

Flow Sheet of CRI - MVSK Cement Plant

19

Fig 7A;

Flow Sheet of 200 TPD Vertical Shaft Kiln of M/s Dalmia Cement (Bharat) Ltd.

23

Fig 7B:

Process Flow Sheet of M/S Saboo Tiny Cement Plant

25

Fig 7C

Flow Sheet of Dry Process Rotary Kiln Cement Plant

28

Fig 8:

Schematic of Gravity Settling Chambers

69

Fig 9:

Design Proportions of A Cyclone Dust Separator

70

Fig 10:

Longitudinal Section of Multicyclone

72

Fig 1 l :

Typical Bag House

74

Fig 12:

Wet Scrubber

76

LIST OF TABLES Page No. Table 1: Table 2: Table 3: Table 4: Table 5: Table 6: Table 7: Table 8: Table 9: Table 10: Table 11: Table 12: Table 13: Table 14: Table 15: Table 16: Table 17: Table 18: Table 19: Table 20: Table 21: Table 22: Table 23: Table 24: Table 25: Table 26: Table 27: Table 28: "Table 29: Table 30: Table 31: Table 32: Table 33: Table 34: Table 35: Table 36:

Status of Mini Cement Plants at a Glance as on March 31, 2001 Status of Mini Cement Plants at a Glance as on March 31, 2006 Global Survey of Vertical Shaft Kilns in Operation Operation Data on Vertical Shaft Kiln based on CRI -MVSK Technology Raw Materials Consumption Factor Electrical Energy Requirement Sections Causing Air Pollution for Plant 1 Stacks Emission Monitoring Results at outlet of APCD Other Stacks Emission Monitoring Results Ambient Air Quality Monitoring Results Chemical Composition of Raw Materials & Raw Meal Design Parameters of Air Pollution Control Devices Installed at Various Sections Capital and Operation & Maintenance Cost of Air Pollution Control Devices Noise Level Water Quality Sections Causing Air Pollution for Plant 2 Stacks Emission Monitoring Results at outlet of APCD Other Stack Emission Monitoring Results Ambient Air Quality Chemical Composition of Raw Materials & Raw Meal Design Parameters of Existing Air Pollution Control Devices Noise Level Sections Causing Air Pollution for Plant 3 Raw Materials Consumption Factor for Plant 3 Sections Causing Air Pollution for Plant 4 Raw Materials Consumption Factor for Plant4 Sections Causing Air Pollution for Plant 5 Raw Materials Consumption Factor for Plant 5 Sections Causing Air Pollution for Plant 6 Raw Materials Consumption Factor for Plant 6 Sections Causing_ Air Pollution for Plant 7 Raw Materials Consumption Factor for Plant 7 Sections Causing Air Pollution for Plant 8 Raw Materials Consumption Factor for Plant 8 Particulate Matter Emission Standards in India Section wise Suggested Dust Collectors

2 2 4 33 34 35 37 37 38 38 39 41 41 42 42 43 44 44 45 45 47 47 49 50 52 53 55 56 58 59 61 62 64 66 67 79

ANNEXURES Page No. Annexure- 1 Annexure- 2 Annexure- 3 Annexure- 4 Annexure- 5 Annexure- 6 Annexure- 7

81 137 139 141 143 145 147

List of VSK Mini Cement Plants Emission Data of Plant No. 3 Emission Data of Plant No. 4 Emission Data of Plant No. 5 Emission Data of Plant No. 6 Emission Data of Plant No. 7 Emission Data of Plant No. 8

EXHIBITS Page No. Distribution of Mini Cement Plants in India Exhibit-- I Flow sheet of Plant- 1 Exhibit 2 Location of Noise measurement Plant- 1 Exhibit 3 Flow sheet of Plant-2 Exhibit —4 Location of Noise measurement Plant- 2 Exhibit 5 Flow sheet of Plant-3 Exhibit 6 Location of Noise measurement Plant- 3 Exhibit 7 Flow sheet of Plant- 4 Exhibit 8 Location of Noise measurement Plant- 4 Exhibit 9 Exhibit 10 Flow sheet of Plant- 5 Exhibit 11 Location of Noise measurement Plant- 5 Exhibit 12 Flow sheet of Plant- 6 Exhibit 13 Location of Noise measurement Plant- 6 Exhibit 14 Flow sheet of Plant-7 Exhibit 15 Location of Noise measurement Plant- 7 Exhibit 16 Flow sheet of Plant- 8 Exhibit 17 Location of Noise measurement Plant- 8 —

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149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165

EXECUTIVE SUMMARY Presently in India there are 333 vertical shaft kiln (VSK) based mini cement plants of various capacities ranging from 20 to 300 tonnes per day (TPD) of various technologies set up in different parts of the country. The distribution is in the form of clusters. 2

Out of 333, only 193 VSK based mini cement plants are in operation having operating capacity of 3.47 million tones per annum.

3

Mini cement plant is basically air polluting industry. The air pollution is mainly in the form of particulate matter emission.

4

To assess the present environmental scenario of Indian Vertical Shaft Kiln (VSK) based Mini Cement Plants, a questionnaire was prepared and sent to 279 VSK Mini Cement Plants. The Mini Cement Plant clusters were divided into two regions namely southern region and northern region. Two plants from southern region and six plants from northern region were selected for the study. The two plants in A.P are based on CRI -MVSK technology having the installed capacity of 200 TPD with two VSKs of 100 TPD each. Six plants selected in Behror, Rajasthan are based on Saboo VSK Technology having the installed capacity ranging from 20 to 50 TPD.

5

In-depth study was pursued in eight plants. The data in these plants were collected with respect to history of the plant, manufacturing process and flowsheet, sources of air pollution, stack emission monitoring, analysis of particulate mater for particle size distribution, raw materials quality and its effect on air pollution, pollution control devices adopted and their design, economics, noise pollution etc.

6

The methodology adopted for collection of data and information includes: a)

Visit to VSK mini cement plants

b)

Discussion of various environmental related issues with the management.

c) Environmental monitoring was carried out for the following: i)

Ambient Air Quality in downwind and upwind directions

ii)

Fugitive dust at various working areas.

iii)

Stack emission: Stacks of VSK: Particulate matter, SO2 Stacks of Other Sections : Particulate matter

iv)

VSK flue gas analysis: Monitoring of 0 2 , CO 2 , CO and N 2

v)

Particle size distribution of particles emanated from VSK.

vi)

Noise monitoring near various processing equipment.

7. In plant no. 1 all the sections were provided with necessary pollution control devices. The particulate matter emission from raw mill, cement mill and VSK is 69, 86 and 348 mg/Nm 3 respectively. It was observed that by changing the raw mix design, the particulate matter emission from VSK can be brought down to 95 mg/Nm 3 .

Ambient air quality monitoring was conducted for RSPM, SPM, 50 2 and NO X in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO X in the up wind direction is 280, 641, 12 and 7 µg/m 3 respectively. The value of RSPM, SPM, SO2 and NO X in the Down wind direction is 310, 899, 14 and 8 µg/m 3 respectively. 8 In plant no.2, Air Pollution Control Devices were provided only in raw mill and cement mill sections. The particulate matter emission from raw mill, cement mill, VSK no. 1 and VSK no. 3 is 153 mg/Nm 3 , 67 mg/Nm 3 , 167 mg/Nm 3 and 73 mg/Nm 3 respectively. Ambient air quality monitoring was conducted for RSPM, SPM, 50 2 and NO in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO in the up wind direction is 142, 910, 7 and 6 µg/m 3 respectively. The value of RSPM, SPM, SO2 and NO in the Down wind direction is 275, 1205, 9 and 7 µg/m 3 respectively. 9. In plant no. 3, the average value of particulate matted emission from VSK is 119 mg/Nm 3 . Ambient air quality monitoring was conducted for RSPM, SPM, SO2 and NO in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO in the up wind direction is 151, 170, BDL and 34 µg /m 3 respectively. The value of RSPM, SPM, SO2 and NO in the Down wind direction is 194, 205, BDL and 65 µg/m 3 respectively. 10 In plant no. 4, the average value of particulate matter emission from VSK is 226 mg/Nm 3 . Ambient air quality monitoring was conducted for RSPM, SPM, SO2 and NO, in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO x in the up wind direction is 144, 507, 17, and 52 µg/m 3 respectively. The value of RSPM, SPM, SO2 and NO in the Down wind direction is 158, 674, 27 and 66 µg/m 3 respectively. 11 In plant no. 5, the average value of particulate matter emission from VSK is 370 mg/Nm 3 . Ambient air quality monitoring was conducted for RSPM, SPM, SO2 and NO in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO X in the up wind direction is 258, 454, 9, and 33 µg/m 3 respectively. The value of RSPM, SPM, SO2 and NO X in the Down wind direction is 415, 900, 12 and 61 µg/m 3 respectively. 12 In plant no. 6, the average value of particulate matter emission from VSK is 473 mg/Nm 3 . Ambient air quality monitoring was conducted for RSPM, SPM, SO2 and NO X in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO in the up wind direction is 121, 238, 15 and 116 µg/m 3 respectively. The value of

RSPM, SPM, SO2 and NO in the Down wind direction is 218, 452, 10 and 150 µg/m 3 respectively. 13

In plant no. 7, the average value of particulate matter emission from VSK is 112 mg/Nm 3 . Ambient air quality monitoring was conducted for RSPM, SPM, SO 2 and NO in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO,, in the up wind direction is 137, 410, 10 and 128 µg/m 3 respectively. The value of RSPM, SPM, SO2 and NO in the Down wind direction is 162, 426, 16 and 153 µg/m 3 respectively.

14

In plant no. 8, the particulate matter concentration at inlet and out let of dust settling chamber of VSK is 584 and 104 mg/Nm 3 respectively. Ambient air quality monitoring was conducted for RSPM, SPM, 502 and NO in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO in the up wind direction is 177, 967, BDL and 155 µg/m 3 respectively. The value of RSPM, SPM, SO 2 and NO in the Down wind direction is 289, 1313, BDL and 164 µg/m 3 respectively.

15

Few CRI -MVSK (Cement Research Institute of India - Modern Vertical Shaft Kiln) cement plants are having pollution control devices in all the sections while other technology based VSK plants are not having pollution control devices in all the sections. These plants are having only open type bags as pollution control devices in all the sections, which needs to be modified.

16

As a guideline following pollution control devices are suggested for various sections of VSK based mini cement plants subject to compliance of emission standards: a)

Crushing and raw materials proportioning section - Bag Filter.

b)

Raw mill section - Twin cyclone and Bag Filter

c)

Homogenising Silo - Bag Filter

d)

Nodulizer - Bag Filter

e) VSK stack - Cyclone

O

Clinker crusher and discharge section - Bag Filter

g) Cement mill and packing house - Bag Filter The above air pollution control devices are indicative in nature. Cement Plant may explore the possibilities of other devices also. The important thing which is to be kept in mind is that in all the cases the plant has to meet the prescribed emission standards.

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1.0 INTRODUCTION The capacity of a mini cement plant based on Vertical Shaft Kiln (VSK) technology is limited to 300 TPD or 99000 TPA and the capacity of a mini cement plant based on Rotary Kiln (RK) technology is limited to 900 TPD or 2,97,000 TPA (For the plant based on RK technology, the capacity has been enhanced from 600 TPD or 1,98,000 TPA to 900 TPD or 2,97,000 TPA vide notification no. 20/99 — Central Excise dated 7 May 1999). These plants are mainly based on vertical shaft kiln technology (VSK). At present there are 333 VSK mini cement plants of capacities ranging from 20 - 300 TPD of various technologies located in different parts of the country. During the various operation of cement manufacturing, dust is emitted which poses problem of air pollution. Majority of these plants are located in clusters in Andhra Pradesh, Karnataka, Madhya Pradesh and Rajasthan. Rests of the plants are distributed in the other parts of the country as shown in Exhibit — 1. 2.0 OBJECTIVES OF THE STUDY In the absence of definite techno-economic control devices, air pollution control in VSK mini cement plants could not be achieved at the desired level. The present technologies adopted by most of the plants are not adequate. Considering the above, it was decided to develop .a comprehensive industry document (COINDS) on VSK mini cement plants. The present study of VSK mini cement plant deals with manufacturing process, identification of sources of dust emission, stack emission monitoring, analysis of particulate matter for particle size distribution, air pollution control devices adopted, ambient air quality monitoring and section wise suggestions for dust control system. 3.0 GROWTH OF MINI CEMENT PLANT The prevailing scenario of acute cement scarcity in mid seventies with inadequate investment in this core sector, led to the Government policy for promotion of mini cement plants which could fulfill many objectives in addition to producing cement to meet the local needs. Taking into account various factors which were prevailing then, the Government of India came out with the policy for promotion / establishment of mini cement plants in early 1979. In addition to the several incentives and concessions offered by the Government for establishing mini cement plants, the policy also had laid stress on certain socio-economic objectives to be fulfilled in setting up the mini cement plants. As a result of the Government's encouragement backed by the technological support extended by the National R&D laboratories in the country, a number of mini cement plants came up in different parts of the country, mostly on conventional dry process rotary kiln and vertical shaft kiln technologies of CRI, Saboo & RRL, Jorhat. The first VSK based (30 tpd CRI -MVSK) mini cement 1

plant became operational in early 1981, whereas the first (200 tpd) mini cement plant based on rotary kiln technology went on stream in 1982. In addition, some VSK plants mostly in small-scale sector came up, whose plant and machinery were supplied by M/s. Shree Engineers, Jodhpur. Status of mini cement plants at a glance as on 31 March 2001 and 31 March 2006 is given in Table 1 and Table 2 respectively. Thus, it could be seen that during the Xth Five Year Plan, there has been an addition of 8 plants based on Rotary Kiln Technology, increasing the operating capacity from 5.96 MTPA to 6.4 MTPA. Number of mini cement plants in the country, installed capacity, location, year of commissioning of various technologies is listed at Annexure 1. Table 1: Status of Mini Cement Plants at a Glance as on March 31, 2001

SI. No.

Technology

1 2 3 4

Rotary Kiln CRI -MVSK RRL-VSK Saboo-VSK Total

Cement Plants Originally Set up In operation Nos. Installed Installed Nos. Production Capacity Capacity (MTPA) MTPA (MTPA) 4.003 31 24 3.411 2.388 101 3.354 30 1.179 0.825 31 0.286 1.378 202 3.449 78 0.689 365 11.092 132 5.968 3.902 -

-

-

Table 2: Status of Mini Cement Plants at a Glance as on March 31, 2006 Originally Set Up

Rotary kiln: 39 Verticlal Shaft Kiln: 333 Total 37 2

No. of Cement Plants Closed In operation

26 140 1 66

13 193 20 6

Operating Capacity (MTPA) 2.93 3.47 6.40

4.0 WORLD SCENARIO OF MINI CEMENT PLANT

The Chinese cement industry has seen a rapid growth over the last five decades. The production of cement was less than 3 Million tonnes in 1952, but in 1999 the total production of cement reached 573 Million tonnes. Thus, China, accounting for about one third of the global cement production ranks first in the world today in terms of cement output. The total installed capacity of the Chinese cement industry is estimated at 700 Million tonnes from over 7000 cement plants, which means that the average capacity of each cement plant is about 1,00,000 tonnes per annum. In China, K

the cement industry has a multiple ownership structure and a major part of the industry belongs to the Ministry of Agriculture under its Administration of Town and Village Industrial Enterprises (TVIE). The cement plants belonging to this sector are small and based on Vertical Shaft Kilns (VSK), which traditionally have consumed high levels of raw materials, fuel and power and therefore cause serious environmental pollution. During the last five years, there have been planned efforts to look at the energy and environmental issues of these plants with the help of international organizations like UNIDO, IVAM Environmental Research and University of Amsterdam. These international bodies have undertaken the study for cleaner production technology and energy conservation measures in these cement plants. As previously mentioned, the Chinese cement industry still uses the VSK process as its principal technology. However, in the last two decades, there has been the introduction of modern preheater and precalciner kiln systems at medium and large sized plants. The sum total effect has been the existence of a mix of technologies and there are now over 13,000 VSK plants in China. Currently, the modern large cement plants with precalciner technology cover less than 10 percent of the total cement output of the country. About 12 percent of the output comes from a plethora of small and medium size rotary kiln plants. The total output from the VSK plants constitutes about 78 percent. According to a regulation issued in 1997, the VSKs with a capacity of 44,000 tonnes per annum or less were to be discontinued by the end of 2000, barring only a few regions where the deadline is 2005. By the end of 1999, it had been officially reported that the VSK plants with an aggregate production capacity of about 20 Million tones per annum had been closed down. The production and distribution of Vertical Shaft Kiln (VSK) mini cement plants worldwide are given in Table 3. 5.0 COMPARISON OF LARGE AND MINI CEMENT PLANTS Cement is one of the most important building materials. The total cement production in the world reached 1950 million tonnes in 2003. A major percentage of this total production is from large-scale plants with capacities ranging from 2000 to 20,000 tpd and transported to the place of use in bulk or bags. Large capacity plants are appropriate for deriving the benefits from economies of scale in locations where: - - - -

Large enough deposits of the basic raw material i.e. limestonne is available. Infrastructural needs such as power and transportation system are sufficient. Cement consumption is substantially concentrated. Transportation costs are low 3

Capital-intensive technology is preferable from socio-economic considerations. Table 3: Global Survey of Vertical Shaft Kilns in Operation

SI Country

No. of VSK Cement Plants 1

No. of Active Kiln 2

Production X103 TPA) 100

-

-

-

3 Iraq

1

2

292

4

Bhutan 5 Indonesia 6 Lao Peoples Dem Rep. 7 Nepal

3

4

74

1

2

110

1

1

65

4

5

150

8 Germany 9 Italy 10 Slovak Republic

2 1

15 1

1200 60

1

4

150

5 1 107

20 6 221

1500 310 25202

-

-

-

-

-

-

1

2

200

-

-

-

-

-

-

-

-

No 9 Kenya

2

Brazil

-

11 France 12 Russia 13 China 14 USA 15 Australia 16 Madagaskar 17 European Union

18 CEMBUREAU 19 Central America 20 South America

400 400

-

Mini cement plants are appropriate for other areas particularly in cases like : - - - -

Small countries, which intend to develop their own cement industry to cater to their limited needs, thus becoming independent of imports. Large countries with low population density and/or low per capita cement consumption. Only scattered limestonne deposits, which cannot sustain large-scale cement plants, are available. Large cement plants cannot be set-up due to infrastructural constraints — specially hilly and remote regions. 4

Areas where local and regional market will absorb the production of a mini cement plant only and that industrial size plants could not operate at economic production rates. Socio -economic consideration justifies a Labour intensive technology rather than a capital intensive one. Mini cement plants have following advantages. - - - - - - - - -

Lowers capital investment per unit production without sacrificing quality of either the plant or the product. Helps realise quicker returns on capital invested because of lower gestation periods. Brings cement industry within the financial access of smaller entrepreneur and thus enlarge entrepreneurship in the country. Contributes to uplifting local economy and development as well as to formation of rural cooperatives as owners of cement plant. Creates employment opportunities in rural areas on a well dispersed basis Enables development of cement industry in terrains where movement of heavy machinery and cement are difficult. Makes it possible to exploit small deposits of limestonne as well as limited quantities of calcareous industrial wastes. Avoids wasteful movement and thus helps to bring down the average unit cost of transportation of cement in the country as well as strain on Nation's transportation system. Eliminates packing charges where the utilisation point is localised by resorting to bulk supply.

6.0 CEMENT MANUFACTURING TECHNOLOGIES

The various technologies, which have been tried for adoption in mini cement plant, are: i) ii) iii) iv) v)

Fluidized Bed Process (Fuller Pyzel) Reba Process Travelling Grate (Lurgi sinter grate) Rotary kiln and Vertical Shaft Kiln

In a nutshell, in all these five alternative schemes of technological lines, there is an upper and lower threshold of size beyond which either it is technologically not feasible or economically not viable. Down scaling of plants under any particular technology even within these threshold results in Increase in investment per annual tonne of installed capacity Increase in the cost of production per tonne.

5

So when the technical and economical threshold is reached for any given technology line, other technology lines may still give technically feasible and economically viable results. The conventional rotary kiln is normally uneconomical below 300 to 600 tpd and so the technology lines like Sintergrate and Reba evolved, but they could not succeed due to inherent defects. A brief process description for all these technological lines which were tried or adopted for manufacture of cement in small scale are given in the following sections: 6.1

Fluidised Bed Process

Of these the fluidised bed or Pyzel process is the least popular because the number of plants working on this process are extremely few even on global basis and not much is known except for some broad principles of working. This process, invented by Robert Pyzel, has been developed in USA by Fuller. A 100 tpd pilot plant based on this technology is reported to be in operation on experimental basis for the last six years with M/s. Scientific Design Company, New York, USA. (Fig. 1) 6.1.1 Process Details

The plant consists of a fluidised bed reactor; raw meal consisting of finely ground feed mixture is pneumatically conveyed to the fluidised bed alongwith fuel and preheated air. The temperature of the fluidised bed is maintained at approximately 1315°C by introducing the fuel directly into the fluidised bed. Cement clinker being almost refractory, coarse clinker particles of 0.8 to 8 mm can be maintained in granular form in suspension, when finely ground raw mix is pneumatically blown in, raw cement phases are formed on the hot surface of characteristically round clinker particles, so that they grow in size continuously. The Specific heat consumption reported without any heat recovery system is 2600 Kcal/kg of clinker and with heat recovery system 1046 Kcal/kg of clinker. Energy requirement for production of clinker alone by the fluidised bed reactor is 55 Kwh/t as against 20-25 Kwh/t of clinker in case of rotary or shaft kilns. Fuels like gas, oil, coal, anthracite and coke could be used in this process. This process stands a good chance for a promising market in USA as there are very strict environmental protection specifications regarding oxides of sulphur and nitrogen. At the same time special `low alkali' cement specifications

0

-•-

HOT KILN GAS

SIZE RECYCLE CLINKER

REFRACTORY LINING

CLINKER OVERFLOW

CARBON STEEL SHELL

CAST REFRACTORY PRE HEATED AIR

AIR PLENUM

RAW FEED FUEL

FIG. 1

FLUID BED PROCESS

7

necessitate the rejection of large quantity of dust in rotary kiln burning operation. This dust with high alkali content can be used as a cement raw mix in the Pyzel reactor. The specific advantages of Pyzel process have been claimed where there is (a) high alkali problem; (b) strict environmental protection regulations regarding oxides of sulphur and nitrogen from exit gases; (c) disposal problem of kiln dust with high alkali content; and (d) using different fuels like gas, oil, coal, anthracite and coke. The high investment cost for the heat recovery systems and stringent controls through an elaborate instrumentation and automation and non-availability of highly skilled personnel for the operation of the reactor, go against the very philosophy of mini cement plant. Due to the inherent technological problems in stabilising the operation of plants based on the above process and also due to the reported high investment cost per annual tonne of installed capacity, mini cement plants based on the above technology have not been reported to be a commercial success anywhere in the world. 6.2 Reba Process

In this process, the feed operation requires crushing of limestonne to — 15 mm size, storing in bays/bins, proportioning of raw materials and final grinding in a roller/ball mill, homogenisation of raw meal and storage. The fuel used is oil or gas. The homogenised raw meal is fed to a noduliser where nodules are formed with addition of water and are then fed to a combustion chamber. The nodules are dried in the preheating zone and heated in the calcining zone to about 1100°C. The granulated material is then sintered at about 1450°C and cooled in the shaft cooler. The flow of gases is in opposite direction to flow of material and thus air used to cool the clinker heats up and is used as secondary air together with primary air when burning the fuel. Reba process has not so far been operated on solid fuel, i.e. coal and as such no operational data are available on such applications. It was claimed by the firm M/s. Ready Mix Cement Engineering of FRG that the Reba Kiln installations for production of cement in the range of 50-200 tpd still have low investment costs and less energy consumption. The heat consumption is estimated to be approximately 730 Kcal/kg of clinker. Furthermore, the electrical energy consumption should correspond to that of rotary kilns. The energy consumption for burning of materials alone is claimed to be 14 Kwh/t. It is understood that the Reba process has been tried successfully only for burning of lime and the firm is yet to establish the technology for burning of cement clinker on a commercial basis. Further, the quality of limestonne and fuel tried are of very rich quality, i.e., very high percentage of lime in limestonne of the order of above 52% and coal with every low ash content (10%) and high calorific value and till date the technology has not been proved using cement grade 8

limestonne and coals with high ash content. No commercial plants are known to be in operation in the world on this technology. (Fig. 2) ,

6.3

Travelling Grate (Lurgi Sinter Grate)

