Overview of Air Pollution Control Needs & Choices Available For Cement Industry

DAY-1, Good Morning
[Module-1, Session-1]
Overview of Air Pollution Control Needs

&
Choices available for Cement Industry
Host Plant: Holcim, Indonesia

May 17, 2010
This report is solely for the internal use. No part of it may be circulated, quoted, or reproduced for distribution outside the Holcim Group company organization without prior written approval
from ACC Limited. This material was used during an oral presentation; it is not a complete record of the discussion.
Learning Objectives
Understand the cement manufacturing process & its pollutants
Understand the cause & effect of air pollution world wide
Understand where the dust emissions come from (Sources)
Know about the various possibilities for controlling dust emission
Have an overall idea about various types of air pollution control

equipment & its reduction potential in brief
M1, S1 Regional Training Program on Design, Operation, Maintenance & Trouble Shooting of APC Equipment & Systems [May 17, 2010]
AGENDA
Introduction to Cement Manufacturing Process
Primary Air pollutants Cause and Effects
Air Pollution Major Disasters World wide
Sources of Dust Emissions & its Control Measures
Typical Air Pollution Control Standards
Overview of Air Pollution Control Equipments
Cement Manufacturing Process at a Glance
Cement Manufacturing process are of three types

Wet Process
Semi Wet Process
Dry Process
Wet Process :The input is in slurry form to the kiln which contains
around 40% of water and uses high amount of thermal energy
Semi Wet Process :This process is more efficient than wet

process and less percentage of water and thermal energy
requirement is lower than the wet process
Dry Process :This process is more efficient than earlier

processes and it will not use water at all and uses least amount of
thermal energy 4
Flow Diagram – Manufacture of Cement
Production of Cement by Wet Process
The original rotary cement kilns were called 'wet process' kilns
The slurry may contain about 40% water and length of the kiln
is up-to 200 m
Highly energy and water intensive process 5
Production of Cement by Dry Process
Production of Cement by the Dry Process
Feed Bins
Sampling Station
Quarry (ies) Crushing Plant (s) Raw Materials Storage and Preblending Corrective Materials
Electrostatic
Homogenizing and
Precipitator
Cooler Dedusting Storage Silo
Coal
Raw Meal
Water
Coal
Mill
Cyclone
Rotary Kiln Preheater Cooling Tower Raw Mill
Filter
Clinker Cooler Gypsum Min.Comp. Bulk Dispatch Packing Machine Bag Palletization
Cement Cement
Clinker Silo Silo
Storage
Cement Mill
LG-047e.dsf Kma 27.4.98 Fig.2
AGENDA
Primary Pollutants in Cement Industry
Pollutants from the Cement Manufacturing
Stack emissions containing Dust, CO2, SOx, NOx, VOC ...
Fugitive dust emissions
Effluents from CPP and Colony
Solid waste from Plant, Colony and Mines
Noise pollution and vibrations during to mining activity
10
Primary Air Pollutants – Cause & Effects
POLLUTANT Natural Source Anthropogenic Known or Suspected

Source Effect
Carbon Monoxide Un-noticeable Fuel Rich & Stoichometric Reduces oxygen carrying
Combustion from Industry & capacity of the blood by
[CO] Motor Vehicles combining with haemoglobin,
thus deprives tissues of O2
Carbon dioxide Animal respiration, Fossil fuel, wood and Partly responsible for the
decay and release combustion in all process atmospheric greenhouse effect
[CO2] industry
from oceans
Sulfur dioxides Volcanic Eruptions Coal Combustion from Cause eye, throat & lung
and decay Industry like Kilns, Power irritation. Primary Pollutants
[SO2] Plants, Ore smelters, produces acid rain
petroleum refineries &
diesel Engines
Nitrogen Oxides Lightening & bacterial High temperature from Cause eye, throat & lung
activity in soils Combustion from Industry & irritation. Primary Pollutants
[NO] and [NO2] Motor Vehicles produces photo-chemical
smog, acid rain and destroy
ozone at the stratosphere
11
Primary Air Pollutants – Cause & Effects
POLLUTANT Natural Source Anthropogenic Known or Suspected