In this process, the feed operation requires crushing of limestonne to — 15mm size in a crusher/mill, storing the materials of —15 mm size in gantry/storage bins, proportioning of raw materials and final grinding in closed circuit ball mill/roller mill, homogenisation of raw meal and storage, crushing and screening of coal to —5 mm size in closed circuit operation and storing of crushed coal in bin. The raw meal and crushed coal are then extracted from respective bins according to requirement and conveyed to a drum type nodulizer. In addition, the noduliser is also fed with 15% of —5mm size burnt clinker to form core of nodules and 15% water spray. The nodules are conveyed by a belt conveyor to moving sinter bed made of cast iron grate base. A 75 mm thick layer of + 5 mm and —10 mm burnt clinker is first spread over this bed and then the fresh nodules fall over this. The sinter bed passes through various zones over some distance where suction is maintained through ID fan. Light diesel oil is fired over the bed in hood fixed about 200 mm above the bed height and the resulting clinker is discharged through a rotating arm type breaker in red hot condition over an open pan type horizontal conveyor where it undergoes cooling. (Fig. 3) 6.4 Small Rotary Kiln

Here the kiln feed and fuel preparation requires crushing and grinding operations, like: Crushing of limestone and additives in a hammer mill or 2-stage, viz., jaw - crusher and hammer mill to —15 mm size. Storing the crushed raw materials in storage yard/bins. - Proportioning and grinding the raw materials in a roller/ball mill. - Homogenising and storage of raw meal in blending and storage sections. - Fuel, viz, coal (VM 25-30%) is pulverised in a separate section (combined - coal drying-cum-grinding section). Blended and homogenised raw meal is then fed to the suspension preheater of counter current type, where it is preheated and partially calcined by the kiln hot gases passing in counter current. Raw meal enters the kiln at a temperature of 700°C - 800°C. The exit gases from the preheater are then passed through the dust collection system and discharged to atmosphere. Dust collected is recycled. Pulverised coal mixed with primary air is fired from the lower end of the rotary kiln through coal burners. Secondary air is supplied through clinker cooler to make up for the combustion air. A flame at around 1660°C is maintained. This heat

er



GRANULATING TABLE

CHAMBER-2 PREHEATING SHAFT GRATE

GRATE CALCINATION ZONE GRATE

UPPER PUSH CAR SINTERING ZONE

GRATE LOWER PUSH CAR

CLINKER COUNTER CURREN SHAFT COOLER COOLER DISCHARGE

HG. 2(a) MATERIAL FLOW IN REBA PROCESS

EXHAUST GAS

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EXHAUST o

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FAN -CALCINATING ZONE

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FIG. 2(b) GAS FLOW IN REBA PROCESS 10

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11

the material as the kiln rotates at 1 to 2 rpm. Various chemical reactions (Calcination, sintering, cooling) takes place as the material temperature goes upto 1440°C. Hot gases having transferred the heat to material escape in counter flow i.e. from lower- end to upper end through suspension preheater and dust collectors to atmosphere. Clinker is discharged into clinker cooler, which may be rotary, planetary or moving grate type. Clinker is then transported to storage yard and finally ground with gypsum. Control is maintained through various control instruments and inspection of burning conditions. (Fig. 4) 6.5

Vertical Shaft Kiln

The use of vertical shaft kiln process for cement manufacturing dates back to the year 1824 when Portland cement was invented. However, because of its noncontinuous operation, this process was found uneconomical and produced clinker of non-uniform quality. Later after the development of continuous pan type noduliser, a significant advance was achieved and the shaft kiln performance improved considerably thus permitting its adoption and production of uniform quality of clinker on a continuous basis. Cement manufacture by using Modern Vertical Shaft kiln is reportedly being carried out in different countries like China, India, West Germany, Australia, Italy, Indonesia, Nepal, Bhutan etc. In fact, a wide variety of processes have been adopted for the manufacture of cement through Vertical Shaft Kiln and it would be desirable to mention some of these in the following sections. 6.5.1 Black Meal Process

This is the most popular type of process used for manufacture of cement through Modern Vertical Shaft Kiln in which the fuel (usually low volatile coal or coke breeze) is interground with the raw mix for efficient and uniform burning. Most of the cement plants using Vertical Shaft Kiln like CRI — Modern Vertical Shaft Kiln, Vertical Shaft Kiln supplied by M/s. Loesche of West Germany etc are mainly based on the black meal process. In this process, the vertical shaft kilns are fed with raw mix of appropriate composition in the form of nodules. The feed operation usually requires crushing of limestonne to about -15 mm size in storage bins, proportioning of raw materials and grinding in a roller or ball mill, homogenizing and nodulizing in pan type nodulizer. The successful operation of shaft kiln, to a great extent, depends upon the size of nodules, their uniformity, porosity and thermal stability. The noduliser consists of an inclined disc or pan rotating about its axis. Raw meal is charged into noduliser by means of screw conveyor and water is sprayed, while all the parameters are maintained at optimum conditions. A specially designed rotating scraper continuously cleans the bottom and the collar of the drum of the raw meal deposited. The nodules slide down the chute and are •charged in the

12

AIR LACK FEEDER

SECONDARY AIR BLOWER

CEMENT MILL

CYCLaN

BUCKET ELEVATOR

LOADING 1

BAGGING R BRANDING

FIG. 4 FLOW SHEET OF DRY PROCESS RBTARY KILN CEMENT PLANT 13

vertical shaft kiln evenly all around the periphery continuously with the help of a rotary feeder situated on the top of the kiln. The vertical shaft kiln in which the nodules are converted into clinker consists of a cylindrical shell with conical portion at the top and lined with refractory bricks. The sintering is normally complete within the conical portion, which is specially designed to accommodate for shrinkage of nodules. The various zones of reaction starting from the top of the kiln are; the drying zone, the calcining zone, the sintering zone and the cooling zone. The combustion air supplied by Roots blower ascending from below in the cooling zone absorbs heat from the descending clinker. The whole kiln charge composed of unburnt nodules and clinker rests on a flat grate rotating slowly at the bottom of the kiln and mounted over the kiln shaft. The grate is driven with the help of variable speed motor in order to control the discharge rate of clinker. The clinker is finally taken out of kiln bottom with the help of a triple air lock mechanically (or hydraulically) operated discharge gates or Gamma Ray controlled Material Block Tube System used in Modern Vertical Shaft Kilns. (Fig. 5) 6.5.2 Coal Slurry Process A variation of the Black Meal process as proposed by Dr. Steven Gottlieb is `Coal Slurry Process' the main difference being in the method of feed preparation. The method requires the raw meal to be ground `white', i.e. without fuel. The fuel (coal with volatile matter upto 16-18%) is ground separately in a wet ball mill to make slurry with about 50% moisture. The 'white meal' and the `coal slurry' are separately stored in hoppers over the noduliser platform and are pumped at controlled rates (through flow meters) into a double paddle mixer to mix the feed continuously and discharge into the standard noduliser where practically no or very little water is added to give final shape to the nodules. These nodules are charged and burnt in the vertical shaft kiln in the same manner as in the case of "Black Meal' process. The main advantage claimed by this process is that by wetting of the coal particles before nodulising, the retention time for the volatile component of the fuel is increased, thereby allowing this to travel to a zone where adequate oxygen is available to complete the combustion of the volatile matter within the bed — thereby permitting a higher volatile content in the coal when compared to that used in the 'Black Meal' process. 6.5.3 Differential Heat Burning Process This process, which is a slight variation of the black meal process, has been reportedly tried out in a number of cement plants in China. In this process about 50% of the total fuel required is interground with the raw meal and the balance is added later prior to nodulisation. This has been based on the assumption that the heat requirement at the periphery of the bed in a VSK is usually more by

14

WEIGH BRIDGE ADDITIVE

LIMESTONE

STORAG

E

HOPPER HOPPER HOPPER HOPPER TABLE ^ TABLE TABLE TABLE FEEDER FEEDER FEEDER FEEDER

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BUCKET ELEVATOR

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RAW MEAL STORAGE

1jJ

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SCREW CONVEYOR NODULISER

EXHAUST

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VERTICAL SHAFT KILN

ROOTS BLOWER

CLINKEI

TABLE I HOPPER FEEDER CEMENT

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BUCKET ELEVATOR

LOADING

IG. 5

WARE

PACKING &

HOUSE

BRANDING

FLOW SHEET OF BLACK MEAL VERTICAL SHAFT KILN

CEMENT PLANT 15

about 150 kcal/kg of clinker than that in the middle and in this process some additional fuel is added at the periphery of the bed as compared to that in the middle to balance the heat distribution. 7.0 TYPES OF MINI CEMENT PLANTS IN INDIA 7.1

CRI — Modern Vertical Shaft Kiln Technology CRI — Modern VSK technology was pioneered in India by Cement Research Institute of National Council for Cement and Building Materials as early as 1972 and was first tried out in 1974. General arrangement of CRI- Modern Vertical Shaft Kiln is shown in Fig. 6. The CRI — Modern VSK cement plant as a compact unit incorporates the following salient features: a) b)

c)

d)

e) f)

g) h)

i)

j)

k)

A hopper with ramp and reciprocating/laminated feeder has been provided to ensure continuous feed of uncrushed limestonne to primary crusher. Crushing section usually consists of two stage crushing, Jaw Crusher as primary and Hammer Mill as secondary one. This will ensure better mill performance due to uniform feed to the raw mill. Continuous, automatic and accurate raw materials extraction for proportioning by rotary table feeder/vibratory feeder, with electronic weigh feeder as an optional feature. Conventional closed circuit air swept ball mill system with trunion and girth gear arrangement with grit separator, cyclone and bag filters for grinding of raw materials to ensure the desired granulometry of raw meal resulting in proper burning. Differential (HP & LP) pneumatic blending with quadrant system reduces the variation to 1:10 within the smallest possible time. Specially designed Double Collar Noduliser with automatic closed loop control results in nodules of higher green strength due to extra rolling action and desired size, porosity and moisture content. Continuously operated rotary feeder drive with adjustable tilt angle and adjustable height in order to achieve the desired bed profile in the MVSK. Material Block Tube along with `Gamma ray level control device' for clinker extraction from the MVSK has the advantages of less air leakage, less dust and noise, lower maintenance and more efficient burning process due to reduced fluctuations in the combustion air supply. Improved instrumentation system has been provided to monitor all important process parameters on a continuous basis. All major system parameters are indicated and recorded. Fully equipped laboratory for physical testing and chemical analysis as per requirements of BIS. Provision for optimum raw mix design also exists through CRI -MVSK raw mix design software. In order to improve the burning process inside the VSK and to achieve higher output and better quality of product, automatic closed loop process control has been incorporated in the noduliser and VSK section.

16

SP

MATERIA WITH GAMMA

=R

UrU v ilw ARRANGEMENT

GENERAL ARRANGEMENT CRI MODERN VERTICAL SHAFT KILN FIG. L 17

I)

Safety measures including carbon-monoxide alarm system and electrical interlocking of drives have been provided in order to protect the manpower and equipment which include a special alarm for combustion air failure to prevent any flame shoot out due to carbon-monoxide formation. m) Dust collection system with stacks is incorporated in all the sections like crushing, raw mill, blending, cement mill and cement packing which will ensure a very clean and dust free environment in the CRI -MVSK cement plant. In addition, modern and proper dust collection arrangements at all transfer points including proper ventilation of tunnels and a specially designed low cost dust limitator in the MVSK chimney have been provided.

A typical flow sheet for mini cement plant based on CRI- Modern Vertical Shaft Kiln is shown in Figure 7. The process is explained below: CRI -MVSK technology is based on the black meal process in which all the raw materials, viz, limestonne, clay fuel (coke breeze, pet coke, Jhama coal or any suitable low volatile coal) and other corrective materials are ground together to a fineness of 10% retained on 170 mesh as in dry process and intimately blended to satisfy the chemical requirements for the raw meal. The homogeneous raw meal is formed into nodules of the desired size by adding water in a pan nodulizer and fed into the vertical shaft kiln through a revolving feed hopper. As the material passes down the kiln, it is dried heated and then burnt into clinker. The clinker is then cooled and discharged from the kiln by a rotary grate at the bottom of the kiln through a triple air lock discharge device or gamma ray controlled Material Block Tube (MBT). The combustion air to the kiln, which is provided by a Roots blower, also serves the purpose of cooling the clinker and thus avoids wastage of heat. The clinker then passes to a cement mill where it is ground with about 5% gypsum to produce cement of standard quality. }

7.2 RRL Technology Regional Research Laboratories (RRL), Jorhat constituent laboratories of Council of Scientific and Industrial Research (CSIR), has also done considerable work on the development of Vertical Shaft Kiln Technology under Indian conditions. About 5 plants based on RRL technology are operating in India and about 10 plants are under various stages of erection and commissioning. Out of these plants only one is of 100 tpd capacity and the remaining are of 40 tpd and smaller sizes. This technology could not become very popular as RRL, unlike NCB, does not directly associate with the project right from the inception to the commissioning stage and the licenced fabricators/consultants could not effectively manage the turn-key supply, erection and commissioning of such plants. The details of RRL Technology are not available since even a single plant is not in operation.

18

THIS DRAWING IS PROPERT OF NATIONAL COUNCIL FOR CELTENT A4O BUILDING MATERIALS. AND ITS COPY RIGHTS SOLELY WITH NCB.. IT SHOULD NOT BE COPIED. REPRODUCED. LOANED OR DISPOSED .. OF WITHOUT WRITTEN PERMISSION OF N C B.

-'

7.3 M/S Dalmia Cement (Bharat) Ltd.

A mini cement plant of 170 tpd based on the Gottlieb Coal Slurry Process is presently under operation in India at M/s. Dalmia Cement (Bharat) Ltd. at Dalmiapuram. Although the production of cement from the plant is reported to be satisfactory, the plant has not been able to achieve the advantage of using the high volatile Indian coal used by other rotary kiln cement plants and is reported to be using low volatile coal/coke breeze as being used by other VSK plants in India based on the black meal process. Thus the additional investment incurred by the plant due to separate coal slurry grinding and handling system has not given the expected returns. 7.3.1 Process

A 200 tpd vertical shaft kiln was installed at M/s Dalmia Cement (Bharat) Ltd, Dalmiapuram during 1982 and it is now working satisfactorily. This VSK is operating on 'coal-slurry' process. It is an imported technology supplied by Dr. S Gottlieb of Australia. A detailed study of this VSK starting from quarry to cement stage is explained below. 7.3.1.1 Quarrying and Crushing

The limestone is being brought from open cast mines — Kallakudi, Vadugarpet, Kovandakurichi and Perianagalur by means of locos and lorries. The limestone will be dropped into the hopper by means of winches or electrical hoist depending upon the case. The uncrushed limestone will be fed into Double Swing Hammer Mill, supplied by. FLS., Copenhagen, through a laminated conveyor. This mill is being driven by 2 HT motors (3.3 KV). The crushed limestone will be carried by means of inclined belt conveyor to the limestone storage yard. 7.3.1.2 Raw Mill

The crushed limestone, clay and additives if required will be fed into the respective hoppers by means of EOT crane. These raw materials through the weigh feeder dropped into `Loesche' mill which is supplied by West Germany. The capacity of the mill is 52 tonnes per hour. This mill is consisting of 2 rollers kept over a moving thick metallic pad. The raw materials come in between the moving pad and the rollers will be ground to the required fineness. These rollers can be moved up and down by means of hydraulic pressure. The white meal thus produced in this `Loesche' mill will pass through ESP and this will be fed into the top of the blending silo of the double decker silo by means of flexo pump. The corrected white meal will be dropped into the storage silo. The white meal from the storage SP 10 will be pumped into VSK hopper through Flexo pump. The capacity of this hopper is 400 tonnes. The white meal will be fed into the boot of an elevator by means of double screw conveyor. The output

of the elevator is fed into the sieve screw conveyor. The capacity of elevator is 17 tonnes per hour and the capacity of sieve screw conveyor is 15 tph. The foreign bodies will be removed in the sieve screw conveyor. The output of the sieve screw conveyor will be fed into the weigh feeder where the quantity of white meal will be weighed and fed into double shaft paddle conveyor. The rate of white meal feeding is 11 tph. A special provision is provided underneath the weigh feeder so that 95% of white meal will go to double shaft paddle conveyor and the remaining 5% of white will be used for surface conditioning in the noduliser. 7.3.1.3 Coal Mill

Single chamber tubular mill is used in M/s DCB Ltd, Dalmiapuram for coal grinding. The capacity of this mill is 8 TPH. 50% coal or coke breeze and 50% water will be fed into this mill. The output of this coal mill is called 'coal slurry' which will be fed into the storage tank 'T 1 '. This coal slurry will be transferred from tank 'T 1 ' into tank `T 2 ' by means of pump. The capacity of tank 'T2' is 60 to 80 tonnes. From the tank `T 2 ' the coal slurry is fed into the tank `T 2 A', situated at a height of 8.6 m from the ground, by means of an elevator. From the tank `T 2A', this coal slurry is pumped into tank 'T 3 ' ( called constant level tank) situated at a height of 23.7 m from the ground by means of pump. From tank `T 3 ' the coal slurry will be fed into double shaft peddle conveyor. The white meal and the coal slurry will be thoroughly blended by means- of the paddles of the double shaft paddle conveyor. This slurry will be fed into the noduliser drum. 7.3.1.4 Noduliser

Controlled amount of water will be added and the pellets will be formed in the drum. The size of the pellets is 10 to 16 mm. There is a provision provided for the white meal coating — surface conditioning — over the pellets. 7.3.1.5 Rotary Feeders

Thus the pellets formed in the noduliser drum will be fed into the kiln through rotary feeder. This is imported equipment. This rotary feeder can be moved up and down and also left and right side by operating the controller. The nodules will be distributed uniformly in the kiln. 7.3.1.6 Vertical Shaft Kiln

These nodules are thus distributed uniformly in the kiln and the kiln is kept changed to a constant level and operates continuously. The material is first dried in the enlarged upper portion and then falls slowly to the narrow portion. Decarbonisation takes place at about 950 ° C and the final burning of the clinker

21

takes place at 1450 ° C. The clinker thus formed will be cooled in the lower part of the kiln before it reaches the discharge gate. The clinker is discharged through a rotary grate and a discharge gate. 7.3.1.7 Rotary Grate By adjusting the speed of rotation of the grate, the amount of clinker discharged and thus the rate of burning can be controlled. The type of grate is flat grate. This grate consists of 6 segments of opening size 95 x 95 mm, 7.3.1.8 Discharge Gate The discharge gate is provided with a triple gate air lock mechanism to prevent loss of drought and production of dust. The discharge is automatic and the parts of which are actuated hydraulically. The rotary feeder, discharge gate mechanism and the king shaft assembly are all imported equipment and their total cost is approximately one crore. 7.3.1.9 Blower The air required for combustion is supplied by means of 2 blowers driven by 75 kw motors. One blower will be always running at constant speed and delivering air at the rate of 125 Nm 3 /min constantly. The other blower is driven by a viable speed motor, whose quantity of air can be varied from 26 Nm 3 /min to 100 Nm 3 /min. The air requirement for this VSK (at DCB) is 187 Nm 3 /min. 7.3.1.10 Cement Mill Thus the clinker formed in VSK will be fed into the vibrating screen I. From there this will go to clinker yard through vibrating screen II. This clinker will be fed in to the cement mill hopper by means of EOT crane. Clinker and gypsum will be fed into the 3 compartment tubular mill where these materials will be ground and the output of this mill be fed into the cement silos through flexo pump. Earlier Dalmia Cement (Bharat) Ltd, provided a clinker crusher underneath the discharge gate and now they removed it since there is not much of lumps. The flow sheet of 200 tpd VSK of M/s Dalmia Cement (B) Ltd is shown at Fig. 7A. 7.4 Tiny Cement plants In India, any industry for which the cost of plant and machinery does not exceed Rs 1,46,00,000 comes under the definition of `Small Scale Industry (SSI)' and is offered certain concessions. Keeping this primarily in view, certain individuals / small organisations have downscaled the VSK technology so as to offer such plants under the SSI. Such plants are in the size range of 5 to 20 tpd and are

22

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popularly known as Tiny Cement Plants. In this direction, an individual called Mr. D.P. Saboo of Jodhpur in Rajasthan has put in considerable efforts, and has put up about 25 nos. of such tiny plants; most of these being based on high grade limestonne deposits in the state of Rajasthan. The investment cost in such plants have been brought down by resorting to in-house fabrication of machinery as well as by elimination of certain equipment from the process line and resorting to manual operation. However, unfortunately, the tiny cement plant concept in India has taken a dangerous turn with a large number of other individuals/spurious organisations having entered the field of fabricating and supplying these plants, which are in fact poorly copied version of certain proven technologies without the provision of requisite technical back-up. This has already resulted in setting up of a few such tiny cement plants, which have since become sick and have discontinued production. Brief Process of Manufacture of Portland Cement from Saboo VSK Tiny Cement Plant is given below. Limestone, Breeze Coke, Clay (Red-burning clay of Village Potters) and other additives, as required, are crushed and stored automatically in different silos, wherefrom they are again taken out in the desired proportions by a weighbatcher. They are further conveyed to a pre-blender and the blended materials are thoroughly ground in an open-circuit Ball Mill to form homogenized Raw Meal, from where it is conveyed through an elevator to blending silos and later to a storage silo. This raw meal is subsequently lifted to the hopper of a noduliser, where nodules are formed. These nodules travel downwards into the kiln through a Rotary Chute and find an access to the pre-heating zone followed by calcinations and clinkering zones, wherein drying, pre-heating, calcining and sintering take place, leading to conversion of nodules into clinker. This clinker, as received from the kiln through the cooling zone, is subsequently mixed with gypsum in suitable proportion for further grinding in the cement mill to produce the finished product, i.e pure Portland Cement. The flow sheet of Saboo VSK Tiny Cement Plant is shown at Fig. 7B. 7.5 J & K Cements, Wuyan This 60-tpd plant is based on Lurgi Sinter Grate Process. This requires use of light diesel oil as a fuel in addition to the low volatile coal already contained in the nodules. The cement production at the plant has never exceeded 55% of the installed capacity. The cost of fuel is as high as Rs 700 per tonne of clinker. Apart from the high cost of production, the plant also finds it difficult to cope with frequent breakdowns and quite involved maintenance is required due to complicated machinery. The electrical energy consumption per tonne of cement

24

DAw kirAl VAfn

MILL BUCKET ELEVATOR STORAGE SILOS WEIGH BATCHER

BUCKET ELEVATOR

RAW MILL (OPEN CIRCUIT BALL MILL) BUCKET ELEVATOR BLENDING SILOS BLOWER

BUCKET ELEVATOR

RAW MEAL SECTION



SCREW CONVEYOR

SURGE SILO WATER SURLY

SCREW CONVEYOR Cat?



NODUUZER

SABOO V S K

GYPSUM

KILN SECTION BLOWER

CLINKER YARD

CEMENT MILL SECTION

CEMENT MILL(OPEN CIRCUIT BALL MIIL)

LrING L 0 0

I

• WEIGHING • NOT SUPPLIED

FIG.7B PROCESS FLOW SHEET M/s SABOO TINY CEMENT PLANT

25

produced is as high as 208 Kwh. The heat consumption per kg of clinker production is also as high as 2404 Kcals. Although the quality of the cement produced by this process is 'reported to be meeting all the specifications well, the working of the plant and its profitability has all along been headache for the plant management. Due to the above constraints, the plant management has ultimately decided to discard the complete sinter grate system and have placed an order for CRI — Modern Vertical Shaft Kiln along with the necessary balancing equipment to replace the existing system. This clearly shows that the sinter grate technology has failed to be a techno-economically viable solution for the manufacture of cement in small scale. Since the above plant is not in operation for the last 1 1/2 decades and also the equipment are obsolete in nature, plant is not able to provide data in this regard. 7.6

Small Rotary Kilns

Use of small rotary kilns has been adopted by many countries for cement manufacture in small scale by downscaling the conventional rotary kilns. In India, there are about 31 nos. of rotary kiln based mini cement plants under operation and about another 5 nos. under implementation; most of these being designated as 200 tpd in order to derive incentives offered by the Government of India in terms of rebate in excise duty (which has since been discontinued) and a free market. However, most of these plants are using kilns of 3 m dia and 40 or 45 m length — which under Indian conditions are rated as 300 tpd. One of the major reasons for this has been the fact that the machinery fabricators/consultants did not find it technically appropriate to further reduce the kiln dimensions in view of anticipated problems relating to higher refractory failure. Thus, although a few mini cement plant based on the rotary kiln technology have been set up in India as well as other countries of the world, mainly because of the reason that this technology is a direct down-scaling of the conventional rotary kilns which are technically well established, the cost of production and the investment cost per annual tonne of installed capacity in such plants are found to be exceptionally high due to the scale effects. Moreover, if one attempts to make these small rotary kiln plants economically viable, then certain process and operations have to be eliminated and the degree of sophistication of instrumentation and process control systems would have to be lower which would amount to sacrificing some of the modern features which are essential for satisfactory performance and economic operation. Due to the inherent technoeconomic disadvantages of mini cement plants based on rotary kiln as compared to those based on Modern Vertical Shaft Kiln — like higher investment cost, higher operating cost, higher energy consumption, higher pollution etc; the Government of India, as a matter of policy, is not encouraging any further setting up of mini cement plants based on rotary kiln technology.

26

The process flow sheet of Small Rotary Kiln is shown in Fig. 7C.

8.0 TYPES OF MINI CEMENT PLANTS IN CHINA China uses minor variations in the process with the vertical shaft kiln technology. There are some plants which use black meal process as in India, there are others which use semi-black meal process in which only a part of the total coal required is interground with the raw meal and the balance is added in coarse fraction later prior to nodulisation. Some plants use compound mineralizers also for lowering the firing temperature. Different types of discharge grates have been used in the vertical shaft kiln, like roller grate, flat grate, conical grate, reciprocating grate etc. Non-mechanised kilns use stationary grate. Since the Chinese plants, because of this design and operational features, emit sizeable amounts of dust, dust collection equipment like electrostatic precipitators, bag filters, etc. is being installed. The smallest and the largest sizes of mechanized vertical shaft kilns in China have diameters of 1.7 metres and 3.6 metres producing about 35 tonnes per day and 300 tonnes per day against design capacities of 45 tonnes per day and 380 tonnes per day respectively. A number of mini cement plants in China have been facing problems of nonuniform cement quality, poor management and operational skills, higher cost of production, high heat consumption, environmental pollution, etc. The Government of China has therefore decided to slowly disband the old nonmechanised plants numbering about 2000 and take up modernization of those plants which can produce cement of good quality through mechanization (at the rate of about 300 plants a year).

9.0 TYPES OF MINI CEMENT PLANTS IN COUNTRIES OTHER THAN INDIA AND CHINA Although the latest information regarding the exact number of mini cement plants operating in different parts of the world are not available. Table 3 shows a global survey of vertical shaft kilns under operation in different countries. So far as mini cement plants based on CRI -MVSK technology are concerned, M/s. Penden Cement Authority of Bhutan, have installed a 50 tpd CRI -MVSK plant at Gomtu and later expanded it to 100 tpd by installation of another 50 tpd CRI -MVSK line. One more cement plant of M/s. Lakhi Cements Pvt. Ltd. 100 TPD CRI -MVSK cement plant installed at Gomtu, Bhutan. One mini cement plant of 160 TPD capacity based on Vertical Shaft Kiln of size 2.4 metre dia and 8-metre height supplied by M/s. Loesche, West Germany is already under operation at the works of M/s. Himal Cement Company, Nepal. Another mini cement plant of 30-tpd capacity based on CRI -MVSK is presently in operation at Anboo-Khaireni in Nepal. This plant purchased 100 TPD (2x50 TPD) CRI -MVSK cement plant of Penden Cement Authority and expanded upto 200 TPD.

27

WE HOUSE

BAGGING & BRANDING

FIG. 7C FLOW SHEET OF DRY PROCESS ROTARY KILN CEMENT PLANT

28

M/s. Loesche of West Germany have supplied more than 14 mini cement plants based on black meal VSK process in more than nine countries. The first multiple VSK plant supplied by M/s. Loesche had gone into operation in 1955 at the cement plant of M/s. Portlandzemtnfabrik Blaubeuren Gebr. Spohn Ag at Blaubeuren, Germany. Later on M/s Loesche have supplied plants based on VSK to various countries like Japan, New Zealand, Austria, Spain, Italy, Nepal, Brazil, Madagascar and Indonesia. In the latest design of 400 tpd (2x200 tpd) plant at Kupang in Indonesia, pre-blending techniques for controlling of the variation in quality of limestonne and clay were employed. Different fuels of various mixtures have been used at Paggau ranging from anthracite dust to coke breeze and petrol coke, the application of which in all the cases have been reported to be a success. In addition to above, M/s Maerz Ofenbau of Zurich also supplied mini cement plants based on VSK technology on turnkey basis. M/s. Maerz are the exclusive licencee for the manufacture of Prerov machinery designed mini cement plants with as many as 16 cement shaft kilns operating in different parts of the world. The heat consumption in these plants is claimed to be about 900-Kcal/Kg clinker. 10.0 OPERATION OF A CRI -MODERN VERTICAL SHAFT KILN As already explained, in the black meal process, the cement raw materials are interground with the fuel and the resultant raw meal is blended and then converted into nodules of sufficient uniformity, strength and porosity in an inclined disc type noduliser by the addition of required quantity of water. The nodules are fed to vertical shaft kiln where the pyroprocessing takes place. 10.1 Before Lighting up The kiln should be checked for a) Rotary Grate: The grate segments and crown with cutter teeth should be intact and in position. A full revolution should be given to the grate to ensure it does not touch lining plates anywhere. b) Lining plates should not be loose. c) Refractory Lining: The lining must be checked and repaired wherever necessary. If the thickness of lining in burning zone gets reduced below 80mm, it must be replaced. All starters/main switches of the electrical installation should be checked d) whether they are all in working condition. e) Roots Blower. In accordance with the manufacturer's recommendations, oil must be checked. Filters must be cleaned. The weights in the safety valve are to be adjusted to suit to the anticipated kiln bed resistance. Chimney's dampers, rotary feeder, kiln hood doors, discharge gates must f) be checked for their mechanical operation and lubrication.

29

g)

All the flanges of the kiln, bottom hood cup, chutes, discharge gates etc. should be properly sealed so that the combustion air does not leak through the gaps between the joints.

10.2 Lighting up of the Kiln The kiln should be filled with either the clinker already manufactured, or limestonne chips or brickbats upto a level of 1-1.5 metres from the conical portion. Care should be taken that the material is dust free and while filling the refractory lining is not damaged. In order to remove the dust, the roots blower has to be run for about 15 minutes after every 1-metre depth of new material is loaded or better if the blower is run continuously while the kiln is loaded with the chips or clinker. After-every 2 metres depth of new material has been loaded, the grate is set in motion, to ensure that the material is moving down the shaft evenly. Above this material, about 100 kg of dry firewood is now stacked uniformly over this bed in two or three layers. The chimney damper has to be opened partly and the air by-pass valves/ball valves are to be kept open in the kiln air duct. The firewood so spread would be lighted up using torches and after an incandescent bed is formed, steam coal is charged into the kiln. There will be an uniform incandescent bed of fire after few minutes. Now charging of the nodules can commence. One should refrain from adding a new charge of nodules until the edges of the fire can be just seen. When the bed level reaches to about 50 cm. below the conical portion, the discharge gate is to be operated slowly. 10.3 Normal Kiln Operation Stabilised kiln operation as obtained after the initial lighting up may now be continued under the following instructions: 1. 2. 3.

4.

5.

Uniform discharge rate should be maintained as far as possible by adjusting the grate speed whenever necessary. The nodule size, feed rate and bed level must be maintained. The bed should always be covered with the nodules by continuously feeding them on a circle some distance away from the refractory lining so that the nodules themselves distribute both over the periphery and in the centre. A glowing ring on the periphery and continuous steam emerging from the centre of bed indicates good fire and good combustion conditions. The temperatures of various zones should be periodically recorded. It is necessary to ascertain frequently that the entire bed is descending uniformly. This is ensured by cleaning the sides frequently with the help of a rod with flattened tip. While cleaning the sides, care must be taken not to damage the refractory of kilns. Once the kiln is stablised neither the process parameters nor the raw mix composition should be changed frequently.

M

10.4 Kiln Controls 10.4.1 Feed Strict controls should be observed on the preparation of feed right from the raw material stage. The table feeders/weigh feeders should be monitored periodically so that the component ratios conform to the values for raw mix design. Blending operation is carried out till a uniform blending with the desired T C content is obtained. The T C in raw mix should not vary beyond ± 0.20% of the desired value. The nodules should be checked for appropriate size, porosity, moisture and strength on hourly basis. The feed rate and discharge rate should be synchronised to maintain constant bed level.

10.4.2 Combustion Air The combustion air can be regulated by adjusting the valve on by-pass pipe. The measurement is done with the help of two instruments provided on the burner's platform; one from the orifice plate to give combustion air flow and the other connected at the bottom for measuring the pressure at the inlet to the kiln which gives an idea of the bed resistance. If during a normal operation both the instrument readings are constant, the burner should understand that the kiln is filled with properly burnt clinker. In case the inlet pressure varies the burner gets indication that the bed resistance is varying and necessary corrective action should be applied.

10.4.3 Discharge Rate Under stabilized operating conditions, the discharge and feed rates should be synchronised to maintain constant bed level. If there are too big lumps or too loose a clinker near the grate, the discharge rate will fall or increase. Depending on the case, immediately the grate speed is to be changed; otherwise the bed level would rise or burning zone would collapse destroying the entire kiln operation in next few hours. Intermittent discharge is not desirable. The rotary grate speed should not be abruptly changed and it should be done gradually step by step.

10.4.4 Temperature A normal kiln operation is also judged from, in addition to the above, the temperatures of flue gases, clinker, burning zone, cooling zone and also of the kiln shell from outside. The temperature of the kiln is judged from the thermocouple based temperature indicators and also crosschecked by touching the kiln shell around periphery at various heights to feel the uniform temperature gradient. The desired temperature profile for a VSK is shown in Fig. 8.

31

10.5 Kiln Disorders 10.5.1 Bridging When the clinker produced is so lumpy that it does not contain any loose material, there are chances that the lumps form a bridge and rest over the sides of the conical portion of kiln resulting in rise in fire bed. In such a case the feed should either be slowed down or stopped and air reduced. The bed should be given some disturbance in clearing the sides and poking from burner's platform. If necessary the roots blower should be stopped and then the feed. The bed should be able to descend with some effects. The cause should be investigated and the process parameters immediately rectified in order to avoid repetition of this.

10.5.2 Side Discharge Sometimes if the clinker produced is suddenly too loose it would pass through the bigger lumps and get discharged quickly. Even red-hot yellow nodules (clinker) may discharge representing that at a certain position there is no bed to support the burning zone. The burning zone seems to collapse and loose fire. In such a condition, the grate speed should be reduced or it should be stopped, to reduce discharge for some time and the burning zone built up slowly even though the level may rise. The discharge may be reduced till the trouble is overcome. The underburnt clinker may be separately stocked and appropriately blended with the good clinker at the time of grinding after ascertaining a suitable proportion. The kiln process parameters should be immediately attended to. This may be a result of maintaining the bed level too low inside the cone.

10.5.3 Lump Formation Sometimes a big lump may be noticed in the burning zone, which is very strong and as big as kiln internal diameter. This may not descend. This generally occurs due to melting on account of a very high temperature there. The raw mix composition should be immediately examined and feed should be accordingly corrected. The fuel with low ash fusion or too much of fuel will cause this. The lump so formed should be broken with poking rods and grate speed should be adjusted to ensure its descent. At the same time too much poking should be avoided. The lumps that descend though big, give no trouble as they would get crushed and discharged as soon as they reach the rotary grate.

10.6 Operational Optimisation and Training with Simulator Achieving the rated output at high and consistent quality clinker is the real task for the burners. For this all the input parameters are to be maintained at an optimum level and the kiln operations should be monitored continuously. Even a

32

slight disturbance to any of the input parameters for a short duration will destabilize the steady state and disturb the entire process. In this connection, understanding the interdependency of the input parameters to the other operational and process parameters in a quantitative way is very much essential for the process optimization of the kiln. CRI -MVSK simulator is an extra-ordinary powerful tool for imparting training to the plant operating personnel in the quickest way possible without causing any damage to the plant, machinery or process and can also be utilized for optimization of CRI -MVSK plant operation, including optimum Raw Mix Design and proportioning almost at the flick of a button. The CRI -MVSK Simulator is a device, which shows the working of complete vertical shaft kiln section of a cement plant without any physical connections to the plant, wherein all the inputs, the process as well as the output are electronically generated within a computer. The simulator through a specially developed software programme simulates the actual operating conditions of a vertical shaft kiln cement plant on an ordinary desktop IBM-PC compatible computer. A mimic diagram of the vertical shaft kiln section of a cement plant is displayed on the computer screen with all values of process parameters, which keep on changing with respect to time just as in an actual plant. The operator can adjust or change any process parameter as per his wish and see the effect of the same on the plant operation. All the disturbances normally encountered in the kiln operation either due to changes in raw materials / fuel quality and / or improper operation can be created on the simulator and the operator can be trained to effectively deal with such situations. Working on CRI -MVSK simulator does not require any knowledge of working on a computer terminal or computer programming. The simulator consists of a colour graphic monitor, which shows the live mimic of the nodulizer — vertical shaft kiln section. The operation data on vertical shaft kilns based on CRI -VSK Technology are given in Table 4. Table 4: Operation Data on Vertical Shaft Kiln based on CRI -MVSK Technology SI. No.

1 2 3 4 5 6 6.1 6.2 6.3 7 8

Name of the item

Units

Nodule Size Moisture in nodules Raw meal fineness Retained on 170 mesh Fuel in raw meal Bed level from the top of kiln Temperature of Chimney Burning zone Clinker discharged Heat input Bed Rasistance

6 to 12 12 to 14 6 to 14

% mm

12 to 13 200 to 400

°C °C °C Kcal/kg of clinker mm WG 33

Value

mm % %

80 to 200 1400 to 1450 30 to 100 950 to 1050 150 to 600

9 10 11 12 13 14 15 15.1 15.2

Quality of air Litre weight Resistance time Rotary grade speed Chimney draft Maximum size of clinker lump Energy consumption Clinker (upto kiln section) Cement grinding alone (Only cement mill section)

NM3/kg of fuel gm/cc hrs. rph mm WG mm

10 1080 to 1180 8 to 10 0.2 to 5 1 to 3 100

Kwh per tonne of clinker Kwh per tonne of cement

80 to 90 30 to 40

11.0 RAW MATERIALS AND THEIR CONSUMPTION FACTOR

Raw materials to be used in Vertical Shaft Kiln mini cement plants and their consumption factors (material balance) per tonne of clinker and cement are given below in Table 5. Table 5: Raw Materials Consumption Factor

SI. No.

Raw Materials

1 2 3

Limestonne Clay Additives like iron ore, Bauxite, Laterite etc. Low Volatile fuel like coke breeze, saleable low volatile coal, Pet Coke, Jhamma Coal etc. Gypsum

4

5

Consum ption factor Per tonne of Per tonne of clinker cement

1.25 to 1.30 0.10 to 0.30 0.05 to 0.10

1.19 to 1.24 0.095 to 0.285 0.048 to 0.095

0.13 to 0.22

0.124 to 0.209

—

0.03 to 0.05

12.0 ELECTRICAL ENERGY AND THERMAL ENERGY

The electrical energy consumption for various sections and thermal energy consumption of Vertical Shaft Kiln mini cement plants are given below:

12.1 Electrical Energy

The electrical energy requirements for different sections are given below in Table 6.

34

Table 6: Electrical Energy Reuirement

SI. No. 1 2

Section

Crushing Raw mill (including mill auxiliaries) VSK RK Coal Mill Cement Mill (Including mill auxiliaries)

3 4 5 6

Electrical Energy in Kwh/tonne of materials 1 to 3 28 to 35

20 to 25 12to15 25 to 35 35 to 40

12.2 Thermal Energy

Thermal energy requirement varies from 850 — 950 K.cal/kg of clinker. 13.0 FIELD STUDIES

Indepth study was conducted at 8 VSK mini cement plants including identification of sources of air pollution (stack & fugitive), stack emission monitoring, constituent of flue gases in terms of 0 2 , CO2, CO and N2 etc, pollution control technology adopted, annual operation and maintenance cost, water requirement and ambient air quality monitoring. Most of the VSK mini cement plants are not equipped with pollution control devices in all the sections due to the involvement of capital cost especially in Saboo and RRL VSK mini cement plants. A few CRI -MVSK cement plants of higher capacity are only having pollution control devices in all the sections of unit. Many VSK mini cement plants are closed except the plants located in Jammu & Kashmir and North Eastern region. The study was conducted at 2 VSK cement plants in Andhra Pradesh and 6 VSK cement plants in Rajasthan. The indepth studies conducted in all the 8 VSK mini cement plants are given in the subsequent paragraphs. 13.1 Plant - I 13.1.1 History

1 2

Name of the plant Location

Plant—I Tirupati, Andhra Pradesh

3 4 5

Installed Capacity (TPD) Year of Commissioning Technology adopted

200 (2 x 100 TPD) April 1996 CRI — MVSK Technology

6

Machinery Supplier

7 8 9

Actual Cement Production Future Expansion Types of Cement Manufactured (BIS: 445 - 1989)

NCB's licensee M/s Promac Engineering Industries, Bangalore. 57,083 Tonne/Annum Yes Slag Cement

The above plant is put up in order to utilize the slag generated by their steel plant, situated in the same premises. The quality of granulated slag generated by their steel plant is as per Bureaau of Indian Standards. The slag consumption was upto 50% depending upon the quality of clinker produced. The specific thermal energy consumption is 900 K.Cal/ Kg of clinker and specific electrical energy consumption is 110 Kwh / tonne of cement. Actual production from VSK (average) on the day of monitoring was 85 TPD. 13.1.2 Manufacturing Process and Flow Sheet CRI — MVSK technology is based on the black meal process in which all the raw materials, viz, limestonne, clay, fuel (coke breeze, Jhama coal or any suitable low volatile coal) and other corrective materials are ground together to a fineness of 10% retained on 170 mesh as in dry process and intimately blended to satisfy the chemical requirements for the raw meal. The homogeneous raw meal is formed into nodules of the desired size by adding water in a pan nodulizer and fed into the vertical shaft kiln through a revolving feed hopper. As the material passes down the kiln, it is dried, heated and then burnt into clinker. The clinker is then cooled and discharged from the kiln by a rotary grate at the bottom of the kiln through a triple airlock discharge device or gamma ray controlled material Block Tube (MBT). The combustion air to the kiln, which is provided by a Roots blower, also serves the purpose of cooling the clinker and thus avoids wastage of heat. The clinker then passes on to a cement mill where it is ground with about 5% gypsum to produce cement of standard quality. Flow Sheet of Plant - I is shown in Exhibit — 2. 13.1.3 Sources of Air Pollution Sources of air pollution are shown in Table 7.

0

Table 7: Sections Causing Air Pollution Section 1 Type of Pollution Control Equipment 1. Crushing Bag Filter 2. Raw Materials Bag Filter Proportioning Bag Filter 3. Raw Mill Bag Filter 4. Blending Bag Filter 5. Nodulisation Wet Scrubber 6. VSK 7. Clinker discharges Bag Filter 8. Clinker tunnel -Bag Filter 9. Cement Mill Bag Filter 10. Packing (Note: Wet scrubber was not connected) 13.1.4 Stack Emission

The stack emission monitoring was conducted at all the important sections and details are given in Table 8 and 9. Table 8 : Stacks Emission Monitoring Results at outlet of APCD S. No.

Parameters

1. 2. 3. 4. 5. 6.

Stack dimension (m) Stack cross sec (m 2 ) Flue gas temp ( ° C) Exit velocity of flue gas (mps) Flow rate (m 3 / hr) PM (mg/Nm 3 )

7. 8.

Emission rate (kg / hr) S0 2 (mg/Nm 3 )

Kiln (outlet)

Raw Mill (outlet)

Cement Mill (outlet)

0.50 0.196 42 8.76

0.50 0.196 48 7.66

1.2 1.131 85 3.31

After stabilization with continuous feeding _ 1.2 1.131 85 3.31

6181 1) 45 2) 66 3) 96 Avg. 69 0.43

5405 1) 70 2) 96 3) 92 Avg. 86 0.46

-

-

13436 1) 580 2) 559 3) 550 Avg. 563 7.56 7

13436 1) 358 2) 340 3) 346. Avg. 348 4.67 7

37

With intermittent feeding

Table 9: Other Stacks Emission Monitoring Results

Section

Particulate Matter Conc. (mg/Nm 3 Sample I )

Particulate Matter Conc. (mg/Nm 3 Sample I )

Particulate Matter Conc. (mg/Nm 3 Sample I )

Particulate Matter Conc. (mg/Nm 3 Average )

Raw mill (Bag Filter Inlet)

873

852

843

856

Cement mill (Bag Filter Inlet)

185

176

164

-175

Packing plant (loading activities not continuous)

52

60

50

54

Raw mill tunnel exhaust

70

81

77

76

TALD gate (Bag Filter Inlet)

800

815

815

810

TALD gate (Bag Filter Outlet)

315

325

332

324

The efficiency of bag filters in raw mill and cement mill was found to be 92% and 95% respectively. 13.1.5 Ambient Air Quality

The ambient air quality was monitored in respect of suspended particulate matter, respirable particulate matter, SO 2 , NO X and CO The sampling was done at two locations in upwind and downwind directions on 8-hourly frequency and 24 hours average value is computed. The ambient air quality monitoring results are given in Table 10.

Table 10: Ambient Air Quality Monitoring Results SI. No.

Parameters

Up Wind Direction Down Wind Direction (gIm 3 /m 3 _ 280 310 641 899 12 14 7 8 Traces Traces )

1 2 3 4 5

RSPM SPM SO2 NO CO

38

13.1.6 Analysis of Particle Size Distribution of Particulate Matter

The particle size analysis of the dust collected in thimbles at the VSK Kiln is as given below: µ Size %

0-3 10.70

3-5 6.20

10-20 19.50

5-10 8.50

20-40 7.10

40-60 26.90

60-90 20.3

90-105 0.71

13.1.7 Raw Mix Design and its Effect on Emission

The plant is using 5 component mixes for clinker manufacture. The raw materials used are two type of limestonne high & low grade, clay, Iron dust and coke breeze. The chemical composition of the above materials and the raw meal is given in Table 11. The raw materials consumption factor per tonne of cement is given below: Limestonne - I Limestonne - II Clay Additive Coke breeze

0.50 0.89 0.07 0.03 0.18

: : : :

Table 11: Chemical Composition of Raw Materials & Raw Meal Materials Limestonne - I Limestonne - II Clay Additive Coke Breeze Raw meal

LOl% 39.40 35.07 10.00 4.00 82.00 40.00

S102% 6.71 13.60 55.0 3.00 7.35 12.23

Al203% 2.07 3.10 17.00 3.00 2.60 3.30

Fe20 %o 0.93 1.40 8.00 85.00 5.10 3.60

The modulii values obtained of the raw meal is given below: 1.77 : SM 0.92 : AM 0.92 : LSF %LC : 31.00 The Cement quality obtained is shown below: Compressive strength 3 days : 340 - 380 Kg / cm 2 7 days :440-480 Kg / cm 2 28 days: 550-600 Kg / cm 2

39

CaO% 48.45 44.40 5.00

MgO% 1.30 0.70 2.00

--

--

1.25 38.40

0.15 0.85

Soundness Le Chatlier expansion (mm): Autoclave (%) :

2.7 0.3

To study the effect of different raw materials proportions on clinker quality and particulate matter emissions, using the same quality raw materials and only changing the raw mix design (RMD), stack emissions were measured. The present RMD had been changed to new RMD having following Modulii values and increased liquid content which is given below: LSF %LC SM AM 1.55 0.66 0.88 36.88 When the material with new RMD was fed to the kiln, the quality of clinker was improved, the stack emissions were observed as given below: Stack Emission Data with New Raw Mix Design a) b)

c) d) e) f) g)

Stack dimension (m) Stack cross section area (m 2 Flue gas temp. (°C) Flue gas velocity (m /sec) Flow rate (m 3/hr) Particulate Matter Emission (mg/Nm 3 Emission rate (kg/hr)

:

)

:

:

:

:

)

:

:

1.2 1.131 84 3.31 13436 95 4.00

Thus, it is observed that if the kiln is fed with proper nodules of optimum RMD and proper process parameters are strictly followed as per the norms, particulate matter emission from VSK is well below the stipulated norms. 13.1.8 Process Parameters of VSK

The process parameters of Vertical Shaft Kiln are given below: a) Nodule Size (mm) 6-10 Moisture (%) 13-14 b) Fuel in Kiln Feed (%) 11 c) 600-750 Rotary Grate Speed d) (Dyno drive rpm) 60-80 Clinker Temperature (°C) e) 300-500 f) Bed length from top (mm) :

:

:

:

:

:

13.1.9 Air Pollution Control Devices adopted and Design Efficiency

The air pollution control devices installed in various sections are given in Table 7. The design parameters like fan capacity, drive hp, no. of bags in various sections alongwith the capacity of equipment are given in Table 12. 40

Table 12: Design Parameters of Air Pollution Control Devices installed at Various Sections S. No.

Section

Capacity (tph)

1 2

Crushing Raw Materials Proportioning Raw Mill Blending VSK Clinker Discharge (TALD) Cement Mill Packing

30

3 4 5 6 7 8

Fan Capacity m 3/hr 4000 6600

-

11 75 T. Cap. -

No. of Bags

Efficiency

10 15

32 56

70 74

144 92 18000 100 70 10 32 4000 -------- Wet Scrubber --------70 10 32 4000 13300 7000

12 20

Drive (HP)

25 15

96 60

95 73

Economics

13.1.10

The capital cost of air pollution control devices along with its maintenance cost per annum for various sections are given in Table 13. Table 13: Capital and Operation & Maintenance Cost of Air Pollution Control Devices S. No.