Source Effect
Particulates Forest fires, wind Coal, Cement, Clinker, Nuisance and Breathing
erosion, volcanic Fly Ash Coal process & difficulties
handing from cement
eruptions & decay
Industry, Waste & Fossil
fuel burning
Ozone Lightening & Products of Cause eye, throat & lung

photochemical reactions photochemical irritation, impairs lung function
[O3] in the troposphere reactions in
photochemical smog
Hydrocarbons Biological Processes Incomplete Combustion Primary Pollutants that

& volatiles from Industry produces photo-chemical
other than & Motor Vehicles smog
methane (VOCs)
Methane Anaerobic decay and Natural-gas leak & Partly responsible for the
chewing animals (cows, Combustion atmospheric greenhouse effect
[CH4] sheeps..) & oil wells
12
Primary air pollutants – Cause & Effects
POLLUTANT Natural Anthropogenic Known or Suspected

Source Source Effect
Chloro-fluorocarbons None Used as Solvent, Destroys Ozone at the
aerosol propellant and stratosphere, thus reduce the
[CFCs] Ozone UV protective layer
refrigerant
Heavy Metals -- Process Industry and Nervous system disorders

refineries
Normal rain has a pH of about 5.6
Rain with a pH < 5.5 is called acid rain

Rain has been reported with pH as low as 2.1
13
Photochemical Smog Formation
14
CO2 Concentration – Overview
15
CO2 Concentration – Overview
16
CO2 Concentration Vs Excess Air for Combustion
1T) Temperature
2T) Turbulence
3T) Time
17
AGENDA
18
Primary air pollution disasters
19
Air Pollution Disasters – World Wide
Place Pollutant Source No. of No. of Persons
Deaths reported ill
Meuse Valley, SO2 & Smoke Steel & Zinc 60 6000
Manufacture
Belgium, 1930
Donora, SO2 & Smoke Steel & Zinc 20 5900

Manufacture
Pennsylvania, 1984
Poza Rice, H2S Sulphur Recovery 22 320

- Accident
Mexico, 1950
London, SO2 & Smoke Domestic Coal 12000 > 20000

Burning
1952
Bhopal, Methylisocyanide Fracturing of tank > 2500 10000
in Union Carbide
India, 1984 -Accident
20
Air Pollution Disasters
1948
Donora PA – smog so dense local people

got lost. 20 people died
21
Air Pollution Disasters
1952
London - “Killer Smog” lasted for over a
week. Visibility was only a few meters.
22
London - Killer Smog
23
Acid Rain - Effects on Ecosystems
High concentrations of acid can cause direct death of

plants, fish
Lower concentrations can reduce vigor of organisms
making them vulnerable to diseases (or insects)
24
Acid Rain - Effects on Soil
Kills soil organisms
Releases Aluminum, which inhibits plants ability to

absorb nutrients
Reduce available Calcium which is needed for plant

growth
25
AGENDA
26
Sources Of Dust Emission & Fugitive Dust Areas
Cement Kiln Circuit
Raw Mill VRM / Ball Mill - Circuit
Clinker Cooler Circuit
Coal Mill Circuit
Cement Mill – VRM / Ball Mill / AVMP Pre-Grinder Circuit
Slag Dryer Circuit
Cement Packing Plant Circuit
Fly Ash Dryer Circuit
Captive Power Plant / Boiler Circuit
All Material Handling Equipment Transfer Points & Storage Silo Circuit
(Limestone, Coal, Clinker, Cement, Gypsum, Additives, Fly ash …)
27
Choices Available for Cement Industry?
Air
Pollution
Control
Dust
BAG
ESP Scrubbers Suppression
HOUSE
System
Dry Plate Dry Plate Reverse Plain

Shaker Pulse Jet Dry Semi Dry Wet Fog
(MIGI) (Hammer) Air Water
Wet Dry Fog
28
Emission Control Equipment used in Cement Industry
Application Choice of APC Equipment

Cement Kiln Venting ESP with or without GCT,
Baghouse (PJBH / RABH), Wet Scrubber
Raw Mill Venting ESP, Baghouse (PJBH / RABH)
Clinker Cooler Venting ESP, Bagfilter with FD Cooler, Multi-cyclone
Coal Mill Venting ESP, Bagfilter
Cement Mill / Pre-Grinder Venting ESP, Bagfilter
Slag Dryer Venting ESP, Bagfilter
Cement Packing Plant Venting ESP, Bagfilter
Fly Ash Dryer Venting Bagfilter
Captive Power Plant Venting ESP, Hybrid Bagfilter (PJBH), Wet Scrubber
Material Handling Equipment Transfer Bagfilter with Dust Extraction system,