Section

1

Crushing

2 3

Raw Materials Proportioning Raw Mill

4

Raw Meal Blending

5

Raw Meal Storage

6 7 8

VSK Clinker Discharge (TALD) Cement Mill

9

Packing

Air Pollution Control Devices

Capital Cost (Rs. Lakh)

Ordinary Bag Filter Ordinary Bag Filter Pnu-jet bag filter Pnu-jet bag filter Ordinary Bag Filter Wet Scrubber Ordinary Bag Filter Pnu-jet bag filter Ordinary Bag Filter

1.50

Operation and Maintenance Cost / Annum (Rs.) 25,000

1.50

25,000

3.50

1,00,000

3.50

1,00,000

1.50

1,00,000

3.50 1.50

35,000 25,000

3.50

1,00,000

1.50

25,000

41



13.1.11

Environmental Standards

The limit stipulated by Andhra Pradesh Pollution Control Board for particulate matter emission is 115 mg/Nm 3 . Ambient air quality standard for SPM is 500 µg /M 3 . 13.1.12

Noise Pollution

Detrimental and unpleasant sound energy transmitted from one area to another is classified as "Noise". The noise is generated in various sections has been measured as shown in Table 14. The major sources of noise generation are raw mill and cement mill. The distance between source of noise and point of measurement is approximately 3 m. About 3 persons were working near each mill. The location of noise measurement is indicated in the plant layout and shown at Exhibit — 3. Table 14: Noise Level SI. No.

1 2 3 4 5 6 7 8 9 13.1.13

Noise Measurements (dBA) Night Time Day Time 55 59 41 43 42 36 91.0 91.8 43 46 43 45 45 57 47 43 92.4 93.4

Sections Near DG Set Second Gate Colony Cement Mill Near Kiln Shed Near Laboratory Crusher Control Rooms Near Packing Near Raw Mill

Water Requirement

Water required for a 200-tpd CRI -MVSK cement plant is 200 KUday for the process and domestic purpose. The water quality of the plant is shown in Table15. Table 15: Water Quality pH Suspended Solids Total dissolved solid

13.1.14

:

5.5-9.0 200 mg/I 2100 mg/I

Solid Waste

There is practically no solid waste generation in the plant.

42

13.2 Plant - 2 13.2.1 History 1 2 3 4

Name of the plant Location Installed Capacity (TPD) Year of Commissioning

5 6

Technology adopted Machinery Supplier

7 8

Actual Cement Production Future Expansion

Plant-2 Near Vijayawada, A.P. 300 (3 x 100 TPD) 2x100 = 200 TPD, 1991 1x100 = 100 TPD, 1997 CRI — MVSK Technology NCB's licencee Mis Promac Engineering Industries, Bangalore & M/s. Kay Iron Works Pvt. Ltd., Yamunanagar. 69,000 Tonnes / Annum No

The specific thermal energy consumption is 1050 Kcals / kg of clinker and specific electrical energy consumption is 115 Kwh / tonne of cement. The actual production for both the kilns (average) on the day of monitoring was 70 TPD. 13.2.2 Manufacturing Process and Flow Sheet

Manufacturing process is same as explained earlier in Plant-1. The flow sheet of Plant-2 is based on crane layout for handling raw materials, fuel, clinker & gypsum which is shown in Exhibit-4. 13.2.3 Sources of Air Pollution

Sources of Air pollution are shown in Table 16. Table 16: Sections Causing Air Pollution Section 1. Crushing 2. Raw Materials Proportioning 3. Raw Mill 4. Blending 5. Nodulisation 6. VSK 7. Clinker discharges 8. Clinker tunnel 9. Cement Mill 10. Packing

Type of Pollution Control Equipment -

-

Pnu

—

jet Bag Filter

-

-

-

-

-

Pnu —jet Bag Filter -

43

13.2.4 Stack Emission

The stack emission monitoring was conducted at all the important sections and details are given in Table 17 and Table 18. Table 17: Stacks Emission Monitoring Results at outlet of APCD Parameters

Raw Mill (outlet)

1.03 Stack dimension (m) 0.834 Stack cross sec (m 2 ) 48 Flue gas temp ( C) 8.85 Exit Velocity of flue gas (m/s) 26571 Flow rate (m 3 / hr) 1) 161 PM (mg/Nm 3 ) 148 2) 3) 150 Avg. 153 4.07 7. Emission rate (kg / hr) 8. SO 2 (mg/Nm 3 )

1. 2. 3. 4. 5. 6.

°

Cement Mill (outlet)

0.315 0.078 42

8.76 2460 1) 82 2) 69 3) 50 Avg. 67 0.166 -

Kiln (outlet)

III

I* 1.3 1.328 105 3.4 16255 171 1) 2) 166 164 3) Avg. 167 2.72 6

1.3 1.328 62 4.5 21514 1) 75 2) 82 3) 62 Avg. 73 1.58 6.5

* many leakages in stack Table 18: Other Stack Emission Monitoring Results Section

Raw Mill (Bag Filter Inlet)

Particulate Matter Emission (mg/Nm )

1. 1300 1200 2. 3. 1118 Avg. 1206

Bag Filter Efficiency

The dust concentration at raw mill bag filter inlet was measured to estimate the efficiency of the dust collector which was found to be 87.3%. 13.2.5 Ambient Air Quality

The Ambient Air Quality was monitored in down wind and up wind directions. The ambient air quality monitoring results are given in Table 19.

44

Table 19: Ambient Air Quality SI. No.

Parameters

1 2 3 4 5

Down-wind Direction

Up-wind Direction /m3

/m 3 275 1205 9 7 Traces

RSPM SPM SO2 NO CO

142 910 7 6 Traces

13.2.6 Analysis of Particle Size Distribution of Particulate Matter

The particle size analysis of the dust collected in thimbles at the VSK Kiln is as given below: Size

0-3

3-5

5-10

10-20

20-40

40-60

60-90

90-105

%

9.98

6.56

8.86

19.40

7.20

26.75

20.44

0.81

13.2.7 Raw Mix Design

The plant is using 6 component mixes for clinker manufacture. The raw materials used are two types of limestonnes, coke breeze, clay, iron ore and bauxite. The chemical composition of the above materials and the raw meal is given in Table 20. Table 20: Chemical Composition of Raw Materials & Raw Meal

LOI% 38.88

Si02% 8.61

Al203% 1.12

Fe203% 1.74

CaO%

M O%

48.05

1.06

37.76 69.76

10.32 17.61

1.27 2.46

2.22 6.53

46.91 2.34

1.10 0.78

Clay

13.13

48.23

8.45

16.95

8.24

3.25

Iron Ore

1.73

1.28

89.25

6.28

0.99

0.25

Bauxite

10.41

28.58

33.52

27.73

0.89

0.16

Raw Meal

39.77

12.49

4.15

4.15

37.79

1.10

Materials

Limestone Low Grade Limestone Coke Breeze

The raw materials consumption factor per tonne of cement is given below: 1.28 Limestone 0.21 Coke Breeze 0.09 Clay 0.025 Iron Ore 0.058 Bauxite -

-

-

-

-

45

The cement quality obtained is shown below: Compressive Strength 3 days :270-330 Kg / cm2 7 days :340-360 Kg / cm 2 28 days: > 480 Kg / cm 2 The raw mix design adopted by the plant is properly implemented with appropriate process parameters. 13.2.8 Process Parameters of VSK The process parameters of Vertical Shaft Kilns (Kiln 1 & Kiln 2) are given below: Kiln 1 Kiln 2 a) Nodule Size (mm) 8-12 8-12 13-14 b) Moisture (%) 13-14 c) Fuel in Kiln Feed (%) 13.0-13.50 13.0-13.50 600-800 600-800 d) Rotary Grate Speed (Dyno drive rpm) Clinker Temperature (°C) 65-85 65-85 e) 300-500 f) Bed level from top (mm) 300-500 :

:

:

:

:

:

13.2.9 Pollution Control Devices adopted and Design Efficiency The pollution control devices installed in various sections are given in Table 16. The design parameters like fan capacity, drive hp, no. of bags in various sections alongwith the capacity of equipment are given in Table 21. 13.2.10

Economics

The capital cost of air pollution control devices along with its operation and maintenance cost per annum for various sections were not made available. It was informed that 32 & 22 Nos. of polyster needle woven bags per annum were changed in Raw Mill & Cement Mill Pnu-jet bag filters respectively. 13.2.11

Environmental Standards

The environmental standards stipulated by AP Pollution Control Board are already given in the details of Plant No. 1. 13.2.12

Noise Pollution

The noise measurements taken at various locations in the plant are shown in Table 22. The major sources of noise generation are raw mill and cement mill. The distance between source of noise and point of measurement is approximately 3m. The numbers of persons working near the mills are 3 each.

46



The location of noise measurement is indicated in the plant layout and shown at Exhibit-5. Table 21: Design Parameters of Existing Air Pollution Control Devices S. No.

Section

1 2 3

Crushing Raw Materials Pro ortionin Raw Mill

4

Blending

5 6 7 8

VSK MBT Cement Mill Packing with 2 spouts

I

Efficiency (%)

Capacity (tph)

Fan Capacity m 3/hr

Drive (HP)

No. of Bags

35

-

-

-

-

22

Not working

-

325 polyester needle bags

90

132t each 2 Nos.) 300 TPD 5 13

-

-

-

-

-

-

-

-

16000

25

92

85

-

-

-

-

-

-

Table 22: Noise Level

SI. No. 1 2 3 4 5 6 7

13.2.13

Noise Measurements (dBA) Night Time Day Time 52 63 25 32 92.5 93.5 87 88.4 36 38 43 _ 48 43 45

Sections Near DG Set Colony Raw Mill Cement Mill Near Laboratory Crusher Control Rooms Near Packing

Water Requirement

Water required for the plant is 200 KUday mainly for the process purposes. Water is used for nodulisation, raw mill trunion bearing cooling and cement mill shell cooling.

13.2.14

Solid Waste

There is practically no solid waste generation in the plant.

47

13.3 Plant - 3 13.3.1 History

1. 2. 3.

4. 5. 6. 7. 8.

Name of Plant Location Installed Capacity Actual output obtained (Average) on the days of monitoring Year of Commissioning Technology Adopted

Plant-3 Behror, Rajasthan 50 TPD 40 TPD 1993 Semi Dry Process Saboo VSK Technology 2,880 Tonnes/ Annum No Ordinary Portland (OPC)

Actual Cement Production Future Expansion Types of cement Manufactured

Cement

13.3.2 Manufacturing Process and Flow Sheet

Saboo VSK Technology based on black meal process in which all Raw Materials viz. Limestone, Clay, Coke Breeze, and Iron ore are ground together to a fineness of 10% residue on 170 mesh (90µ) as in dry process and immediately blended to satisfy the chemical quality requirement for the Raw Meal. The homogenous Raw Meal is formed into nodules of desired size (6 to 12 mm diameter) by adding water in a pan noduliser and fed into Vertical Shaft Kiln through revolving feed hopper inside VSK arrangement. As the material passes down the kiln, it is dried, calcined and burnt into clinker. The clinker is then cooled and discharged by a rotary grate at the bottom of the kiln. through discharge arrangement. The combustion air is supplied through Roots Blower, also serves the purpose of cooling the clinker and thus avoids wastage of heat. The cooled clinker then passes on to cement mill where it is ground with about 5% Gypsum to manufacture Cement of Standard Quality. Flow sheet of Plant — 3 is shown in Exhibit — 6. 13.3.3 Sources of Air Pollution

Sources of Air Pollution are shown in Table 23.

48

Table 23: Sections Causing Air Pollution

SI. No. Section 1. Crushing 2. Raw Materials Proportioning 3. Raw Mill 4. Blending 5. Nodulisation 6. VSK 7. Clinker Discharge 8. Clinker Tunnel 9. Cement Mill 10. Packing

Types of Pollution Control Equipment

Bags Bags Bags Bags Bags Wet Scrubber Bags -

Bags -

13.3.4 Stack Emission

The stack emission monitoring carried out in important sections is given in Annexure II. Three samples of particulate matter emissions were taken at VSK stack and these values are varying from 96 to 140 mg/Nm 3 . Particulate matter emissions rate varies from 1.69 to 2.47 Kg / hr. SO 2 concentration in the flue gas vary from 6 to 7 mg/Nm 3 . The details of the stack (VSK chimney) are given below: • • • • •

Stack dimension Dia (m) / height (m) : Stack cross sectional area (m 2 ) : Flue gas temp. (°C) : Exit gas velocity of flue gas (Average)(m/sec) : : Flow rate (m 3/hr)

0.9 /4.0 0.6362 60 8.60 17618

Flue gas analysis was carried out with "Flue Gas Analyser". The flue gas analysis indicates presence of Carbon Monoxide to the extent of about 4091 ppm. The flue gas analysis for 02, CO2, CO and N 2 is given at Annexure II. 13.3.5 Ambient Air Quality

Fugitive dust emissions were measured near Raw Mill and are given in Annexure II. Ambient air quality monitoring was carried out in upwind and downwind directions and results are given in Annexure II. 13.3.6 Analysis of Particulate Matter for Particle Size Distribution

Particle size distribution of the collected dust in thimbles (VSK Flue Gas) was carried out and the values are given in Annexure II.

49

13.3.7 Raw Materials

The plant is using 4 component mixes for clinker manufacture. The raw materials used are limestonne, clay, coke breeze and Iron ore. The raw mix design followed by the plant is given below. Limestonne Clay Coke breeze Iron Ore

= = = =

73% 12% 13% 2%

i3.3.8 Consumption Factor of Raw Materials

The raw materials consumption factor per tonne of clinker and cement are given below in Table 24.

Table 24: Raw Materials Consumption Factor

SI. No. 1 2 3 4

Consum tion Factor Per tonne of Per tonne of clinker cement 1.219 1.158 0.200 0.190 0.217 0.206 0.033 0.031

Raw Materials

Limestonne Clay Coke Breeze Iron Ore

The specific thermal energy consumption is 1056 Kcals/Kg of clinker. Whenever there is no power supply, the plant is being operated with Diesel Generator set. 13.3.9 Process Parameters of VSK

The process parameters of Vertical Shaft Kiln are given below: a) b) C)

d) e) 13.3.10

Nodule Size (mm) - Moisture (%) - Fuel in Kiln Feed (%) - Clinker Temperature (°C) - Bed Length from top (mw) -

6-12 12-14 13 50-80 300-500

Noise Pollution

Noise levels were monitored at varius sources in the plant and are given in Annexure II. The distance between source of noise and point of measurement is approximately 3 m. The number of persons working near the sources is 3 each.

50



13.3.11

Water Requirement

The average quantity of water required for this VSK cement plant is 10,000 litres / day as reported by the plant. Solid Waste

13.3.12

Solid waste generation is practically nil. 13.3.13

Manpower

The total manpower deployed, as reported by plant authorities, is 21 staff and 30 contract labours. 13.4 Plant - 4 13.4.1 History

4. 5.

Name of Plant Location Installed Capacity Actual output obtained (Average) on the days of monitoring Year of Commissioning Technology Adopted

6.

Actual Cement Production

7. 8.

Future Expansion Types of cement Manufactured

1. 2. 3.

Plant —4 Behror, Rajasthan 50 TPD 25 TPD 1993 Semi Dry Process Saboo VSK Technology 9907 Tonnes / Annum No OPC

13.4.2 Manufacturing Process and Flow Sheet Saboo VSK Technology based on black meal process in which all Raw Materials viz. Limestonne, Clay, Coke Breeze, and Iron ore are ground together to a fineness of 10% residue on 170 mesh (90).L) as in dry process and immediately blended to satisfy the chemical quality requirement for the Raw Meal is formed into nodules of desired size (6 to 12 mm diameter) by adding water in a pan noduliser and fed into Vertical Shaft Kiln through revolving feed hopper inside VSK arrangement. As the material passes down the kiln, it is dried calcined and burnt into clinker. The clinker is then cooled and discharged by a rotary grate at the bottom of the kiln through discharge arrangement. The combustion air is supplied through Roots Blower, also serves the purpose of cooling the clinker and thus avoids wastage of heat. The cooled clinker then passes on to cement

51

mill where it is ground with about 5% Gypsum to manufacture Cement of Standard Quality. Flow sheet of Plant —4 is shown in Exhibit — 8. 13.4.3 Sources of Air Pollution

Sources of air pollution for this plant are shown in Table 25 Table 25: Sections Causing Air Pollution

SI. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Types of Pollution Control Equipment Section Crushing Raw Materials Proportioning Raw Mill Blending Nodulisation VSK Clinker Discharge Clinker Tunnel Cement Mill Packing

-

-

3 Bags 2 Bags Bags Wet Scrubber -

-

6 Air Filter Bags 2 Bags

13.4.4 Stack Emission

The stack emission monitoring carried out in important sections is given in Annexure Ill. Three samples of particulate matter emissions were taken at VSK stack and values observed are 430, 119 and 129 mg/Nm 3 with average of 226 mg/Nm 3 . Particulate matter emissions rate in kg/hr are 4.33, 1.20 and 1.30 respectively. SO 2 concentration in the flue gas varies from 1.5 to 2 mg/Nm 3 . The details of the stack (VSK chimney) are given below: • • • • •

Stack dimension Dia (m) / height (m) Stack cross sectional area (m 2 ) Flue gas temp. (°C) Exit gas velocity of flue gas (m/sec) Flow rate (Average - m 3/hr)

= = = = =

0.6096/3.5 0.3 32 9.77 10,070

Flue gas analysis was carried out with "Flue Gas Analyser". The flue gas analysis indicates presence of Carbon Monoxide in traces. The flue gas analysis for 02, CO2, CO and N2 is given at Annexure Ill.

52

13.4.5 Ambient Air Quality

Fugitive dust emissions were measured at Jaw Crusher and are given in Annexure III. Ambient air quality monitoring was carried out in upwind and downwind directions and results are given in Annexure Ill. 13.4.6 Analysis of Particulate Matter for Particle Size Distribution

Particle size distribution of the collected dust in thimbles (VSK Flue Gas) was carried out and the values are given in Annexure lil. 13.4.7 Raw Materials

The plant is using 4 component mixes for clinker manufacture. The raw materials used are limestonne, clay, coke breeze and Iron ore. The raw mix design followed by the plant is given below. Limestonne Clay Coke breeze Iron Ore

= = = =

75% 8.75% 12% 3.75%

13.4.8 Consumption Factor of Raw Materials

The raw materials consumption factor per tonne of clinker and cement are given belowin Table 26. Table 26: Raw Materials Consumption Factor

SI. No. 1 2 3 4

Consumption Factor Per tonne of Per tonne of cement clinker 1.188 1.250 0.143 0.150 0.200 0.210 0.060 0.063

Raw Materials

Limestonne Clay Coke Breeze Iron Ore

The specific thermal energy consumption is 1008 Kcals/Kg of clinker. Whenever there is no power supply, the plant is being operated with Diesel Generator set. 13.4.9 Process Parameters of VSK

The process parameters of Vertical Shaft Kiln are given below: - 6-12 a) Nodule Size (mm) 12-14 - Moisture (%) b) 12 - Fuel in Kiln Feed (%) c) 53

d) e)

50-80 300-500

Clinker Temperature (°C) - Bed Length from top (mw) - Noise Pollution

13.4.10

Noise levels were monitored at various sources in the plant and are given in Annexure III. The distance between source of noise and point of measurement is approximately 3 m. The number of persons working near the sources is 3 each. Water Requirement

13.4.11

The average quantity of water required for this VSK cement plant is 15,000 Ilitres / day as reported by the plant. Solid Waste

13.4.12

Solid waste generation is practically nil.

13.4.13

Manpower

The total manpower deployed , as reported by them, is 6 staff and 32 contract labours. 13.5 Plant - 5 13.5.1 History

1. 2. 3.

4. 5. 6. 7. 8.

Plant-5 Behror, Rajasthan 50 TPD 30 TPD

Name of Plant Location Installed Capacity Actual output obtained (Average) on the days of monitoring Year of Commissioning Technology Adopted

1993 Semi Dry Process Saboo VSK Technology 10,372 Tonnes / Annum Yes Ordinary Portland Cement

Actual Cement Production Future Expansion Types of cement Manufactured

13.5.2 Manufacturing Process and Flow Sheet

Saboo VSK Technology based on black meal process in which all Raw Materials viz. Limestonne, Clay, Coke Breeze, and iron ore are ground together to a fineness of 10% residue on 170 mesh (90.t) as in dry process and immediately 54

blended to satisfy the chemical quality requirement for the Raw Meal. The homogenous Raw Meal is formed into nodules of desired size (6 to 12 mm diameter) by adding water in a pan noduliser and fed into Vertical Shaft Kiln through revolving feed hopper inside VSK arrangement. As the material passes down the kiln, it is dried, calcined and burnt into clinker. The clinker is then cooled and discharged from the kiln through discharge arrangement. The combustion air is supplied through Roots Blower, also serves the purpose of cooling the clinker and thus avoids wastage of heat. The cooled clinker then passes on to cement mill where it is ground with about 5% Gypsum to manufacture Cement of Standard Quality. Flow sheet of Plant — 5 is shown in Exhibit — 10. 13.5.3 Sources of Air Pollution (Stack & Fugitive)

Sources of air pollution are shown in Table 27. Table 27: Sections Causing Air Pollution SI. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10

Types of Pollution Control Equipment Section

Bag Filter Bag Filter Bag Filter Bag Filter Hood Dust Setting Chamber Hood

Crushing Raw Materials Proportioning Raw Mill Blending Nodulisation VSK Clinker Discharge Clinker Tunnel Cement Mill Packi g

-

Bag Filter Bag Filter

13.5.4 Stack Emission

The stack emission monitoring carried out in important sections is given in Annexure IV. Three samples of particulate matter emisions were taken at VSK stack and the values observed are 400, 359 and 351 mg/Nm 3 and its average is 370 mg/Nm 3 . Particulate matter emission rate in kg/hr are 7.2, 6.46 and 6.32 respectively. SO2 concentration in the flue gas analysis varies from 5 to 5.5 mg/Nm 3 . The details of the stack (VSK chimney) are given below: • • • • •

Stack dimension Dia (m) / height (m) Stack cross sectional area (m 2 Flue gas temp. (°C) Exit gas velocity of flue gas (Average)(m/sec) Flow rate (m 3/hr) )

55

= = = = =

0.9/5.0 0.632 65 8.9206 18,011

Flue gas analysis was carried out with "Flue Gas Analyser". The flue gas analysis indicates presence of carbon monoxide in traces. The flue gas analysis for 02, CO2, CO and N 2 is given at Annexure IV. 13.5.5 Ambient Air Quality

Fugitive dust emissions were measured near raw mill section and the values are given in Annexure IV. Ambient air quality monitoring was carried out in upwind and downwind directions and results are given in Annexure IV. 13.5.6 Analysis of Particulate Matter for Particle Size Distribution

Particle size distribution of the collected dust in thimbles (VSK Flue Gas) was carried out and the values are given in Annexure IV. 13.5.7 Raw Materials

The plant is using 4 component mixes for clinker manufacture. The raw materials used are limestonne, clay, coke breeze and Iron ore. The raw mix design following by the plant is given below. Limestonne Coke Breeze Clay Laterite

= = = =

72.40% 12.00% 12.30% 3.30%

13.5.8 Consumption Factor of Raw Materials

The raw materials consumption factor per tonne of clinker and cement are given below in Table 28. Table 28: Raw Materials Consumption Factor

SI. No. 1 2 3 4

Consumption Factor Per tonne of Per tonne of clinker cement 1.216 1.155 0.202 0.192 0.210 0.200 0.052 0.055

Raw Materials

Limestonne Clay Coke Breeze Iron Ore

The specific thermal energy consumption is 1008 K.cals/Kg of clinker. Whenever there is no power supply, the plant is being operated with Diesel Generator set.

56

13.5.9 Process Parameters of VSK The process parameters of Vertical Shaft Kiln are given below: 6-12 Nodule Size (mm) a) 12-14 Moisture (%) b) 12 Fuel in Kiln Feed (%) C) 50-80 Clinker Temperature (°C) d) 300-500 Bed Length from top (mw) e) -

-

-

-

-

Noise Pollution

13.5.10

Noise levels were monitored at various sources in the plant and are given in Annexure IV. The distance between source of noise and point of measurement is approximately 3 m. The number of persons working near the sources is 3 each. Water Requirement

13.5.11

The average quantity of water required for this VSK cement plant is 15,000 litres/ day as reported by the plant. Solid Waste

13.5.12

Solid waste generation is practically nil.