Points & Storage Silo Venting Dust Suppression System
29
Reduction Potential of APC Technology Available
Application Reduction Potential

Electrostatic For handling large Volumes & Dust Emission >
50mg/Nm3 or up-to 30mg/Nm3 (in few exceptional cases)
Precipitator (ESP)
Reverse Air Baghouse (RABH) / For handling large Volumes &
Pulsejet Baghouse (PJBH) < 10mg/Nm3 Dust Emission
Pulsejet Bagfilters For handling medium / lows Volumes &
< 30 mg/Nm3 Dust Emission
Multi-cyclones (MDC) For handling medium Volumes with particles
>10microns & > 150 mg/Nm3 Dust Emission
Wet Scrubbers For Dust & SO2 Reduction up-to 200mg/Nm3. Need
Effluent / Water Treatment Plant
Dust Suppression For Fugitive Emission & Control for Raw Coal & Crushed
Limestone Handling up-to stockpile Area, where moisture
System addition of 0.5 – 5% Max. is allowable, considering
availability of water of desired quality & quantity
30
AGENDA
31
HOLCIM – EUROPEAN DESIGN VALUES
Parameter European Norms (mg/Nm3, Dry 10% O2)

Particulates 30
SO2 400
NOX 500
VOC 100
CO --
HCl 30
NH3 30
Hg 0.05
Cd 0.05
TI 0.05
As+Co+Cr+Cu+Mn+Ni+Pb+Sb+V 0.5
Dioxins / Furans 0.1 (ng TEQ/Nm3)
32
Holcim ERT: Target Emission Levels
Achievable emission levels and abatement techniques

recently defined by Holcim:
Dust: 20 mg/Nm3 (dry at 10% O2 ): preferably

with bag filters
SO2: from > 1200 to 200 mg/Nm3 with wet scrubbers

from < 1200 to 500 mg/Nm3 with hydrated lime
injection
NOx: 500 mg/Nm3 with SNCR on short PH/PC kilns

800 mg/Nm3 with SNCR on long kilns
33
INDIAN CENTRAL POLLUTION CONTROL BOARD
Pollutants Time- Concentration in ambient air Method of measurement
w eighted
Industrial Residential, Sensitive
average
Areas Rural & other Areas
Areas
SulphurDioxide (SO2) Annual 80 µg/m3 60 µg/m3 15 - Improved W est and Geake

Average* µg/m3 Method - Ultraviolet
Fluorescence
24 hours** 120 80 µg/m3 30

µg/m3 µg/m3
Oxides of Nitrogen as Annual 80 µg/m3 60 µg/m3 15 - Jacob & Hochheiser

(NO2) Average* µg/m3 Modified (Na-Arsenite)
Method
24 hours** 120 80 µg/m3 30 - Gas Phase

µg/m3 µg/m3 Chemiluminescence
Suspended Particulate Annual 360 140 µg/m3 70 - High Volume Sampling,

Matter (SPM) Average* µg/m3 µg/m3 (Average flow rate not less
than 1.1 m3/minute).
24 hours** 500 200 µg/m3 100

µg/m3 µg/m3
RespirableParticulate Annual 120 60 µg/m3 50 - Respirable particulate

Matter (RPM) (size less Average* µg/m3 µg/m3 matter sampler
than 10 microns)
24 hours** 150 100 µg/m3 75
µg/m3 µg/m3
Lead (Pb) Annual 1.0 0.75 µg/m3 0.50 - ASS Method after sampling
Average* µg/m3 µg/m3 using EPM 2000 or
equivalent Filter paper
24 hours** 1.5 1.00 µg/m3 0.75 .

µg/m3 µg/m3
Ammonia1 Annual 0.1 mg/ 0.1 mg/ m3 0.1 .