13.5.13

Manpower

The total manpower deployed at this plant, as reported by them, is 12 staff and 18 contract labours. 13.6 Plant - 6 13.6.1 History 1. 2. 3.

4. 5. 6. 7. 8.

Name of Plant Location Installed Capacity Actual output obtained (Average) on the days of monitoring Year of Commissioning Technology Adopted Actual Cement Production Future Expansion Types of cement Manufactured

Plant —6 Behror, Rajasthan 20 TPD 15 TPD 1985 Semi Dry Process Saboo VSK Technology 5,116 Tonnes / Annum No Ordinary Portland Cement (OPC)

13.6.2 Manufacturing Process and Flow Sheet

Saboo VSK Technology based on black meal process in which all Raw Materials viz. Limestonne, Clay, Coke Breeze, and laterite are ground together to a fineness of 10% residue on 170 mesh (90µ) as in dry process and immediately blended to satisfy the chemical quality requirement for the Raw Meal. The homogenous Raw Meal is formed into nodules of desired size (6 to 12 mm

diameter) by adding water in a pan noduliser and fed into Vertical Shaft Kiln through revolving feed hopper inside VSK arrangement. As the material passes down the kiln, it is dried, calcined and burnt into clinker. The clinker is then cooled and discharged by a rotary grate at the bottom of the kiln through discharge arrangement. The combustion air is supplied through Roots Blower,

also serves the purpose of cooling the clinker and thus avoids wastage of heat. The cooled clinker then passes on to cement mill where it is ground with about 5% Gypsum to manufacture Cement of Standard Quality. Flow sheet of Plant —6 is shown in Exhibit — 12

13.6.3 Sources of Air Pollution (Stack & Fugitive) Sources of air pollution are shown in Table 29. Table 29: Sections Causing Air Pollution Types of Pollution Control Equipment

SI. No.

1 2. 3. 4. 5. 6. 7. 8. 9. 10

Section

3 Bag 2 Bag 3 Bag 2 Bag 1 Bag Cyclone system 3 Bag—-- —^ 4 Ba g

Crushing Raw Materials Proportioning Raw Mill Blending Nodulisation VSK Clinker Discharge Clinker Tunnel Cement Mill Packing

13.6.4 Stack Emission The stack emission monitoriong carried out in important sections is given in Annexure V. Three measurements of particulate matter emisions were taken at VSK stack and these values vary from 455 to 504 mg/Nm 3 _ Particulate matter emission rate vary from 0.67 to 0.75 Kg/hr. SO2 concentration in the flue gas vary

from 5 to 6 mg/Nm 3 . The details of the stack (VSK chimney) are given below: • •

Stack dimension Dia (m) / height (m) Stack cross sectional area (m 2 )



= =

0.8/4.8 0.5027

• • •

= Flue gas temp. (°C) Exit gas velocity of flue gas (Average)(m/sec) = = Flow rate (Average - m 3/hr)

55 0.8827 1,480

Flue gas analysis was carried out with "Flue Gas Analyser". The flue gas analysis indicates presence of carbon monoxide in traces. The flue gas analysis for 02, CO2, CO and N2 is given at Annexure V. 3.6.5 Ambient Air Quality

Fugitive dust emissions were measured near Jaw Crusher and are given in Annexure V. Ambient air quality monitoring was carried out in upwind and downwind directions and results are given in Annexure V. 3.6.6 Analysis of Particulate Matter for Particle Size Distribution

Particle size distribution of the collected dust in thimbles (VSK Flue Gas) was carried out and the values are given in Annexure V. 3.6.7 Raw Materials

The plant is using 4 component mixes for clinker manufacture. The raw materials used are limestonne, clay, coke breeze and Iron ore. The raw mix design followed by the plant is given below. Limestonne Coke Breeze Clay Laterite

= = = =

72% 11% 13% 4%

3.6.8 Consumption Factor of Raw Materials

The raw materials consumption factor per tonne of clinker and cement are given belowin Table 30. Table 30: Raw Materials Consumption Factor

SI. No. 1 2 3 4

Consumption Factor Per tonne of Per tonne of cement clinker 1.150 1.210 0.178 0.185 0.209 0.220 0.065 0.062

Raw Materials

Limestonne Clay Coke Breeze Iron Ore

The specific thermal energy consumption is 888 Kcals/Kg of clinker. Whenever there is no power supply, the plant is being operated with Diesel Generator set. 59

13.6.9 Process Parameters of VSK

The process parameters of Vertical Shaft Kiln are given below: 6-12 a) Nodule Size (mm) 12-14 Moisture (%) b) 11 Fuel in Kiln Feed (%) c) 50-80 Clinker Temperature (°C) d) 300-500 Bed Length from top (mw) e) -

-

-

-

-

Noise Pollution

13.6.10

Noise levels were monitored at various sources in the plant and are given in Annexure V. The distance between source at noise and point of measurement is approximately 3 m. The numbers of persons working near the sources are 3 each. Water Requirement

13.6.11

The average quantity of water required for this VSK cement plant is 5,000 litres / day as reported by the plant. Solid Waste

13.6.12

Solid waste generated is practically nil. Manpower

13.6.13

The total manpower deployed at this plant, as reported by them, is 8 staff and 9 contract labours. 13.7 Plant-7 13.7.1 History

1. 2. 3.

4. 5. 6. 7. 8.

Plant —7 Behror, Rajasthan 50 TPD 27 TPD

Name of Plant Location Installed Capacity Actual output obtained (Average) on the days of monitoring Year of Commissioning Technology Adopted

1990 Semi Dry Process Saboo VSK Technology 10,990 Tonnes / Annum No Ordinary Portland Cement

Actual Cement Production Future Expansion Types of cement Manufactured 60

13.7.2 Manufacturing Process and Flow Sheet

Saboo VSK Technology based on black meal process in which all Raw Materials viz. Limestonne, Clay, Coke Breeze, and laterite are ground together to a fineness of 10% residue on 170 mesh (90µ) as in dry process and immediately blended to satisfy the chemical quality requirement for the Raw Meal. The homogenous Raw Meal is formed into nodules of desired size (6 to 12 mm diameter) by adding water in a pan noduliser and fed into Vertical Shaft Kiln through revolving feed hopper inside VSK arrangement. As the material passes down the kiln, it is dried, calcined and burnt into clinker. The clinker is then cooled and discharged by a rotary grate at the bottom of the kiln through discharge arrangement. The combustion air is supplied through Roots Blower, also serves the purpose of cooling the clinker and thus avoids wastage of heat. The cooled clinker then passes on to cement mill where it is ground with about 5% Gypsum to manufacture Cement of Standard Quality. Flow sheet of Plant — 7 is shown in Exhibit —14 13.7.3 Sources of Air Pollution (Stack & Fugitive)

Sources of air pollution are shown in Table 31. Table 31: Sections Causing Air Pollution SI. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10

Types of Pollution Control Equipment Section

Crushing Raw Materials Proportioning Raw Mill Blending Nodulisation VSK Clinker Discharge Clinker Tunnel Cement Mill Packing

Bags Bags Bags Bags Bags Dust settling chamber Bags -

Bags -

13.7.4 Stack Emission

The stack emission monitoring carried out in important sections is given in Annexure VI. Three measurements of particulate matter emisions were taken at VSK stack and these values varying from 87 to 126 mg/Nm 3 . Particulate matter emission rate vary from 0.30 to 0.43 Kg/hr. SO2 concentration in the flue gas analysis vary from 6 to 7 mg/Nm 3 . The details of the stack (VSK chimney) are given below: 0.9 / 4.5 Stack dimension Dia (m) / height (m) = • = 0.6362 Stack cross sectional area (m 2 ) • 61

• • •

Flue gas temp. (°C) Exit gas velocity of flue gas (m/sec) Flow rate (m 3 /hr)

= = =

123 1.6319 3392

Stack flue gas analysis was carried out with "Flue Gas Analyser". The flue gas analysis indicates presence of carbon monoxide in traces. The flue gas analysis for 02, CO2, CO and N2 is given at Annexure VI. 13.7.5 Ambient Air Quality

Fugitive dust emissions were measured near raw mill and are given in Annexure VI. Ambient air quality monitoring was carried out in upwind and downwind directions and results are given in Annexure VI. 13.7.6 Analysis of Particulate Matter for Particle Size Distribution

Particle size distribution of the collected dust in thimbles (VSK Chimney Flue Gas) was carried out and the values are given in Annexure VI. 13.7.7 Raw Materials

The plant is using 4 component mixes for clinker manufacture. The raw materials used are limestonne, clay, coke breeze and Iron ore. The raw mix design followed by the plant is given below. Limestonne Coke Breeze Clay Laterite

= = = =

77.10% 15.70% 4.30% 2.90%

13.7.8 Consumption Factor of Raw Materials

The raw materials consumption factor per tonne of clinker and cement are given below in Table 32. Table 32: Raw Materials Consumption Factor

SI. No. 1 2 3 4

Consum tion Factor Per tonne of Per tonne of cement clinker 1.235 1.30 0.247 0.26 0.067 0.07 0.048 0.05

Raw Materials Limestonne Clay Coke Breeze Iron Ore

62

The specific thermal energy consumption is 1248 Kcals/Kg of clinker, whenever there is no power supply, the plant is being operated with Diesel Generator set. 13.7.9 Process Parameters of VSK The process parameters of Vertical Shaft Kiln are given below: 6-12 Nodule Size (mm) a) 12-14 b) Moisture (%) Fuel in Kiln Feed (%) 15.7 c) 50-80 Clinker Temperature (°C) d) Bed Length from top (mw) 300-500 e) -

-

-

-

-

13.7.10

Noise Pollution

Noise levels were monitored at various sources in the plant and are given in Annexure VI. The distance between source of noise and point of measurement is approximately 3 m. The numbers of persons working near the sources are 3 each. Water Requirement

13.7.11

The average quantity of water required for this VSK cement plant is 14,500 litres / day as reported by the plant. 13.7.12

Solid Waste

Solid waste generated is practically nil. 13.7.13

Manpower

The total manpower deployed at this plant, as reported by them, is 12 staff and 28 contract labours. 13.8 Plant - 8 13.8.1 History 1. 2. 3.

4. 5.

Plant-8 Behror, Rajasthan 50 TPD 21 TPD

Name of Plant Location Installed Capacity Actual output obtained (Average) on the days of monitoring Year of Commissioning Technology Adopted

1993 Semi Dry Process Saboo VSK Technology 63

6. 7. 8.

Actual Cement Production Future Expansion Types of cement Manufactured



5,121 Tonnes / Annum No Ordinary Portland Cement (OPC)

13.8.2 Manufacturing Process and Flow Sheet

Saboo VSK Technology based on black meal process in which all Raw Materials viz. Limestonne, Clay, Pet Coke and Laterite are ground together to a fineness of 10% residue on 170 mesh (90µ) as in dry process and immediately blended to satisfy the chemical quality requirement for the Raw Meal. The homogenous Raw Meal is formed into nodules of desired size (6 to 12 mm diameter) by adding water in a pan noduliser and fed into Vertical Shaft Kiln through revolving feed hopper inside VSK arrangement. As the material passes down the kiln, it is dried, calcined and burnt into clinker. The clinker is then cooled and discharged by a rotary grate at the bottom of the kiln through discharge arrangement. The combustion air is supplied through Roots Blower, also serves the purpose of cooling the clinker and thus avoids wastage of heat. The cooled clinker then passes on to cement mill where it is ground with about 5% Gypsum to manufacture Cement of Standard Quality. Flow sheet of Plant — 8 is shown in Exhibit —16 13.8.3 Sources of Air Pollution (Stack & Fugitive)

Sources of air pollution are shown in Table 33. Table 33: Sections Causing Air Pollution Types of Pollution Control Equipment

SI. No.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Section

Crushing Raw Materials Proportioning Raw Mill Blending Nodulisation VSK Clinker Discharge Clinker Tunnel Cement Mill Packing

Bags Bags Bags Bags Bags Dust setting chamber Bags -

Bags -

13.8.4 Stack Emission

The stack emission monitoring carried out in important sections is given in Annexure VII. Three samples of particulate matter emissions were taken at VSK stack and these values are varying from 541 to 648 mg/Nm 3 before dust setting 64

chamber and 64 to 184 mg/Nm 3 after dust setting chamber. Particulate matter emission rate varies from 0.85 to 1.02 Kg/hr before dust setting chamber and 0.10 to 0.13 Kg/hr after dust setting chamber. SO2 ,concentration in the flue gas analysis varies from 7 mg/Nm 3 to 8 mg/Nm 3 . The details of the stack (VSK chimney) are given below: • • • • •

= Stack dimension Dia (m) / height (m) = Stack cross sectional area (m 2 ) = Flue gas temp. (°C) Exit gas velocity of flue gas (Average)(m/sec) = = Flow rate (Average - m 3 /hr)

0.6096 / 3... 1.169 50 1.65 1574

Flue gas analysis was carried out with "Flue Gas Analyser". The flue gas analysis indicates presence of carbon monoxide in traces. The flue gas analysis for 02, CO 2 , CO and N 2 is given at Annexure VII. 13.8.5 Ambient Air Quality

Fugitive dust emissions were measured near Jaw Crusher and are given in Annexure VII. Ambient air quality monitoring was carried out in upwind and downwind directions and results are given in Annexure VII. 13.8.6 Analysis of Particulate Matter for Particle Size Distribution

Particle size distribution of the collected dust in thimbles (VSK Chimney Flue Gas) was carried out and the values are given in Annexure VII. 13.8.7 Raw Materials

The plant is using 4 component mixes for clinker manufacture. The raw materials used are limestonne, clay, coke breeze and Iron ore. The raw mix design followed by the plant is given below. Limestonne Pet Coke Clay Laterite

= = = =

74.70% 8.70% 13.30% 3.30%

13.8.8 Consumption Factor of Raw Materials

The raw materials consumption factor per tonne of clinker and cement are given below in Table 34.

65

Table 34: Raw Materials Consumption Factor SI. No.

1 2 3 4

Consumption Factor Per tonne of Per tonne of clinker cement 1.27 1.207 0.143 0.15 0.209 0.22 0.06 0.057

Raw Materials Limestonne Clay Coke Breeze Iron Ore

The specific thermal energy consumption is 1275 Kcals/Kg of clinker. Whenever there is no power supply, the plant is being operated with Diesel Generator set. 13.8.9 Process Parameters of VSK The process parameters of Vertical Shaft Kiln are given below: 6-12 Nodule Size (mm) a) 12-14 b) Moisture (%) Fuel in Kiln Feed (%) 8.70 C) 50-80 Clinker Temperature (°C) d) 300-500 Bed Length from top (mw) e) -

-

-

-

-

13.8.10

Noise Pollution

Noise levels were monitored at various sources in the plant and are given in Annexure VII. The distance between source of noise and point of measurement is approximately 3 m. The numbers of persons working near the sources are 3 each.

13.8.11

Water Requirement

The average quantity of water required for this VSK cement plant is 15,000 Its / day as reported by the plant.

13.8.12

Solid Waste

Solid waste generation is practically nil.

13.8.13

Manpower

The total manpower deployed at this plant, as reported by them, is 10 staff and 9 contract labours.

66

14.0 EMISSION STANDARDS FOR CEMENT SECTOR The emission standards for cement plants notified under the Environment Protection Act, 1986 are given below in Table 35. Table 35: Particulate Matter Emission Standards in India Emission Limit(mg/Nm 3 Other Area Protected Area 400 250 2 50 150 )

Capacity < 200 TPD > 200 TPD

The emission standards for cement plants including grinding units locared in critically polluted or urban areas with a population of one lakh and above (including 5 km distance outside urban boundary) is given below. Particulate matter emission: 100 mg/Nm 3 The emission standards for new cement kils including grinding units is given below. Particulate matter emission: 50 mg/Nm 3 15.0 DUST COLLECTION SYSTEMS Particulate matter, commonly called dust, is the primary emission in the manufacture of Portland cement. For the control of dust, the Cement Industry employs the following dust collectors. i) ii) iii) iv)

Gravity settling chambers Cyclones Fabric filters Wet Scrubbers

The basic mechanism of removing particulate matter from gas stream may be classified as: 1. 2. 3. 4. 5.

Gravitational Settling Centrifugal Impaction Inertial Impaction Direct Interception Diffusion

15.1 Gravity Settling Chambers Gravity settling chambers will always be of importance for pre-cleaning of high dust laden gases. They work on the principle of removing dust by reducing the

67

velocity of gas (or) air stream. The gas is directed from the dust generating equipment into the large volume settling chamber, where the velocity drops low enough to let large dust particles drop out by gravity. Dust settling chambers are sometimes equipped with deflectors, to charge the direction of gas flow and so to shorten the settling path of particles, improving collection efficiency. Because of the simple construction, gravity-settling chambers are the lowest in cost, but at the same time also the least effective dust collection devices. The efficiency of gravity settling chamber The gas velocity in the settling chamber The pressure drop

4 4 4

30 — 70% 100 ft/min 0.2 — 1.0 mmWG

Schematic of gravity settling chambers for dust removal is shown in Fig. 8. 15.2 Cyclones 15.2.1 Operation A cyclone consists essentially of two sections: a cylindrical and a conical one. At the top of the cylindrical section the gas enters tangentially and spirals along the walls downward into the conical section (outside vortex); from here it starts to occupy the center space of the cyclone, and spirals upwards (inside vortex) to the outlet. Centrifugal forces push the dust particles towards the wall where they accumulate and descend down by gravity as well as under the influence of the outer vortex. Most of the particles fall down to the bottom into a hopper from where they are removed by rotary valves (or) screw conveyors. The ascending gas vortex represents the clean gas, but it always contains a certain amount of fine particulates. The Inside Vortex occupies only a small part of the cyclones cross-section, and along its axis there is the so called neutral sector; if the size of this sector is large, then a considerable amount of dust is taken away with the escaping gases. From this it results that the longer distance a dust particle has to cover for reaching the boundary gas layer, the less particles are separated in the cyclone; therefore it can be said that the efficiency of cyclone is inversely proportional to its diameter. Diameter (inches) Efficiency

9 96.7%

16 92.6%

24 88.2%

124 57.5%

Cyclones are low cost dust collectors, without moving parts, and can be furnished with refractory linings for high temperature upto 1800°F. The pressure drop of cyclones is in the range from 1.2 to 6.5 inches water column and depends on - The temperature of the gas; The size of the cyclone; and on - - The inlet velocity of the gas. Design proportions of a cyclone dust separator are given in Fig. 9.

FIG. 8 SCHEMATIC OF GRAVITY SETTING CHAMBERS

A

A

--I

A

L

GAS

Bc = De = He Lc = Sc = Zc = Jc =

DUST OUT

FIG.9 DESIGN PROPORTIONS OF A CYCLONE DUST SEPAR 70

15.2.2 Maintenance Operational problems in cyclone are more due to process factors rather than constructional aspects. Some of the operational problems in cyclone are given below. Plugging of cyclone either in inlet duct, cyclone body or in exit duct. i) Plugging of inlet duct can occur when dust agglomerates due to fineness or presence of moisture particularly when temperature falls below due point of gas. Plugging of cyclone body occurs when hopper is plugged and dust level rises in cyclone. Erosion in cyclone is caused by impingement and rubbing of dust ii) particles on cyclone wall due to high dust loading, high inlet velocity and coarse dust particles. 15.3 Multiple Cyclones or Multicyclones Multicyclones are enclosed units arranged in banks for parallel flow with feed gas from a plenum chamber and with a common dust discharge hopper; multicyclone units can contain upto 400 individual cyclones. Efficiency of Multicyclones Pressure drop

4 4

85 — 94% 5 — 7 in of water column

A disadvantage of multicyclones is plugging of small tubes. Longitudinal section of multicyclone for dust collection is given in Fig. 10. 15.4 Fabric Filters Particle collection in fabric filter is based on several collecting mechanisms gravitational diffusion and interception, impaction, inertial including sedimentation. Generally, inertial impaction, interception and diffusion mechanisms are important for particles below one micron. Gravitational settling and filteration by the packed bed of accumulated dust on the surface of filter media are decisive factors for coarse particles. The pressure drop across the fabric filter is about 100-125 mmWG and the collection efficiency is as high as 99.99% depending on the type of fabric used. It is a constant efficiency dust collector and minor variations in process parameters affect the performance of fabric filter. Bag house filter media and cleaning system constitute basic components of the fabric filter. Fabric filter systems typically consist of a tubular bag or an envelope suspended or mounted in such manner that the collected particles fall into a hopper when dislodged from the fabric. The structure in which the bags hang is known as bag house. Generally, particle-laden gas enters the bag at the bottom and passes

71

CLEAN AIR DISCHARGE

INTAKE OF DUST LADEN AIR

ACCESS DOORS

DISCHARGE FOR FINE DUST

DISCHARGE FOR COURSE DUST

FIG. 10 LONGITUDINAL SECTION OF MULTICYCLONE FOR D COLLECTION 72

through the fabric while the particles are deposited on the inside of bag. Large bag houses are constructed with several compartments, so that one compartment may be isolated for cleaning as needed while the other compartments are operating. The bags should be arranged in each compartment provided for dust collection and the dust is removed by rotary or screw valves. The cleaning mechanisms can be mechanical shaking system, reverse air cleaning system or high pressure pulse jet cleaning system. The cleaning may be accomplished by shaking the bags or by increasing the air pressure on the bag in a manner that causes the bag to collapse or otherwise deform sufficiently to dislodge the accumulated dust. The following advantages makes the fabric filters the best choice in many cases. i) ii) iii) iv)

Very high efficiency Retention of finest particles Collection of particulates in dry form Relatively low pressure drop

Some of the disadvantages using fabric filters are: i) ii) iii) iv)

Their large size High construction cost This application only to process temperature generally below 285°C High operating costs

The main operational problems of fabric filters are: - - - - - - -

Variation in filtration velocity Gas temperature below due point causing clogging of bags Variation in pressure drop Improper gas flow distribution in various compartments Cleaning system and its operation Flow control systems, inlet ducting, fans etc. Fire and explosion hazards. Schematic diagram of typical bag house is given in Fig. 11.

15.5 Wet Scrubbers 15.5.1 Operation The basic function of wet scrubbers is to provide contact between the scrubbing liquid, usually water, and the particulate to be collected. This contact can be achieved in a variety of ways as the particles are confronted with so called impaction targets — which can be wetted surfaces or individual droplets. Whether the particles encounter wetted surfaces as in packed Scrubbers or individual droplets as in spray scrubbers, the basic mechanism are the same as 73

.EAN GAS

MECHANISM

SAGS

DUSTY GAS

ON

DUST OUTLET

FIG.1 I TYPICAL BAG HOUSE

74

in filters; inertial impaction, interception and diffusion. Generally impaction and interception are the predominant mechanisms for particles of diameter above 0.3 µm, and for particles of diameter below 0.3µm, diffusion begins to prevail. In addition, diffusiophoretic deposition and electrostatic precipitation also effect particle collection. Diffusiophoretic deposition can be significant when mass transfer within the scrubber, caused by condensation of water vapour from the gas onto a cold liquid surface, exerts a force upon the particles and causes them to get deposit on the surface. There are many scrubber designs presently available where the contact between the scrubbing liquid and the particles is achieved in a variety of ways the major types are i) ii) iii) iv)

Spray Towers Centrifugal scrubbers Packed beds and plate columns Venturi Scrubbers

Each type of design has a certain range of applicabitty. Thus low energy scrubbers such as spray towers are most often used to handle particles largely about 5-10 µm in diameter. The effectiveness of the conventional spray tower ranges from 94% for 5 µm particles to 99% for 25µm particles. Schematic diagram of spray tower is given in Fig. 12

15.5.2 Advantages of Wet Scrubber - - - - - -

Simultaneous removal of gases and particulates Effective performance over a wide loading range Equipment occupies only a moderate amount of space compared to dry collectors such as bag house Hazards of explosive dust-air mixtures are reduced Indifference to the temperature and moisture content of gas Corrosive gases may be neutralized by proper choice of scrubbing liquid

15.5.3 Disadvantages of Wet Scrubber - - - - -

Relatively high energy cost Problem of wet sludge disposal Corrosion problems Visible wet plume, reduction in buoyancy Very small particles (sub-micron sizes) may not be captured.

75

CLEAN GAS OUT

II MIST EL

WATER IN

0

0 0 0 00

° ° o

DIRTY GAS IN

^ o 0

SLURRY OUT

FIG.12 SPRAY TOWER

76

SPRAYS

16.0 SOURCES OF AIR POLLUTION 16.1 Introduction Pollution control aspects are being given increasing attention in recent years. Mini cement plant is basically air polluting industry. Air pollution, which basically, can be caused by both particulates and gaseous pollutant, the CRI — MVSK cement plant operation ensures negligible emission of the latter such as NO etc as optimised operating conditions of the kiln generally prevents emission of such gases. The generation of particulates, however, is inherent in the manufacturing process and the associated unit operations, which is controlled by the application of dust collectors wherever required. The operation of vertical shaft kiln, which is the heart of process, is such that less emission takes place as the shaft kiln itself acts as an effective filter.