Average* m3 mg/m3
24 hours** 0.4 mg/ 0.4 mg/m3 0.4 .

m3 mg/m3
CarbonMonoxide (CO) 8 hours** 5.0 2.0 mg/m3 1.0 mg/ - Non Dispersive Infra Red
mg/m3 m3 (NDIR)
1 hour 10.0 4.0 mg/m3 2.0 Spectroscopy

mg/m3 mg/m3
34
AGENDA
35
ESP
36
REVERSE AIR & PULSEJET BAGHOUSE
PULSEJET REVERSE AIR 37
TYPICAL WET SCRUBBER
38
Typical Wet scrubber
SO2 reduction
secondary
Stack
Clean gas
Mist eliminators
Inlet with
quench
Contact zone
Raw gas between SO2
with SO2
and CaCO3
Recircul.
Absorber pumps Treatment and dewatering of
Mixer sump gypsum suspension
39
Wet scrubber Untervaz (CH)
SO2 reduction
secondary
Water
Flocculent Settling
tank
Centrifuge Bleed stream
Gypsum Moisture 5 – 8%
40
Examples of SO2 Wet Scrubbers in Holcim Group
SO2 reduction
secondary
Untervaz, CH
Dundee, US
Midlothian, US 41
Polvitec
SO2 reduction
Investment 30 Mio
CHF
Reduction from
max.1500 to 7
mg/Nm3
Coke: 2600 t/yr
Costs 400 CHF/t
Eliminates as well
NOx, VOC, Hg, etc.
Operating costs ca.
5 CHF/t cli (1.5
CHF/t cli for coke)
42
Injection of “micromist” into the cooling tower
SO2 reduction
43
SNCR – Installation
NOx
reduction
44
Dust Suppression Systems for Fugitive Dust Control
Pond
Deepening
Dust Suppression System at Limestone

Unloading Hopper
45
Questions & Thanks
46

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DAY-1, Good Morning

Overview of Air Pollution Control Needs

Host Plant: Holcim, Indonesia

Understand the cement manufacturing process & its pollutants

Understand the cause & effect of air pollution world wide

Understand where the dust emissions come from (Sources)

Know about the various possibilities for controlling dust emission

Have an overall idea about various types of air pollution control

Introduction to Cement Manufacturing Process

Primary Air pollutants Cause and Effects

Air Pollution Major Disasters World wide

Sources of Dust Emissions & its Control Measures

Typical Air Pollution Control Standards

Overview of Air Pollution Control Equipments

Cement Manufacturing process are of three types

Semi Wet Process :This process is more efficient than wet

Dry Process :This process is more efficient than earlier

Production of Cement by Wet Process

Production of Cement by Dry Process

LG-047e.dsf Kma 27.4.98 Fig.2

Introduction to Cement Manufacturing Process

Primary Air pollutants Cause and Effects

Air Pollution Major Disasters World wide

Sources of Dust Emissions & its Control Measures

Typical Air Pollution Control Standards

Overview of Air Pollution Control Equipments

Stack emissions containing Dust, CO2, SOx, NOx, VOC ...

Fugitive dust emissions

Effluents from CPP and Colony

Solid waste from Plant, Colony and Mines

Noise pollution and vibrations during to mining activity

POLLUTANT Natural Source Anthropogenic Known or Suspected

POLLUTANT Natural Source Anthropogenic Known or Suspected

Ozone Lightening & Products of Cause eye, throat & lung

Hydrocarbons Biological Processes Incomplete Combustion Primary Pollutants that

POLLUTANT Natural Anthropogenic Known or Suspected

Heavy Metals -- Process Industry and Nervous system disorders

Normal rain has a pH of about 5.6

Rain with a pH < 5.5 is called acid rain

Introduction to Cement Manufacturing Process

Primary Air pollutants Cause and Effects

Air Pollution Major Disasters World wide

Sources of Dust Emissions & its Control Measures

Typical Air Pollution Control Standards

Overview of Air Pollution Control Equipments

Donora, SO2 & Smoke Steel & Zinc 20 5900

Poza Rice, H2S Sulphur Recovery 22 320

London, SO2 & Smoke Domestic Coal 12000 > 20000

Donora PA – smog so dense local people

High concentrations of acid can cause direct death of

Kills soil organisms

Releases Aluminum, which inhibits plants ability to

Reduce available Calcium which is needed for plant

Introduction to Cement Manufacturing Process

Primary Air pollutants Cause and Effects

Air Pollution Major Disasters World wide

Sources of Dust Emissions & its Control Measures

Typical Air Pollution Control Standards