16.2 Manufacturing Process The manufacturing process involved in the VSK mini cement plants essentially consists of the following steps: • Mining and crushing of limestonne (and additives, if necessary) ; • Proportioning of raw materials and fuel based on raw mix design; • Grinding and blending to obtain fine homogenised black meal; • Preparation of nodules ; • Feeding the nodules to vertical shaft kiln wherein the drying, preheating, calcining and sintering takes place resulting in the formation of clinker; • Clinker cooling in the kiln; • Grinding of clinker and gypsum in controlled proportion to produce ordinary portland cement; • Storage, packing and despatch of cement.

16.3 Dust Generation Sources The various dust generation sources are given below:

16.3.1 Mining Mostly mini cement plant sector does not have its own captive mines. They buy limestone mostly from other agencies. Wherever captive mines are there, mining is generally carried out manually. The level of dust generation during drilling / blasting and loading of limestonne is generally low. Dust suppression techniques such as water spray are generally found adequate.

16.3.2 Crushing and Raw Materials Proportioning In crushing section, generally combinations of primary and secondary crushers are used for size reduction. Various raw materials, i.e. crushed limestonne, clay,

riA

coke breeze, additive are stored in hoppers. These materials are extracted from individual hoppers and are conveyed to the raw grinding section. A single cyclone/fabric filter is mostly used to collect dust from both the crushing as well as raw materials proportioning section and sometimes separate dust collectors for these two sections are also recommended depending on the specific situation. 16.3.3 Raw Material Grinding Depending upon the raw material characteristics, air swept ball mills or vertical roller mills are usually employed for the intergrinding of raw materials and fuel. In both the cases, cyclones and fabrics filters are used to keep the emission low. 16.3.4 Raw Material Blending and Homogenising The ground raw meal is blended and homogenised pneumatically in blending silos. The generated dust is collected in fabric filters to ensure low emission. 16.3.5 Kiln Section Raw meal is extracted from the noduliser feed hopper and is fed to noduliser where water is also sprayed to form nodules. In order to collect dust from noduliser a fabric filter is used. The system design and the technology used in the CRI - Modern vertical shaft kiln (CRI - MVSK) have adequate in built provision to restrict dust emission from chimney. This is a unique feature performed by the MVSK, which in addition to clinkerisation also reduce the dust generation significantly. The green bed of moist nodules, which are constantly distributed on the top by the rotary feeder, would trap most of the dust particles and only allow gases into the stack. In fact when CRI — MVSKs are operated as per the norms and procedures, the emission levels are very much within the stipulated norms. In addition, the principle of natural draft, which is employed in the system, further ensures very little entrainment of dust particles and even the small particles which may get into the gas stream, would settle down on the bed due to gravity as the velocity is very less in the stack. Whilst, in general the operational experiences have proved that the kilns based on CRI — MVSK technology do not pose any problem in regard to dust emission, a dust collector of simple design has been developed by NCB which has been successfully installed in CRI — MVSK cement plants. The flue gases from the VSK is made to pass through the dust settling chambers, wherein the dust particles get settled in the chamber, the dust so collected can be re-used in the process.

7a

16.3.6 Clinker Handling Clinker discharged from MVSK through triple air lock discharge gas / material block tube is crushed in a jaw crusher. Clinker and gypsum stored in separate hoppers are extracted to feed to the grinding mill. A fabric filter is used to collect dust from discharge gate / material block tube, clinker crusher and clinker and gypsum extraction points beneath their respective hoppers. 16.3.7 Cement Grinding In mini cement plants based on CRI -MVSK technology, generally open circuit tube mills are employed for cement grinding. The mill works on overflow principle and the product is directly conveyed to the storage silo. Fabric filters are used to facilitate dust collection to ensure very low emissions. 16.3.8 Fugitive Emission Specific instances of fugitive dust generations include dust blown by wind from raw materials stockpile, dust caused by vehicular traffic within the factory, dust leakage from conveyors, conveyor transfer points, silos, storage hoppers and packers etc. Good house keeping, proper maintenance, wetting of dusty areas, use of enclosed storage wherever feasible etc would eliminate fugitive dust. 17.0 GUIDELINES TO CONTROL THE DUST EMISSION As a guideline suggested air pollution control devices for various sections of VSK based mini cement plants are given in Table 36, subject to compliance of emission standards. Table 36: Section wise Suggested Dust Collectors SI' No.

Type of Dust Collector

Section Raw

Materials

Bag filter with proper metallic casing, stack height and stack monitoring requirement

1

and Crushing Proportioning

2

Raw Mill

Twin cyclone & Bag filter with proper metallic casing, stack height and stack monitoring requirement

3

Homogenising Silo

Bag filter with proper metallic casing, stack height and stack monitoring requirement

79

SI. No.

Type of Dust Collector

Section

4

Noduliser

Bag filter with proper metallic casing, stack height and stack monitoring requirement

5

VSK

Cyclone with proper stack height monitoring stack and requirement

6

Clinker Crusher and Discharge Tube

Bag filter with proper metallic casing, stack height and stack monitoring requirement

7

Cement Mill

Bag filter with proper metallic casing, stack height and stack monitoring requirement

8

Packing House

Bag Filter with proper metallic casing, stack height and stack monitoring requirement

The above air pollution control devices are indicative in nature. Cement Plant may explore the possibilities of other devices also. The important thing which is to be kept in mind is that in all the cases the plant has to meet the prescribed emission standards.

80

Annexure

Al: CEMENT RESEARCH INSTITUTE OF INDIA MODERN VERTICAL SHAFT KILN (CRI -MVSK) CEMENT PLANTS IN OPERATION SL. No. 1

Plant's Name and Address Sh. M. Sivachalam Chief Engineer, Nilgiri Cements (P) Ltd. Mirduvathur, Kallakudi 621652, Lalgudi Taluq, Trichy Distt. Tamil Nadu

Year of Commissioning

Capacity (tpd)

1976

20

1981

90

1981

90

1983

100

1984

150

1984

30

—

2

Sh. G.S. Puttabuddi Managing Direictor Veda Cements Ltd., 7/2, Ilnd Cross, Palace Cross Road. Bangalore 560020 —

3

Sh. Aravind Jawalkar Chairman Lokapur Cements Pvt. Ltd. Lokapur 587122 Mudhol Taluk, Bijapur Distt., Karnataka —

4

Sh. R.N. Aggarwal Director Sri Durga Cement Company Ltd., Village Hesla Post Box No. 6, Ramgarh Cantt. Hazaribagh 829122 Jharkhand —

5

6

Shri Praful Varia Managing Director Sandip Cements Pvt. Ltd., P. B. No. 51, Udyog Nagar, Mahuva 364290 Bhavnagar District, Gujarat. The Managing Director Parasuram Cements Ltd., Tezu — 792001 Lohit Distt., Arunachal Pradesh

81

SI. No.

7

8

9

10

11

12

Plant's Name and Address

Year of

Shri Nim Dorji, Managing Director Penden Cement Authority P.O.Gomtu, - 734401 Siliguri R.M.S. (VIA) Bhutan Shri T.D. Katwa Technical Director, Katwa Cement Pvt. Ltd., 125, Khade Bazar, Shahpur — 590 003 Belgaum. Karnataka Shri S.K. Aggarwal Chairman & MD, Jan Priya Cement Ltd., 8/53, Katwa Opp. Railway Station Neem-ka-Thana — 332713 Sikar District Rajasthan Col R.L. Sharma (Retd.) Managing Director Venus Cements Ltd., P.O. Rani Pokhari, Distt. Dehradun, U.P. — 248145 The Managing Director Alagappa Cements Pvt. Ltd., Kilapaluvur — 621 707 Ariyalur Taluq, Trichy Distt. Tamil Nadu Shri A.V. Bagi, Managing Director, Sangam Cements Pvt. Ltd., 3481, Somadevi Galli, Belgaum 590002 Karnataka

82

Commissioning

Capacity (tpd)

1983

100

1984

30

1985

200

1985

100

1985

90

1985

20

SI. No. 13

14

15

16

17

18

Plant's Name and Address

Sh. Sunil Aggarwal Managing Director Prominent Cement Pvt. Ltd., 1-12/C Gandhi Nagar, Gwalior 474002 Madhya Pradesh Sh. S.B. Bhasin Managing Director Kalinga Cement Ltd., 31-A, Kharvela Nagar, Bhubaneswar — 751001 Orissa Sh. V.K. Srivastava General Manager Ajmera Cements Pvt. Ltd., P.O. Bhanduri Distt. Junagarh Gujarat — 362248 Sh. S.S.M. Soundappan Chairman & MD, Tan India Ltd., P. B. No. 191 21, Gandhipuram Main Road, Komarapalayam — 638183 Rajaji Distt. Tamil Nadu. Sh. V.L. Bavishi Managing Director Suvin Cement Pvt. Ltd., Lakhanka Chotila Taluq, Surendra Nagar Distt. Sh. G. Karisiddappa Managing Director Shiva Minerals & Cement Inds. P. Ltd., 409, 1s t Floor, 12` h Cross, Sadashivanagar, Bangalore — 560080

83

Year of Commissioning

Capacity (tpd)

1984

100

1985

150

1986

150

1986

200

1988

100

1985

100

SI. No.

19

20

Plant's Name and Address

The Managing Director, Lakshmi Cements I& Ceramics Inds. Ltd., Ittigehalli Mattodu Hobli, Hosadurga Taluq, Karnataka Sh.D.K. Prabhu Devaiah Managing Director Siddhaganga Cements Pvt. Ltd., B-225, 1s t Stage, 4 th cross, Industrial Estate, Peenya, Bangalore 560058

Year of Commissioning

Capacity (tpd)

1985

100

1985

60

1985

30

1985

100

1986

100

1985

20

—

21

Sh. N.R.A. Krishnan General Manager Shree Shankar Cement Works Pvt. Ltd., Suite 26, J.M. Chamber No. 2, 225, Nariman Point, Bombay 400021. —

22

Sh. Anil Sharma Managing Director Gwalior Cement Co. Pvt. Ltd., 605, Eros Aptt., 56, Nehru Place, New Delhi 110019 —

23

Sh. Kamesh Khaitan Managing Director Abhishek Cements Ltd., Village Patnakuan, Tehsil Jabera Distt. Damoh, Madhya Pradesh —

-

-

24

Sh Manjunath Managing Director Bhagya Cement Pvt. Ltd., Village Nalwar Chittapur Taluk Gulbarga District, Karnataka. —

84

SI. No.

25

26

27

28

29

30

Year of Commissioning

Plant's Name and Address

Sh. Ashok Babu Works Manager (A) Annapurna Cements Pvt. Ltd., Samela Village, Asifabad Taluq, Adilabad Distt, Andhra Pradesh

1987

The Managing Director Amareswari Cements Ltd., Pedaveedu Huzurnagar Taluq, Nalgonda Distt., Andhra Pradesh.



1985

Sh.T kona Reddy Managing Director S. V. Cements Ltd., Kanakadrilli, Koilkunta Taluq, Kurnool Distt. 518123 Andhra Pradesh

200



1986

The Managing Director MIC Cement Limited, Mehta Nagar, Jewargi, Gulbarga Road, P.O. Jewargi - 585310, Gulbarga Distt, Karnataka

100



1987

Sh. Balwant Singh Managing Director Bharat Food India Ltd., Village Baghwar Distt. Sirohi, Madhya Pradesh

100



1986

Sh. M.M. Tramboo Managing Director Khyber Industries (P) Ltd., Khayam Building, New Pora, Srinagar, - 190001 Kashmir

200



1987

85

Capacity (tpd)



100

200

SI. No. 31

32

33

34

35

36

Plant's Name and Address

Sh. S.R. Sehgal Managing Director Calcar Producuts Pvt. Ltd., Bhupdeopur, Kharasia Taluq, Raigarh Distt. Madhya Pradesh — 496661 Sh. Tukaram Hanchatte Managing Director Chitapur Cement Works Pvt. Ltd., Malkhed Road, Chitapur 585211 Gulbarga District Karnataka Sh. Vallabh Sarda Managing Director Sedam Cement Industry Pvt. Ltd., Humnabad Road, Gulbarga District, Karnataka - 585104

Year of Commissioning

Capacity (tpd)

1987

100

1986

30

1986

Sh. K.K. Neelakantappa Executive Director Kaveri Cements Pvt. Ltd., Kumbaranhalli Post, Yeslur (via) Hasan District, Karnataka — 575137

Sh. Ahmed Khan Managing Director Rayhan Minerals & Chemicals Pvt. Ltd., Blue Star, Yelnadu Post, Chicknayakanahalli Taluk Tumkur Distt., Karnataka Managing Director Marls Cements Pvt. Ltd., Dodda Byladakere Hosadurga Taluk Chitradurga District, Karnataka

86

1987

30

1986

200

1986

30

1

SI. No. 37

38

39

40

41

42

Plant's Name and Address The Managing Director Devshree Cement Limited, Kharia Mithapur Jodhpur Distt. Rajasthan Sh. J.S. Bagga Managing Director Mahendra Cements Pvt. Ltd., Jeerabad Village Dhan Distt., Gandhwar Taluq, Indore — 452001 Sunder Thakur Executive Director Varun Cements Pvt. Ltd., B-105, HIG Colony, Indore — 452008 Madhya Pradesh

Sh. B.L. Agarwal Executive Director Hira Industries Limited Plot No. 572 Urla Industrial Area, Urla, Raipur 493221 Madhya Pradesh. Sh. J.K. Sharma Managing Director Jiwan Cements & Chemicals Pvt. Ltd., Dhaula Kuan Sirmaur District Himachal Pradesh Annapurna Cements (P) Ltd., Aboo Khairani, Distt. Tanahu, Kathmandu, Nepal

87

Year of Commissioning

Capacity (tpd)

1988

100

1987

200

1985

200

1987

200

1987

20

1987

30

SI. No. 43

44

45

46

47

48

Plant's Name and Address

Year of Commissioning

Sh,. Shalig Ram Parita Managing Director Balaghat Cements (P) Ltd., 119, 1st Floor Malviya Nagar, Bhopal — 462003 Madhya Pradesh Sh. K.C. Taparia Managing Director Sudarshan Cements & Multi Projects Ltd., Cement Division, D-6, Meera Marg, Banff park Jaipur — 302006 Rajasthan. Sh. G.P. Singhania Managing Director Singhania Cement Pvt. Ltd., P.O. Neora, Raipur Distt., Madhya Pradesh Sh. K.S. Ram Chief Executive Rudra Cement Ltd., Post Box No. 10, Pandripani — 494001 Jagdalpur Bastar Madhya Pradesh Sh. Ramesh Mandakhalli Managing Director Dhanalakshmi Cements (Pvt.) Ltd., 7-1101/34, SBH Colony, Nehru Gunj Gulbarga — 585104 Karnataka Sh. N.R. Jagadeesh Managing Director Ennar Cements Pvt. Ltd., Shivakrupa, B.H. Road, Tumkur — 572103 Karnataka

88

Capacity (tpd)

1988

200

1987

100

1987

30

1987

150

1988

30

1987

60

Plant's Name and Address.

Year of Commissioning

Capacity (tpd)

The Managing Director Seetharam Cements Ltd., Plot No. 79, Panaji Road, Mehboob Nagar District, Pin 509216

1987

100

The Executive Director Progressive Cements Ltd., Old Hazaribagh Road, Ranchi 834001 Jharkand.

1988

100

1985

100

1988

150

1988

100

1988

30

Si. No.

49

—

50

51

Sh. Sanjay Modi, Director, Kalyan Sundaram Cement Inds. Ltd., Century Floor, 3rd Floor, Dr. A.B. Road, Worli, Bombay 400025 —

52

Sh. Navneet Agarwal Managing Director NECEM Cement Ltd., Housing Colony Road, Rukmini Nagar, Dispur, Guahati 781006 —

53

Sh. Ranvir M. Khatau Managing Director Jagadamba Cements Ltd., 407, Maker Bhawan No. 3, 21, New Marinelines, Bombay 400020 —

54

Sh. S.R. Chamaria Managing Director Hanuman Works Pvt. Ltd., 23/1, Tagore Castle Street, Calcutta 700006 —

SI. No. 55

Plant's Name and Address

Sh. S.L. Poddar Managing Director Vallabh Cements Pvt. Ltd., 3rd Floor, Apollo Tower, 2 M G Road, Indore 452001 Madhya Pradesh

Year of Commissioning

Capacity t d

1986

50

1988

100

1987

50

1988

150

1985

50

1987

60

—

56

57

58

The Managing Direcitor, Kohinoor Cements Pvt. Ltd., Raghumathapalam, Via Mellacheru, Mattompally Mandal, Distt. Nalgonda, Andhra Pradesh Sh. Mahesh Gupta Director, Sirohi Cement Pvt. Ltd., RIICO Indl. Area, Sirohi Road, Rajasthan. Sh. P.R.K. Raju, Managing Director, Viswam Cement Ltd., 503, Topaz Building, Panjagutta, Hyderabad 500082 —

59

Sh. N. Indorewala Managing Director, Suvidha Commercial Co. (P) Ltd., 250 Maulana Azad Road (North) Bombay 400008 —

60

Sh. V.S. Taste Managing Director Krishna Cement Utpadaka Sanstha Ltd., 62, Shivaji Nagar, Korad 415110, Satara Distt., Maharashtra

SI. No. 61

62

63

Plant's Name and Address Sh. Saibanna Bajantri Managing Director Kirti Mini Cements Pvt. Ltd., Chittapur 585211 Gulbarga District Karnataka

-T---------

Year of Commissi oni ----

^ 1986

Sh. A. Sennimalai Vice President Dharani Cements Limited, 1 Venus Colony Second Street, Aiwarpet, Madras — 600018

20

1987

Sh. M.V. Chandrasekaran Resident Director Belgundi Cements (P) Ltd., Belgundi Village

1986

30

1987

E

1986

30

Belgaum District Karnataka — 591139 64

Sh. R.K. Mohta Director Mohta Cements Pvt. Ltd.,

Sagar Matha Apartment 18, MG Road, Indore — 452001 65

The Managing Director Yangzon Cement Industries (P) Ltd., Post Box No. 171,

Phuntsholing Bhutan 66

Sh. S.B. Sajjan Shetty

Managing Director 1988

Vikram Cements (P) Ltd., Post Box No. 1, Chittapur — 585211 Station Road, Gulbarga District, Karnataka

91

SI. No. 67

68

69

70

71

72

Plant's Name and Address

The manaaina Director Madurai Cements Ltd., 14712A/1 IA, Melur Main Road, 2 Floor, Near K. K. Nagar Arch. Madurai — 625020 Sh. Virender Singh, Managing Director Thar Cement Ltd., Sitapur, Tehsil — Nawalgarh, Distt.- Jhunjhunu Rajasthan — 333304 Sh. R.P. Agarwal, Director Rishi Cement Ltd., Bharechnagar — 829122 Hazaribagh District, Jharkhand. Shri Dinesh B. Parikh Managing Director Jamshedpur Cement Ltd., Main Road, Bistupur, P.B. # 31,Jamshedpur — 831001 Sh. P. Sharat Chandra Managing Director Manipur Cements Ltd., Dept. Of Industries Lamphalpat, Imphal, Manipur. Sh. G. Kallappa Managing Director Hemavathi Cements Pvt. Ltd., 5 & 6 SSB Mutt Bldg., Tankbund Road, Bangalore 560009

92

Year of Commissioning

Capacity (tpd)

1987

300

1989

150

1989

50

1989

100

1990

50

1990

30

SI. No. 73

Plant's Name and Address

Sh. L.R. Jajee Managing Director Gitanjali Cements (P) Ltd., 8-120 Cloth Bazar, Gulbarga 585102, Karnataka

Year of Commissioning

Capacity (tpd)

1990

30

1990

30

1991

100

1990

30

1991

200

1991

200

—

74

75

Sh. K. Srihari Rao, Managing Director Sri Satyanarayanaswamy Cements (P) Ltd., 1-2-24 Flat No. 104 Venkata Kripa Apartments G.M. Road, Domalguda Hyderabad 500029 Sh. K.V. Narasimha Rao Managing Director Gautam Cements Pvt. Ltd. 5-19-30 Brodiepet 1-2/18, Guntur 522002 Andhra Pradesh —

76

Sh. Gautam Jain Managing Director Utkal Cements Pvt. Ltd., 3, Bentinck Street Calcutta 700001 —

77

Dr. K.S.N. Prasad Managing Director P. R. Cements 29-13-28 Kaleswararao Road, Vijayawada 520002 —

78

Sh. Rohit Jain Managing Director Virgo Cements Ltd., Trade House, (6 th Floor) S. R. C. B. Road, Fancy Bazar, Guwahati 781001 Assam. —

93

SI. No.

Plant's Name and Address

_ 79

80

81

82

83

84

P.S.G. Krishnan Managing Director Rekha Cements & Chemicals Ltd., Basava Nivas 29/1 K.H. Road Bangalore — 560027 Sh. Brij Kishore Sharma Managing Director Sorabh Cement Ltd. Opp. Railway Station Neem-ka-Thana — 332713 Rajasthan Sh. Mehmood-ul-Hassan Managing Director J. & K Minerals Ltd., The Bund Srinagar 190001 J & K.

Capacity Year of Commissi oning 1__ (tpd) ,_l

1991

100

1990

200

1990

The Managing Director Colts Cements Pvt. Ltd., 1, Southern Avenue Maharani Bagh New Delhi —110065

1990

The Managing Director, Katwa Cements Company 125, Khade Bazar Shahpur — 590003 Karnataka

1987

100

1992

100

Sh. A Venkateswara Rao, Managing Director, Vasudeva Cements Ltd., Choutapalli Mathampalli Mandal, Nalgonda Distt., Andhra Pradesh.

94

SI. No. 85

Year of Com mission ing

Plant's Name and Address

Sh. B. Arya, Managing Director, Damoh Clinker (P) Ltd., Peter's Bungalow, Civil Ward 3 Damoh 470661

Capacity _ td

1992

50

1992

50

1993

100

1993

50

1993

100

1993

400

—

86

87

88

Sh. N.N.P. Sinha Managing Director Narsing Cement Company Ltd., Giridih Indl. Area, Giridih, Jharkhand. Sh. Phuntsho General Manager Lakhi Cement Project C/o. Penden Cement Authority Gomtu, Bhutan Sh. Vikho Yshoshu Chairman-cum-Managing Director NSMDC Ltd., Kohima 797001 Nagaland —

89

Sh. S.K. Latoo Managing Director Jaintia Cements Ltd., (Manbha Passah Building) lawrnusiang, Jowai 793150, Meghalaya. —

90

Sh. P. Lohanatha Raja, Managing Director, Everest Cement Limited, P.O. Pattambori, Tq. Kelapur Dt. Yavatnal, Maharashtra 445305 —

95

SI. No. 91

92

93

94

95

96

Plant's Name and Address Sh. D.K. Chetiya Managing Director Umrangso Cements Ltd., Khanapara Narangi Road, Guwahati 781022 Assam. Sh. J.D.Agrawal, Managing Director Quality Cement Industries Ltd., Sr. MIG No. 3, Sector- A, Indrapuri Bhopal — 462021 Sh. M.M. Reddy, Executive Director Banjara Cements Ltd., 8-2-472/A, Road No. 1, Opp. Post Office, Banjara Hills, Hyderabad — 500034. Sh. M. Nageshwara Rao, Managing Director, Grey Gold Cement Ltd., 6-3-655/6/B, 2n d /floor, Somajiguda, Hyderabad — 500482

Sh. A.D. Katwa Chairman & Managing Director Katwa Udyog Ltd. 125, Khade Bazar Shahapur Belgaun — 590003 Karnataka Sh. R.M. Kulloli Managing Director Channagiri Cements Pvt. Ltd., J-9, APMC Market Yard Belgaum Karnataka

96

Year of Commissioning

Capacity (tpd)

1993

100

1994

100

1994

100

1994

200

1994

100

-

30

SI. No. 97

98

99

Plant's Name and Address

Year of Commissioning

Sh. Arvind Bandwalkar Managing Director Bandwalkar Cements Pvt. Ltd. 'TRIMURTI' Shahu Nagar Ichalkaranji — 416115 Karnataka

Capacity (t pd)

30

Sh. Alam John, Director Haroon Cement Factory Pvt. Ltd. Naid Kadal, Srinagar 190002 Kashmir

1995

Sh. C.S. Sharma, Managing Director Gajwa Cement Co. Pvt. Ltd., 29/3, Subhash Nagar, Indore 452003 Madhya Pradesh

20

30

—

100

The Managing Director Shiva Cement Limited, P-25, Civil Township Rourkela 769004 Orissa. Sh. G.P. Agarwal Vandana Cements Pvt. Ltd., Dainik Bhaskar Bhawan 4/54, Press Complex, A-B Road, Indore 452008 Madhya Pradesh

-

50

—

101

-

100

—

102

103

Sh. Anil Dalmia Managing Director Dhruv Industrial Company Ltd. 3A/92-93, Azad Nagar, Kanpur208002

1998

150

The Managing Director Lanco Industries Ltd. Ground Floor, Visaka Towers 1-8-303/69/3, S.P. Road Secunderabad 500003

1997

250

—

97

SI. No. 104

105

Plant's Name and Address

Sh. Ashtaq Ahmed, Managing Director Trumboo Cement Industries (Pvt.) Ltd. 2 Floor, Baba Building Poloview, Srinagar Jammu & Kashmir The Managing Director Vinay Cements Ltd. (Assam) Umrongso, N.C. Hills Distt. Assam Ph. 561101, 562943

98

Year of Commissioning

Capacity (tpd)

1999

200

2001

200

A 2 : CEMENT RESEARCH INSTITUTE OF INDIA MODERN VERTICAL SHAFT KILN (CRI -MVSK) CEMENT PLANTS UNDER IMPLEMENTATION SI. No. 1

Plant's Name Hoysala Cements & Ceramics (I) Pvt. Ltd.

Location, District and State Saradgi `B' Gulbarga Karnataka

Capacity (tpd) 100

2

Gurling Mini Cement Plant Pvt. Ltd.

Taran halli Gulbarga Karnataka

30

3

Vivekananda Cements Pvt. Ltd.

Somkhed Gulbarga Karnataka

30

4

Sree Vasupuja Cements & Allied Chemicals Pvt. Ltd.

Ningapur Halki Bijapur Karnataka

100

5

& Saraf Inds Enterprises Pvt. Ltd.

Metka Rajouri Jammu & Kashmir

100

6

Deepti Cements Pvt. Ltd.

Thimmasandra Bangalore Karnataka

30

7

Mahavir Silicons Pvt. Ltd.

Algundi Bijapur Karnataka

100

8

Bhagyalakshmi Cements Pvt. Ltd.

Vajinepalli Nalgonda Andhra Pradesh

100

9

Himalayan Foot Hills Pvt. Ltd.

Rajpura Mandi Poonch Jammu & Kashmir

100

10

Naya Kashmir Cement

Khalahar Anantnag Jammu & Kashmir

100

Commercial

SI. No. 11

Plant's Name

Location, District and State Udyog Giri Purena Panna Madhya Pradesh

Chanchal Cements Pvt. Ltd.

Capacity (tpd) 50

12

Anand Cements Pvt. Ltd.

Korumanupalli Kurnool Andhra Pradesh

100

13

Everest Cement Co. Pvt. Ltd.

Sandrus Raigarh Madhya Pradesh

150

14

Basaveshwara Cements Pvt. Ltd.

Matakaldevanhally Bijapur Karnataka

100

15

Honhally Cement Industries Pvt. Ltd.

Honhalli Bijapur Karnataka

100

16

KKR Cements & Carbides Ltd.

Ponnambarai V 0 Chidambaranar Tamil Nadu

100

17

Ruparel Cement Pvt. Ltd.

Mahuva Bhavnagar Gujarat

200

18

Jewargi Cements Pvt. Ltd.

Jewargi Gulbarga Karnataka

200

19

Milton Cements Pvt. Ltd.

Patangi Koraput Orissa

200

20

Prominent Cements Pvt. Ltd (Expansion)

Malanpur Bhind Madhya Pradesh

50

21

Balaghat Cements Pvt. Ltd (Expansion)

Mohabatta Balaghat Madhya Pradesh

100

100

Location, District SI. Plant's Name No. and State 22 Janpriya Cements Pvt. Ltd. (Expansion) Neem-ka -Thana Sikar Rajasthan 23 Sree Vikas Cements Ltd.

Capacity (tpd) 100

Yapalamadharam Nalgonda Andhra Pradesh

100

50/100

24

Sri Hukum Singh Cement Factory

Bhind Madhya Pradesh

25

Gujarat Heavy Chemicals Ltd.

Sutrapada Gujarat

200

26

National Mineral Development Corpn. Ltd.

Chawandia Rajasthan

100

27

Nagaland State Corpn. Ltd.

Khonjheri Nagaland

200

28

Premium Industries Ltd.

Dhanbad Bihar

200

29

Republic of Uzbekistan

Kutarma Dzizak Province Uzbekistan

150

30

Mehr Cements Ltd

Kangrail Village Jammu & Kashmir

31

Mahendra Cements Pvt. Ltd (Expansion)

Jeerabad Adilabad Andhra Pradesh

32

Jagadamba Cements Ltd. (Expansion)

Mohabatgadh Banaskantha Gujarat

50

33

Belgundi Cements Pvt. Ltd. (Expansion)

50

34

Abhishek Cements Pvt. Ltd. (Expansion)

Belgundi Belgaum Karnataka Patankuon Damoh, MP

Mineral Development

101

100/200

200

50

SI. No. 35

Kalinga Cement Ltd. (Expansion)

36

Sandip Cements Pvt. Ltd. (Expansion)

Mahuwa Bhavnagar Gujarat

50

37

Viswam Cements Ltd. (Expansion)

Mallacheruvu Nalgonda Andhra Pradesh

150

38

Jiwan Cements Pvt. Ltd. (Expansion)

Dhaula Kuan Sirmour Himachal Pradesh

200

39

Sangam Cements Pvt. Ltd. (Expansion)

Kaladgi Bijapur Karnataka

200

40

Ajmera Cements Pvt. Ltd. (Expansion)

Bhanduri Junagarh Gujarat

150

41

Sudarshan Cements Pvt. Ltd (Expansion)

Danavaw Sirohi Rajasthan

200

42

Venus Cements Ltd. (Expansion)

Rani Pokheri Dehradun Uttarpradesh

100

43

Suvidha Commercial (Expansion)

Dhar Dhar Madhya Pradesh

200

44

Lakshmi Cements & Ceramics Pvt. Ltd (Expansion)

Ittigehalli Chitradurga Karnataka

200

45

Apex Cements Pvt. Ltd.

Madhya Pradesh

50

46

Kaypee Industries

Madhya Pradesh

200

Location, District and State Birmitrapur Sundergarh Orissa

Plant's Name

Co.

Pvt.

102

Ltd.

Capacity (tpd) 50

SI. No. 47

Dhrungadhara Chemicals Ltd.

48

Arctic Cements (P) Ltd.

Vallioor Tamil Nadu

100

49

Rajapalayam Cements & Chemicals Ltd.

Rajapalayam Tamil Nadu

100

50

Sairfco Cements Pvt. Ltd.

Khunmuh Srinagar J & K.

200

51

Raghuveer Cements

West Bengal

200

Plant's Name

Location, District and State Dhrungadhara Sundarnagar Gujarat

103

Capacity (tpd) 150

B SABOO VSK CEMENT PLANTS IN OPERATION :

Si No. 1

2

3

4

5

6

7

Plant's Name and Address

Year of Commissioning

Sh. N. P. Chaudhary, Apu Industrial Enterprises 27, Western St. Calcutta ( Site Bangladesh)



Jan. 1990

Sh. Dawa Panjore, Namgail Cement Pvt. Ltd., Putshillong Bhutan

Dec. 1991

Shri S. S. Dadi Modern Cement Co. Pvt. Ltd. Vill : Chikhodra, Taluka : Godhra Distt. Panchmahal (G ujarat) Sh. D.H. Sinhar Harekrishna Cement & Chem. P. Ltd. Bijapur Road Bijapur Distt — Junagarh (Gujarat)

50



50

April 1985

50

Feb. 1986

20

Shri Kirit C. Parikh Vikki Cement Pvt. Ltd. Vill. Hadad, Paliyad Road, Taluka Botad, Distt. Bhavnagar (Gujarat)

April 1986

Sh. S. Sriniwasan, Modern Portland Cement Co. Pvt. Ltd., Viii. Chikhodra, Taluka — Godhra Distt. Panchmahal (Gujarat)

Jan. 1989

Shri C.M. Phaldur Sardar Cement Pvt. Ltd. C/o. Rajhans Agencies Virani School Chowk, Tagore Marg Rajkot (Gujarat)



20



March 1992

item]

Capacity (t pd)



30

50

SI. No. 8

Plant's Name and Address

Year of Commissioning

Capacity (tpd)

Dec. 1992

50

Shri Ashwani Kumar Shaktiman Cement Pvt. Ltd. M-31, Behind Police Station Industrial Area, Yamuna Nagar-135001 (Haryana)

Feb. 1993

50

Shri S.S. Sikka Zodaic Cements Pvt. Ltd., Banger Theater, Hisar Road, Rohtak (Haryana)

April 1993

50

June 1993

50

Shri R.K. Bhageria Ramuka & Bhgeria Cement Pvt. Ltd. 93/94, KM Stonne From Delhi NH-8, Teh. Bawa; (Rewari) (Haryana)

Nov.1993

50

Shri Moti Singh Garude Clays Pvt. Ltd. 79, Transport Centre New Rohtak Road New Delhi (Site: Bewari)

June 1994

50

1997

50

Mr. I. M. 5hekh

Star Cement Company C/o. Royal Ice Factory Sikari Mohalla, Godhra Distt. Panchmahal. (Gujarat) Site Vanakpur :

9

10

11

Shri J.P. Beni M/s. Sohna Cements Pvt. Ltd. E-1 04, Greater kailash, Enclave —1, New Delhi (Site Rohtak) :

12

13

14

Shri R.P.Agarwal Monchu Cements Ltd. 3103, Sangtrushan Street, Pharganj New Delhi (Site: Vill- Dhulawat)

105

SI. No. 15

16

17

18

19

20

21

Plant's Name and Address

Year ofapacity (tpd) Commissioning

Shri P. C. Gandhi Satyashree Cement Udyog Bhungarni, Distt. Paonta Sahib Himachal Pradeh.

Dec. 1985

30

Shri A.K. Gupta Himachal Cement Pvt. Ltd., Post Box No.13, Poanta Sahib Himachal Pradesh

June 1986

80

Shri Jagdish Kapoor Sirmour Allied & Chem. Pvt. Ltd. Vill. Mugalanwala Kartarpur P.O. Rajban, Paonta Sahib Himachal Pradesh

Oct. 1986

20

Aug. 1987

30

April.1991

35

Shri C.L. Jain Radiant Cement Co. Pvt. Ltd. Vill. Moginand P.O. Kala Amb, Teh. Nahan Distt. Sirmour Himachal Pradesh Shri Gurdeep Singh Yamuna Cement Pvt. Ltd. 86, Industrial Area Paonta Sahib — 173025 Distt. Sirmour Himachal Pradesh Shri Shalin Jain Vikram Cements Ltd. 210, Gagan Deep 12, Rajendra Palace New Delhi (Site: Nalagarh)

Jan. 1990

50

Shri Mallik Mohd. Qasim Shah Allahi Cement Industries Industrial Extension Area Anchidora, Anantnag — 192101 (Jammu & Kashmir)

Nov.1985

70

i<(II•

Si No. 22

23

24

25

26

27

28

29

Plant's Name and Address

Year of Commissioning

Capacity (tpd)

Oct. 1988

20

Closed

30

March 1984

70

Shri O.P. Mittal, Pluton Cements Pvt. Ltd., 138, Sneh Nagar, Indore

May 1985

40

Sh. J.L.T. Tiwari Dinesh Cements Pvt. Ltd., Khokhali Road, Bhatapara Distt., Raipur, Madhya Pradesh

June1986

20

Jan. 1990

100

April 1993

50

Shri G.D. Naidu Seshasaila Cements Pvt. Ltd. 49/8, 4 th Main, 16 th Cross Malleshwaram, Bangalore. Shri Ravindra Sethi Sri Gaj Mukha Cements Pvt. Ltd. Singapura Kaval Hatti Chitradurga, Karnataka Shri .M.L. Jain Abu Cement Works Pvt. Ltd. 2, Sadhna Nagar, Air Port Road, Indore, M.P.

Sh. O. P. Mittal, Polyport Cement 138, Sneh Nagar, Indore, Madhya Pradesh Shri Y. Singh Chitrakut Cement Pvt. Ltd., 128, Chanakyapuri Semaria Chowk Satna (M.P.) (Site: Rewa) Shri K.G. Somani Apex Cements Pvt. Ltd. Krishna Apartments, Behind Gautam Nagar Race Course Circle Baroda (Site Alirajpur)

50

:

30

Sh. B.L. Hajer Patil Vaidyanath Cement Pvt. Ltd. Laxman Villa, Pangri Road Sahu Nagar (BEED), Maharashtra

April 1985

107

20

SI. No. 31

32

33

34

35

36

37

Plant's Name and Address

Year of

Shri R.B. Agarwal Hasi Cement Pvt. Ltd. Cotton Market Road Amravati Maharashtra Shri Vishwanath Jagadale Ichalkaranji Co-operative Cement Ltd. 10-222. Mahatma, Phule Road Near Shakhar Pe'Hospital Ichalkaranji Maharashtra

Shri Praveen S. Lunkad Nay Maharashtra Portland Cement Ind.. 42/43, Sankar Sheth Road Pune, (Maharashtra)

M/s. Yuvraj Shahu Chhatrapati Cement Utpadak Vadgani Vill/Post : Vadgaon Distt. Kolhapur (Maharashtra) Shri B.L. Purohit Purohit Cement Ltd. 13, Purohit & Company New Cotton Market Nagaur (Site : Wani, Yawatmal) Maharashtra

Shri M.D. Mane Chairman Sidhanath Co-op. Cement Ind. Ltd. AT/PO. Mahuli, Tal — Khanapur Distt. Sangi — 415310 (Maharashtra) Sh. B.L. Bajaj RKB Cements Pvt. Ltd. Bara Bazar, G.S. Road Shilong, Meghalaya — 793002

108

Commissioning

Capacity (tpd)

Jan. 1987

30

Feb. 1987

20

May 1987

50

Jan. 1989

20

April 1993

50

1996

50

March 1995

50

St. No.

38

39

40

41

42

43

44

Plant's Name and Address

Year of Commissioning

Capacity (tpd)

Shri N.K. Agarwal Krishna Cement Pvt. Ltd., H-3, Civil Township Rourkela (Orissa)

Oct. 1984

40

Shri R.P. Gupta Shiva Cements Pvt. Ltd. H-6, Civil Township Rourkela Orissa

Dec. 1986

80

Shri Punit Beriwala Vimal Cement Pvt. Ltd. M-10, Civil Township Rourkela Orissa

Feb. 1987

50

Shri K.M. Sinha Neelanchal Cement Pvt. Ltd. 2115, Ratha Road Bhubaneshwar Orissa

1990

50

Shri Ashok Mahant B.S. Cements Pvt. Ltd. 29, Acharya Vihar Bhubaneshwar Orissa

1990

50

Shri Gopal Joshi Shree Gopal Cements Pvt. Ltd. Main Road Rajgangpur Orissa

June 1992

50

Shri K.K. Modi Ambica Cement Pvt. Ltd. D-14, Civil Township Rourkela Orissa

June 1992

50

109

SI. No. 45

46

47

48

49

50

51

52

53

Year of Commissioning

Capacity (tpd)

Feb. 1992

50

1987

20

March 1993

50

1995

140

Shri Arun Jain Vedvyas Cements Pvt. Ltd. K-3, Civil Township Rourkela (Site : Rourkela) Orissa

July 1993

50

Shri Sandeep Kumar Sushila Cements Pvt. Ltd. Gopabhandhu Marg, Rajgangpur, Distt. Sundargarh, Orissa

Jan. 1994

50

Plant's Name and Address

Shri P.K. Saraf, Kanak Cement Pvt. Ltd. OCL Approach Road Rajgangpur (Orissa). Shri L.K. Jalan Mukund Cement Pvt. Ltd. P.O. Rajgangpur, Distt. Sundargarh (Orissa) Shri R.K. Khaitan Rampal Cements Pvt. Ltd. C/o. Utkal Auto Syndicate Panposh Road Rourkela (Orissa) Shri R.K. Sukhani M/s. Shubham Industries Ltd., Premier Court, Chandni Chowk Street, Calcutta.

Shri R.K. Lohia M/s. Kharia Cement Works Pvt. Ltd. Plot No. 11, Assam House 7, New Power House Road Jodhpur (Site: Kharia Mithapur) Rajasthan.

30 Closed

Shri Sukumar Saboo, Saboo Minerals Marudhar Inudustrial Area, Basni, II Phase, Jodhpur, Shri Ramavtar Agarwal Agarwal Cement & Chem. Pvt. Ltd. Near Post Office, Gotan Distt., Nagaur (Rajasthan)

110

Nov. 1982

30

Jan. 1984

40

SI. No. 54

55

56

57

58

59

60

Year of Commissioning

Capacity (tpd)

June 1984

20

Shri Harcharan Singh Saluja Saluja Cements Pvt. Ltd. A-24/B, Industrial Area Behror (Distt. Alwar) Rajasthan.

Oct. 1984

20-40

Shri G.0 Jain Jain Cements Udyog Pvt. Ltd. Cloth Market Kuchamancity, Dist. Nagaur Rajasthan.

Dec. 1984

20

Shir S.P. Jain Central Construction & Engg. Co. Ltd. Vul/Post: Sindhrath Distt. Sirohi, (Site : Sindhrath) Rajasthan

July 1985

20 —40

Shri. D.N. Tiwari Madhu Cement Pvt. Ltd. 14, Hosppital Road, `C' Scheme Jaipur (Site : Behror) (Rajasthan).

June. 1985

20

Shri G.C. Khemka Khemka Cement Pvt, Ltd. 9, Bechum Bag, S.C. Road Jaipur (Site : Behror) Rajasthan

June 1985

40

Shri Devilal Kothari Shreenath Cement Ind. Pvt. Ltd. Vill. Bhujela, PO. Bharza Abu Road (Rajasthan)

Oct. 1985

20

Plant's Name and Address Shri G.S. Agarwal Solar Cements Pvt. Ltd. Vill. Barodara Post — Lachmangarh Distt. Sikar (Rajasthan)

111

SI. No. 61

62

63

64

65

66

67

Plant's Name and Address

Year of Commissioning

Shri S.N. Sharma Om Shiv Shakti Cement Pvt. Ltd. F-15, Industrial Area Sikar (Rajasthan)

Oct. 1985

Shri Pradeep Sarawgi Jodhpur Cement Ind. Pvt. Ltd. Marudhar Industrial Area Basni, II-Phase, Jodhpur (Rajasthan)



Oct. 1985

S.V. Dujodwala Maruti Cement Pvt. Ltd. Dujodwala Sadan, Bajaj Road Sikar (Site : Khandela) Rajasthan

20



Nov. 1985

Shri Natwar Krishna Harsha Shree Shakti Cement Pvt. Ltd. E-24/25, Ambaji Industrial Area Post Box No. 27, Abu Road, Rajasthan

Feb. 1986

A



20



A

Shri Sarad Kaushik Rajdhani Associates Pvt. Ltd. A-22-B Industrial Area Behror (Distt. Alwar) Rajasthan

Feb.. 1986

Shri J.C. Sodani Sodani Cement & Chem. Pvt. Ltd. E-88/89, Arbuda Industrial Area Abu Road Rajasthan

Jan. 1986

Shri Bhawani Singh Rajputana Cement Pvt. Ltd. High Court Colony Road Panchwati, Jodhpur (Site: Buchkala) Rajasthan

1986

112



Capacity (tpd)





20

40

40

SI. No. 68

69

70

71

72

73

74

Plant's Name and Address Shri Umesh Dhoot Silver Cements Pvt. Ltd. C/o. Gulab Dass Jaggnath Agencies Nahata Building, Chopasni Road Jodhpur (Site : Abu Road) Rajasthan

Year of

Capacity

Commissioning

(tpd)

20 Closed

Shri S.N. Todi, Shaunak Industries Pvt. Ltd. B-25, Industrial Area Behror (Distt : Alwar) Rajasthan

1986

40

Jan. 1987

20

June 1985

50

Sh. S.K. Jain Sarawgi Cement Pvt. Ltd. Opp. New Sabji Mandi, Sujangarh, Distt. Churu (Rajasthan)

Dec.1987

50

Shri N.K. Goenka Swati Cement Pvt. Ltd Vill Biramsar, Teh. Ratangarh Distt. Churu Rajasthan

May 1988

50

March 1988

20

Shri G.C. Jain Jawai Cement Pvt. Ltd. E-13/14, Ambaji Industrial Area Abu Road Rajasthan S.G. Saboo Saboo Minerals Pvt. Ltd. Marudhar Industrial Area Basni, II-Phase, Jodhpur Rajasthan

Shri N.D. Maheshwari Soni Ceramics Pvt. Ltd. 14,15,16, Industrial Area Nagaur Rajasthan

113

SI. No. 75

76

77

78

79

80

81

Commissioning

Year of

Capacity (tpd)

Shri Mukesh Gajaraia Unilinks Cements Pvt. Ltd. Vill. Kiverli, By Pass Road Abu Road, Rajasthan

July 1988

30

Shri V.K. Bhatnagar Bhatnagar Cement Co. Pvt. Ltd. A-1, & NDSE-I, Ring Road New Delhi (Site: Behror)

Dec. 1989

30

Shri Vinodji Durga Cement Pvt. Ltd Vill. Bhujela, P.O. Bharrja Distt — Abu Road Rajasthan

Feb. 1990

30

Shri S.K. Jain Raj Cements Pvt. Ltd. E-90/91, RIICO Industrial Area Churu Rajasthan

July 1990

30

Shri S.K. Jain Sumati Cements Pvt. Ltd. Vill. Biramher, Teh. Ratangarh Distt. Churu Rajasthan

April 1989

80

Shri Nathu Ramji K.D. Cements Pvt. Ltd. D-84, Gheeya Marg, Bani Park Jaipur — 302016 (Site : Bidasar)

June 1990

30

Shri R.A. Agarwal Meera Cements Pvt. Ltd Vul/Post: Gotan Distt. Nagaur Rajasthan

April 1991

50

Plant's Name and Address

114

SI. No. 82

83

84

85

86

87

88

Plant's Name and Address

Year of Commissioning

Capacity t d

Shri Duli Chanji Superfine Cement Pvt. Ltd. E-32 Industrial Area Mertacity, Distt. Nagaur Rajasthan

Sept.1991

50

Shri Maheshji Ajmera Sukhsa Cement Pvt. Ltd Hiswal Industrial Area Bikaner Rajasthan

Jan. 1991

50

Sept . 1991

50

April 1992

50

Jan. 1992

50

Feb. 1992

50

March 1992

50

Shri Sirish Jain Arvind Construction Co. Ltd. L-43, Cannaught Circle New Delhi (Site : Kotputli)

Shri Bhagwan Sahay United CementsPvt.Ltd. C/o. Gopal Bhagwan & Cc'. A-3, Govind Marg, Adarsh nagar Jaipur (Site: Shreemadhopur) Rajasthan

Shri Ashok Chaudhary Shreemadhopur Cement Pvt. Ltd. Surani Bazar Shreemadhopur, Distt. Sikar Rajasthan Shri J.C. Khandelwal Pan Asia Industries Ltd. C-1/33, Safdarjang Development Area, New Delhi (Site: Behror)

Shri Deelip Bajaj Chirag Cement Pvt. Ltd. 32, Vansthali Marg Jaipur (Site : Behror) Rajasthan

115

Si. No.

89

90

91

92

93

94

95

Plant's Name and Address

Shri Yoaesh Pal Tanari Jyoti Cement Pvt. Ltd. F-68, E-70, Industrial Area Behror Rajasthan Shri Ravinder Bahal Gunjan Cements Pvt. Ltd. 9B, Deepali Pitampura Delhi (Site: Behror) Shri C.P. Jain Siddha Cements Pvt. Ltd. Jaipur Towers, Opp. A.I.R. M.I. Road, Jaipur (Site: Behror) Rajasthan Shri R. Prakash Javeline Cement Pvt. Ltd: E-21 1, Greater kailash-I I New Delhi —110048 (Site : Sujangarh) Shri Mahendra Chaudhary Hanumant Cement Pvt. Ltd Marwar, Mundwa Rajasthan. Shri Jagdish Chaudhary Pratibha Cements Pvt. Ltd. C/o. Chaudhary Tours & Travels 1-C, Road, Sardarpura Jodhpur (Site: Ransi) (Rajasthan) Shri Shreechand Agarwal Prime Cements Pvt. Ltd. C/o. Jugal Kishore & Co. C-1 3, Nai Anaj Mandi, Chandpole Bazar Jaipur (Site: Behror) Rajasthan

116

Year of Commissioning

Capacity (tpd)

March1992

50

May 1992

50

June . 1992

50

June 1992

50

Sept.1992

50

May 1992

50

July 1992

50

SI. No. 96

97

98

99

100

101

102

Year of Commissioning

Piss Nam. and Address Shri Shreechand Jain Bothra Contractors & Builders E-121, Shastri Nagar Jaipur (Site: Beewar) Rajasthan

July 1992

Shri S.K. Khandelwal Shubham Cement Pvt. Ltd. Shubh Sadan, Adarsh Colony Teh. Sujangarh, Distt. Churu Rajasthan



Aug.1992

Shri Mahaveer Prasad Prajapati Kuber Cement Pvt. Ltd. Tak Sadan, Ward No. 25 Churu (Site: Ratangarh)

50



50

Aug. 1992

Shri P.R. Mundhra Anita Cements Pvt. Ltd. 33-E, Block Sriganganagar (Site: Beewor) Rajasthan



Dec. 1992

Shri Vinod Kumar Jindal Vijeta Cements Pvt. Ltd. E-104, Industrial Area, Behror (Rajasthan)

Feb.1993

Shri Ravi Goyal M/s Shri Modi Cements ( raj) Pvt Ltd Vidyadhar Ka Rasta Jaipur ( site : Behror) Shri Sandeep Karwa M/s Basera Cements Pvt Ltd F-8 to F-13, Riico Indl. Area, P.O. Shrinadhapur Sikar — Distt. Rajasthan.

50



4.x+7



Dec. 1992

50



Aug. 1992

117

Capacity

50

50

SI. No. 103

104

105

106

107

108

109

T Plant's Name and Address

Year of Com missi oning

Capacity

Jan. 1993

50

Shri Anil Jain M/s. R. Sidharth & Co. (India) Pvt. Ltd. P-1/2, Pal Jaw, New Ambedkar Circle Pali Manwar (Site: Ransi) Rajasthan

Feb.1993

50

Shri Rajendra ji Chandak M/s. Tiger Cements Pvt. Ltd., Sarawati Sadan, TD (A) Sardujganj, Bikaner (Site : Nokha) Rajasthan

Feb. 1993

50

March. 1993

50

Shri. Kaushal Dhoot M/s. Metro Cement Pvt. Ltd. 1 5` Floor, Mahesh Hotel Corn plex Opp. Bombay Motors 5 th Chopasani Road, Jodhpur (Site : Near Gotan) Rajasthan

Shri R.B. Gadia Sakambari Cements Pvt. Ltd. C/o. Dwarka Prasad Ramesh Kumar Cloth Market, Jhunjhunu (Site : Jhunjhunu) Rajasthan Shri Bhagwan Singhji Parihar Laxmi Oil Field Services Pvt.Ltd. C/o. Laxmi Udyog 22-23, Light Industrial Area Jodhpur (Site : Sojat Road) Rajasthan

50

Shri Darbar Singh Padam Cements Pvt. Ltd. 435, A-Block, Padampur Sriganganagar (Site : Ratangarh) Rajasthan Shri Mahesh Kumar Bhagirath Cements Pvt. Ltd. C/o. Sikar Hardware & Co. Opp. Main Post Office Sikar (Rajasthan)

118

March . 1993

50

Sept. 1993

50

SI. No.

110

111

112

113

Plant's Name and Address

Shri Mahesh Pareekh Tirupati Cement Pvt. Ltd. E-37. RIICO Industrial Area Behror (Alwar) Rajasthan Shri Basant Kumar Tater Jineshwar Cement Pvt. Ltd. C/o. Basant Tater G-8, Housing Board Colony, Bhagat Ki Kothi Jodhpur (Site: Boranda) Rajasthan

—

Capacity (tpd)

April. 1993

50

May.1993

50

April 1993

50

May 1993

40

April 1993

50

Sept. 1993

50

June1993

50

Year of

Shri Ram Prasad Dhoot Rajasthan Cement Udyog RIICO Industrial Area Phulera, Distt. Jaipur Rajasthan

Shri J.C. Khandelwal Panasia Industries Ltd 1520, Market Chamber 1221, Nirman Point Bombay (Site Kotputli)

Commissioning

V,

:

114

115

Shri Ganesham Dass Lohahti Shyam Cements Pvt. Ltd. 116, Sarwagi Mansion —1 M.I. Road, Jaipur (Site :Bikaner) Rajasthan Shri D.C. Jain Uttam Cements Pvt. Ltd. D-711A, Sawar Area Paras Marg, Bapu Nagar Jaipur (Site Abu Road) Rajasthan :

116

Shri Jitendra Surana Surana Cements Pvt. Ltd. D-146, Savitri Path Bapu Nagar, Jaipur (Site: Gotan) Rajasthan

119

SI. No. 117

118

119

120

121

122

123

Year of Commissioning

Capacity t d

April. 1994

50

Shri S.K. Jain Sargam Cement Pvt. Ltd A-79, Gopalbadi Jaipur (Site : Ratangarh) Rajasthan

April1993

50

Shri R.K. Tangri Umesh Cement Pvt. Ltd. 322-A, Matasya Industrial Area, Alwar (Site : Alwar) Rajasthan

Aug. 1993

Plant's Name and Address

Shri Girish Gupta Gupta Cements Pvt. Ltd. 22, New Rajdhani Enclave, Vikas Marg New Delhi (Site: Chirawa)

Shri B.C. Agarwal Moti Cement Pvt. Ltd. A-114, Ganesh Nagar New Delhi (Site: Behror)



Aug. 1993

Shri R.P. Jain Mradul Cement Works Pvt. Ltd. G-84, RIICO Industrial Area Ratangarh

Shri N.K. Geonka Maharan Cements Pvt. Ltd. E-24, Industrial Area Sikar Rajasthan Sh. D.P.Agarwal Teesta Cement Pvt. Ltd. 3, 2 d Floor, Anukampa Mansion, Opp. Raymonds Showroom M.I. Road, Jaipur — 302001 Rajasthan "

120

50



50

1994

50

1995

50

Sept. 1993

50

SI. No. 124

125

126

127

128

129

130

Plant's Name and Address

Year of Commissioning

Capacity (tpd)

Shri B.L. Maheswari Sarvottam Cement Pvt. Ltd. Charkara, Nokha Distt. Bikaner (Site: Nokha) Rajasthan

Nov.. 1993

50

Shri Mahendra S. Kachhawa M.G.T. Cements Pvt. Ltd. Chemicals Lime Compound Marwar Mundwa (Site: Marwar Mundwa) Rajasthan

Dec. 1993

50

Shri S.P. Agarwal Mahal Cements Pvt. Ltd 630, Vivek Vihar, New Sanganer Road, Jaipur (Site : Viii — Sarrund ) Rajasthan

Jan. 1994

50

Shri Pratap Rai Panjwani Gemini Cements Pvt. Ltd. H/o. WH-84, Mayapuri Indl. Area, 1st Phase, New Delhi (Site : Alwar)

Dec. 1993

50

Shri Prabhuji Jajodia Cements Pvt. Ltd. C/o. Navyug Oil & Dall Mill 21, Industrial Area, Nagaur (Site: Ratangarh) Rajasthan

June 1993

50

Dec.1993

200

June 1994

50

Shri A.K. Jalan Chinar Cements Pvt. Ltd. P-7, Tilak Marg, 'C Scheme Jaipur (Site : Jhunjunu) Rajasthan

Shri O.P. Gyal Mehta Cements Pvt. Ltd. Marte Road — 341511 Distt. Nagaur Rajasthan

121

SI. No. 131

132

133

134

135

136

137

Plant's Name and Address

Shri V.B. Agarwal Gujarat Filaments Limited 1005, Raheja Centre Nariman Point Bombay — 400021 (Site : Kotputli)

Shri S.P..Agarwal Chokani Cements Pvt. Ltd D-140 Durga Marg Bani Park, Jaipur (Site : Jhunjunu) Rajasthan

Year of Commissioning

Capacity (tpd)

June 1995

140

1996

Shri S.K. Jain Sharhad Cements Pvt. Ltd. C/o. Swati Cements Pvt. Ltd. Vill. Biramsar, Teh. Ratangarh Distt. Churu (Site: Shahpura) Rajasthan



1997

Shri S.K. Jain Suparbhat Cement Pvt. Ltd. C/o. Swati Cements Pvt. Ltd. Vill. Biramsar, Teh. Ratangarh Distt. Churu (Site : Shahpura) Rajasthan

50



1997

Shri Murlidhar Rathi Nokha Cements Pvt. Ltd. Bikasar Road, Nokha Bikaner (Site : Nokha) Rajasthan

50



50

June 1994

Shri B.K.Atijsaria Enkay Agro Pvt. Ltd. 109, A/1-A, Biplabi Basu Road Calcutta (Site: Near Behror)

Jan.1994

Shri Manoj Agarwal Castle Cements Pvt. Ltd. D-25, Calcutta Form Shyam Nagar, New Sanganer Road Jaipur (Site: Kotputali) Rajasthan

1997

122







50

50

50

SI. No. 138

139

140

141

142

143

144

Plant's Name and Address

Shri R. Agarwal Namo Cement Pvt. Ltd. 77, N.S. Road, Suite No. S-8, 4 th Floor Calcutta (Site: Kotputli)

Year of Commissioning

Jan 1994

Shri. A.R. Chaudhary Kinker Cement Pvt. Ltd. B-228, Road No. 9E, Vishkarma Ind. Area Jaipur-302001 (Rajasthan)

1997

Shri B.P. Singhania Jagdish Construction Pvt. Ltd. 190 Mohan Colony Banswara Rajasthan



50



50

July 1995

Shri Anurag Jain Devshree Cement Ltd. Vill. Kharia Meethapur Teh. Bilara — 342602 Distt. Jodhpur Rajsathan

1995

Capacity (tpd)





50

50

Shri S.M. Arif Arif Cement Industries `Skylark' 28, Naval Kishore Road, Hazratganj, Lucknow Uttar Pradesh

Dec.1984

Shri A.P. Jain Nirmal Cement Factory 157, Avas Vikas Colony Civil Lines, Moradabad Uttar Pradesh

Feb.1985

30

Oct. 1985

30

Shri Ajay Kumar Ashish Cement Pvt. Ltd. 786, Subhash Bazar Mawane — 250401 Distt. Meerut Uttar Pradesh

123



120

SI. No. 145

146

147

148

149

150

151

Year of Commissioning

Capacity (tpd)

Shri Prem Sheth Vikram Cement Pvt. Ltd. 4/283, Vishnupuri Kanpur Uttar Pradesh

Aug.1987

50

Shri Radha Krishan Agarwal Indra Steels Pvt. Ltd., Indra Palace, Connaught Circus New Delhi (Site: Gaziabad)

July 1987

30

Plant's Name and Address

Shri R.K. Gupta R.A. Cements Pvt. Ltd. 117-H-1 /296, Model Town Pandu Nagar Kanpur Uttar Pradesh

50

Shri Jay Lalwani Indus Laminators Pvt. Ltd. Matra Chaya, Basant Vihar Kanpur Uttar Pradesh

40 Closed

Shri Vijay Arora Brahmavarta Cements Pvt. Ltd. 190-B, Co-operative Industrial Estate Dada Nagar, Kanpur Uttar Pradesh Shri Mukesh Keswani Jagadishpur Cement Pvt. Ltd. 4A, Park Road, Ramjang Building Lucknow — 296001 (Site : Jagdishpur) Uttar Pradesh Shri D.Y. Pichanvthu, Almora Magnesite Limited Vill. Matela, Post Bilari Distt — Almora Uttar Pradesh

124

Oct. 1988

30

1989

30

April 1980

50



SI. No. 152

153

154

155

156

157

Plant's Name and Address

Year of Commissioning

Capacity (t pd)

1990

30

Aug.1992

50

Aug. 1992

50

Shri V.K. Gupta Vikrant Cements Pvt. Ltd. Baghpat, Meerut Uttar Pradesh

Nov. 1993

50

Shri D.N. Gupta Delta Erectors Pvt. Ltd 117/H-2/165, Pandu Nagar Kanpur (Site: Kanpur Dehat) Uttar Pradesh

July 1995

50

Jan. 1994

100

Shri Basant Lai Krishna Fertilizers Pvt. Ltd. 60/45, Nayaganj Kanpur Uttar Pradesh Shri Manmohan Arora Arpit Cement Pvt. Ltd 4-A, New Mandi Muzaffarnagar Uttar Pradesh Shri S. Bhushan Sonu Udyog 1-B, `N' Block Govind Nagar Kanpur Uttar Pradesh

M/s. Champion Cement Ind. Ltd. 2, BBD Bag (East) Calcutta 700001 —

158

Shri S.L. Moondra Director R.T. Udyog A-19, RIECO Industrial Area Behror, Distt. Alwar Rajasthan.

125

I. No. 159

160

Plant's Name and Address

M/s. Pankaj Cements Pvt. Ltd. 416, Kucha Brijnath Chandni Chowk New Delhi

M/s.Modern Industries Kalol Gohdra Highway Popatpura — 389001 Tq. Godhra, Panchmahal Distt. Gujarat

Year of Commissioning

Capacity (tpd)

Dec. 1993

50

Jan.1991

50

161

M/s. Samrat Cement Pvt. Ltd. Gujarat

July 1994

50

162

M/s. Krishna Building Cement (I) Pvt. Ltd Gandhi Chambers, Gonda Road, Rajkot — 360002 Gujarat

May1995

50

163

M/s. Orient Abrasive Ltd. Gujarat

1995

50

Aug.1995

50

164

M/s. Trilok Cement Pvt. Ltd. Gujarat

165

M/s. Krishan Build Cement Pvt. Ltd. Gujarat

1996

100

166

M/s. Gautam Industry, Bhavnagar Gujarat

1996

35

167

M/s. Mahakali Cement Pvt. Ltd. Gujarat

1996

50

168

M/s. Gujarat Minerals Development Corpn. Ltd. (Rotary) Gadhsisa Gujarat

150

126

SI. No. 169

170

Year of Commissioning

Capacity (tpd)

M/s. Katni Cement Pvt. Ltd. M.P.

1993

50

M/s. Aditya Lime Industries Maharashtra

1997

75

Plant's Name and Address

171

M/s. Kuber Cements Pvt. Ltd. Orissa

Aug.1992

50

172

M/s.Gori Cements Pvt. Ltd. Rajasthan

June 1993

50

173

M/s. Delhi Cements Pvt. Ltd. Rajasthan

Feb.1994

50

174

M/s. Mosar Cements Pvt. Ltd. Rajasthan

Sept.1995

50

175

Mts. Shree Madho Cements Pvt. Ltd. Rajasthan

1996

50

176

M/s. Patodia Cements Ltd. Rajasthan

1996

100

177

M/s. Basera Cements Ltd. Rajasthan

1997

350

178

M/s. Vishwakarma Cement Ltd. Pathredi Road, Kotputli 303108 Jaipur Distt. (Rajasthan)

1997

100

1996

50

Aug. 1987

50

—

179

180

M/s. K.C. Cement Pvt. Ltd. Rajasthan M/s. Vikram Cement Pvt. Ltd. Uttar Pradesh

127

I. No.

Plant's Name and Address

Commissioning

Capacity (tpd)

1996

100

1996

100

Year of

181

M/s.Nirmal Cement Pvt. Ltd. U.P.

182

M/s. Ramuka & Bhagaria Cement Pvt. Ltd. Uttar Pradesh

183

M/s.Bahubali Cements Pvt. Ltd. Bihar

Aug.1994

50

184

M/s. Mata Cements Pvt. Ltd. Andhra Pradesh

May 1993

50

185

M/s.Vishwa Cements Pvt. Ltd. Andhra Pradesh

Feb.1995

50

186

M/s.Nirman Cements Pvt. Ltd. Bihar

1996

100

187

M/s. Cresent Cements Kerala

1997

350

188

M/s.Pennco Cement Industries Pvt. Ltd. West Bengal

1996

100

189

M/s. Mittal Cement Pvt. Ltd. West Bengal

1997

75

190

Shri Anil Sharma Director M/s. Gwalior Cement Company Pvt. Ltd. 1 5t Floor, Krishna Mandir Phalka Bazar, Gwalior — 474001

191

M/s. Sangam Cements Pvt. Ltd. R.S. No. 346, Kaladgi Village Tal: Bagalkot, Distt. Bijapur — 587204

128

50

50

SI. No. 192

193

Plant's Name and Address

Year of

M/s. Jayshree Cement Rajasthan M/s. Ved Vyas Cement Ltd. Orissa

Commissioning

Capacity (tpd)

March1993

50

1996

200

194

M/s. Champion Cement Ltd. Orissa

Jan.1994

100

195

M/s.Bombay Mineral Pvt. Ltd Gujarat

1995

50

196

M/s. Garuda Cements Huzura Nagar, Nalagonda Distt. Andhra Pradesh

100

197

M/s. Heritage Cements Pvt. Ltd. P.G. Padu, Piduguralla Konanki, Pidugurala Mandal Guntur Distt. Andhra Pradesh

100

198

M/s. Suji Cements Ltd. Guddapotharam Village Jinnaram Village, Medak Distt. Andhra Pradesh

100

199

M/s. Shakti Cements Ltd. p.b. No. 51, Udyog Nagar Mahuva 364290 Bhavnagar Distt.

100

M/s. Chetan Cement Pvt. Ltd. GAT 78-84, Near Girno Rly. Bridge, Bambhori Village, Erandon Tq.

100

M/s. Sita Cements Ltd. Telighana P.O. Kutra, Distt. Sundergarh

100

—

200

—

201

129

SI. No. 202

203

I

M/s. Pithe Cement & Ind. Ltd. Prithvipura Village (Bilara Jaitaran Highway) Jaitaran Tehsil, Pali Distt.

M/s. Bomber Cement Plant Umbang, Sumer Barapani Ph. 260158, 260051 Assam

205

M/s. A.M.S. Cement Pvt. Ltd Mawpdang Vill. East Khasi Hills Distt. Meghalaya Ph. (0364) 223285

W

M/s. Cement India Ltd. Khaliamani Dibrugarh — 786001 Distt. Dibrugarh Assam

30

M/s. Jumbo Cements (I) Pvt. Ltd. C/o. A.D. Waklin (Beside Continental Tours & Travels) Dr. B. Barvan Road Guwahati — 781007

208

M/s. North Cachar Cement Ltd. Vill Korai Bari Changsari Chowki Gate, Amingoon, Guwahati — 781031

30

M/s. Prag Shiva Cements Pvt. Ltd. Beltola Tinali Guwahati — 781028

210

M/s. Panchavatha Cement (P) Ltd. Titabar, Jorhat Assam Tel: 48538.

211

M/s. Sagar Cements Ltd. Bayya Varam Anaka Palli Andhra Pradesh Ph. 561782

Capacity (tod)

100

207

209

Year of Commissioning

100

M/s. Vijay Cements Ltd., Keela Mathur, Ariyalur — 621713

204

206

I

Plant's Name and Address

30

130

SI. No.

Plant's Name and Address

Year of Commissioning

212

Capacity (tpd)

M/s. Bangur Cement Pvt. Ltd., Abu Road, (Rajasthan)

213

214

215 216

50

M/s. Shree Mahadev Cement Pvt. Ltd. Nagour

50

M/s. Sumo Cement Pvt. Ltd. Gujarat

50

M/s. Kangaroo Cement Pvt. Ltd. Gujarat

50

M/s. Prince Cement Co. Ltd. Morbi, Gujarat.

100

M/s. New Kishan

217

50 M/s. K.G.N. Cement Pvt. Ltd. Rajgangpur Orissa

218

50

219

Yuvraj Sahu Chhatrapah Cement Utpadak, Vadgon

220

M/s. Athulya Cement (P) Ltd. Kerala.

100

221

Mis. Sidhnath Co. Operative Pvt. Ltd. Haryana

222

M/s. Samudra Cement Ltd. A P 150 .

223

50

.

M/s. Desai Cement Limited, Goa

200

131

C1 : REGIONAL RESEARCH LABORATORY (RRL) VSK MINI CEMENT PLANTS IN OPERATION lant's Name and Address SI. No. IP 1 Kutch Cements Pvt. Ltd., Hari Kripa Station Road, Bhuj Kutch — 370001 (Gujarat)

2

3

4

5

6

7

Shakti Cement Co. Pvt. Ltd., Coins Corner, 1 s' Floor Dr. Yagnic Road, Rajkot — 360001 (Gujarat)

Capacity (t pd)

25

100

Patel and Lalka Cement Pvt. Ltd., Naktrana Kutch Gujarat

35

Bharat Cement Industries Plot No. 56, Phase I, GIDC Estate Vatva, Ahmedabad (Gujarat)

25

Somani Cement Co. Pvt. Ltd., Krishna Apartments Behind Gautam Nagar Race Course, Baroda — 390007 (Gujarat)

25

Kalyani Cements Pvt. Ltd. 12-2-37/2/3, Murad Nagar Hyderabad Andhra Pradesh

25

J.K. Cement Pvt. Limited 13, Nanabhai Court Govindjikanny Road, Hindmata Dadar Bombay (Maharashtra)

35

132

SI. No. 8

9

10

11

12

13

14

Plant's Name and Address Subidha Commercial Con. Pvt. Ltd., 250, Maulana Azad Road (North), Bombay — 400008 Maharashtra

Capacity (tpd)

25

Swarajya Cement Industries Pvt. Ltd. H.O. Anand Niketan, Shona, Gurgaon (Haryana) 80, Bungalow Road, Kamla Nagar, Delhi —110007.

25

Saraswati Cement Pvt. Ltd., Manthapal (Kala-Amb) Distt. Sirmaur Himachal Pradesh

25

Venkateswara Cement Ltd. 1132, P. H. Road, Madras — 600003 Tamil Nadu

25

Anuj Cement Industries Pvt. Ltd. 59, Darya Ganj New Delhi

25

Tara Cement Pvt. Limited 694, 2n d Floor, Chawri Bazar Delhi — 110006.

25

R.R. Cement Pvt. Ltd. P. Box —10, Bala Mandi Paonta Sahib Himachal Pradesh —173025

25

133

SI. No. 15

16

17

Plant's Name and Address

Capacity (tpd)

Eastern India Cement Pvt. Ltd. 123, Cooperative Colony, Bokaro Steel Plant City, Bokaro — 827001 Bihar

25

Priti Cement & Chemicals M-22 (DS) Harmn Housing Colony, Ranchi — 834 012 Bihar

25

Durga Cement Pvt. Ltd. 3, Tha, 5 Housing Board, Shastrinagar Jaipur Rajasthan

25

134

C 2: REGIONAL RESEARCH LABORATORY (RRL) VSK CEMENT PLANTS UNDER IMPLEMENTATION SI. No. 1

2

3

4

5

6

7

8

Plant's Name and Address

Baba Cement Pvt. Ltd. A-16, Shellanagar, Visakhapatnam — 530 012. (A. P.)

Capacity (tpd)

25

Shilpa Cement Pvt. Ltd. 15/218, College Road, Sanjeeva Nagar, Tadpatri — 515 411 Anantpur Distt. (A. P.)

25

Bhaskar Cement Pvt. Ltd. Garladenne Village Dhone (H.O.) Kurnool Distt. (A. P.)

25

L C K Cement Pvt. Ltd. Nehru Nagar, Maouerla (TQ) Guntur Distt. (A. P.)

25

Cuddapah Chemicals & Minerals Pvt. Ltd. House No. 1/583 (1) Nagarajpet Cuddapah —516 001 (A. P.)

25

Rajdhani Cements Pvt. Ltd. 3-6-729/8, Himayat Nagar, Hyderabad — 500 029. (A.P.)

25

Amba Cement Pvt. Ltd., House No. 14.11.981 BIR Ban Bagh Hyderabad (A.P.)

25

Bhagyanagar Cements Pvt. Ltd., 11-5-409 Red Hills Hyderabad (A.P.)

25

135

SI. No. IP lant's Name and Address 9 Swastic Cement Industries Pvt. Ltd. Thakar Chambers Bedi Gate, Jamnagar —1 (Gujarat) 10

11

12

13

14

15

16

17

Shree Laxmi Cement Pvt. Ltd. 6-1, 44-47 RIICO Industrial Area, Hindaun City - 322 230 (Rajasthan)

Capacity (tpd)

25

25

Prag Shiva Cement Industries Capital Road, Dispur Assam Sachibalaya Post Box No. 13 Guwahati — 781 006 (Assam)

25

Udayana Cement Pvt. Ltd. Village Basisthapur Guwahati — 781 006 (Assam)

25

Radharani Chemicals (P) Ltd., Maralla Gardens, Rivi Road, Berhampur — 760 005 Ganjam, (Orissa)

25

Aravalli Cements Pvt. Ltd. WZ-109, Shadipur, New Delhi.

25

Javellin Cements Pvt. Ltd., E-484, Greater Kailash-II, New Delhi

25

Ranchi Cement & Chemicals Pvt. Ltd., Balakrishna Bhawan, Manohar Land P.O. Sindri — 828 122 Dhanbad (Bihar) Rachho Commerce & Cement Industries (P) Ltd. 11 th Lane, Ittarsi — 461 111 Distt. Hoshabgabad (M.P.)

136

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