Alternate fuel Usage

Experience of “The India

Cements Ltd” By

D.Sivagurunathan The India Cements Ltd

1.6 2.8

4.0

6.8 7.0

8.8

1989 - 1990 1990 - 1997 1997 - 1998 1998 - 1999 1999 - 2001 2001 - 2005 2005-2010 2011

Experienced cement player with over six decades in business. One of the largest cement

group with a capacity of 16mtpa cement production. Largest manufacturer in South

India with 20% market share. Capacity scaled up 10 times

since 1990 primarily through acquisitions and upgradation.

Brief Overview

Growth history

Chilamkur acquisition

New 1mtpa plant at Dalavoi . Yerraguntla acquisition

New 1mtpa plant at

Malkapur.

Addition of Malkapur-II,

Chennai, Parli &

Upgradation of other plants

Raasi acquisition

Dalavoi 1.3mt

Sankaridurg 0.7mt

Raasi 2.3mt

Malkapur 2.2mt

Chilamkur 1.3mt

Yearraguntla 0.5mt

Sankarnagar 1.6mt

Andhra Pradesh

Tamil Nadu

Kerala

Karnataka

The India Cements Ltd Company Snapshot

15 16

New 1MTPA plant near Banswara, Raj

Non-recyclable Plastic Wastes

as Alternate Fuel

Generation of Plastic Waste in India

Generation of MSW : 1,20,000 tons per day (TPD)

Generation of Plastic Waste : 10,000 tons per day (TPD)

(9% of MSW)

Recyclable plastic : 80% of the total plastic waste

(Taken care by rag pickers)

Non-Recyclable plastic : 20% of the total plastic waste (Matter of concern)

Municipal Waste Combination

WASTE MATERIAL AVERAGE %

PLASTIC 9%

GLASS 11%

METAL 3%

PAPER 13%

BIO DEGRADABLE 55%

INERTS 9%

TOTAL 100%

Environmental Hazards of Plastic Waste Very thin Plastics carry bags, laminated pouches (including Gutka pouches)

and other non-recyclable plastics are littered in tourist places, near ancient monuments and spoil the aesthetic view.

Plastic bags are non-biodegradable and its disposal may make land in-fertile due to impervious nature, choke the open drains and cause death of cattles on ingestion.

Littered plastics spoil beauty of the city and make many important public places filthy.

Garbage containing plastics when burnt in open may cause air pollution problem and particularly burning of plastics may emit obnoxious gases.

Garbage mixed with plastics interferes in processing municipal solid wastes into fertilizers and also causes problems in landfill operations.

Need for safe disposal of plastic waste At present the Non-Recyclable Plastics are disposed to some extent by

open yard burning.

Major portion remains on the soil, which affect the Nature in many forms.

Burning plastic waste in cement plant kiln is the best proven scientific method.

Tamilnadu pollution control board (TNPCB) has initiated action for safe disposal of non-recyclable plastic wastes in cement kilns.

Progress on the usage of Plastic waste Total non-recyclable plastic waste generation in Tamil Nadu

is about 750 Tons/Day.

Tamilnadu has been divided into 7 zones for collection of non-recyclable plastic wastes and each zone is assigned to one cement plant for burning the same.

A work shop was conducted by TNPCB on the usage of plastic waste on 26.08.2009

Trial run of co-processing of plastic waste was started at ICL sankarnagar on 25.10.2009.

Progress on the usage of Plastic waste MoU Signed between ICL and Zone-1 Municipal

corporations on 08.02.2010 for supply of plastic wastes.

Plastic shredders were commissioned in the first week of July 2010.

Originally the plastic fluff was fired in the precalciner with other bio-fuels. Mixing fluff with other fuels was posing problem.

However it was found much easier to pump plastic fluff into the kiln burner from shredder directly. This avoids storage and re-handling of fluff.

Sl. No

Name of the Municipality

Generation of

non -recyclable

plastic T/day

Avg. receipt of

non- recyclable

plastic T/day

Avg.

receipts in %

Gap in %

1 Tirunelveli Corporation

1.80 0.16 10.00 90.87

2. Tuticorin Corporation

2.28

0.07

3.05

96.95 3. Tiruchendur Town Panchayat

4. Nagercoil Municipality

1.66

0.13

7.80

92.02

5. Kanyakumari

Total 5.74 0.36 6.27 93.73

Waste Generation / Usage Summary

Problems in usage of plastic waste Poor collection of non-recyclable plastics from garbage at source.

The gap in collection is more than 90% which means there is high potential in this project if efficiency of collection is improved.

Absence of any regulation for compulsory segregation of plastics at source.

Reluctance of Municipal corporations to segregate at garbage dumps due to financial constraints.

Fool-proof elimination of foreign materials from the plastic waste.

Mechanization of plastic waste feeding to the shredder.

Constant feeding of shredded plastic waste into the kiln with controls.

High investment with uneconomical return is major deterent for progress further. Any investment from developed countries would help expansion of this project

Industrial wastes as alternate fuels

Specification of HW for use of energy recovery (CPCB Guideline – Feb 2010)

Parameter Limit

Calorific Value As received basis >2500 k Cal/ Kg Ash

Liquid Solid

<5% <20%

Chloride <1.5% Halogens ( F+Br+I) <1.0%

Sulphur <1.5% PCB/PCT( ppm) <5.0

Heavy Metals (ppm) Hg

Cd+TI+Hg

<10 <100

pH 4 to 12

Viscosity (cSt) for Liquid < 100 Flash point ( Deg centigrade) ( for Liquid) <60

Specification of HW for use as Alternative Raw Material (CPCB Guideline-Feb 2010)

Parameter Limit

Volatile organic Hydrocarbon < 5000 ppm

Total organic carbon (TOC) <1000 ppm

Cao+SiO2+Al2O3+Fe2O3+SO3 (In Ash) >80%

Chloride <1.5%

Sulphur <1.5%

PCB/PCT( ppm) <5.0

Heavy Metals (ppm) Hg Cd+TI+Hg

As+Co+Ni+Se+Te+Sb+Cr+Sn+Pb+V

<10

<100 <10,000

Potential Waste Generators

Pharmaceuticals Chemicals Paint/coating manufacturers Petrochemicals Printing Ink Manufacturers Printing Companies Automobile Manufacturers Solvent Recyclers Waste disposal Brokers

Typical Chemical Families That make up the liquid Fuels

Aromatic Hydrocarbons Aliphatic Hydrocarbons Alcohols Acetones Acetates Ketones Esters Glycols Chlorinated Hydrocarbons Oxygenated Hydrocarbons

Industrial wastes used in ICL plants Spent carbon, from Pharma Industry as partial fuel replacement (Kiln

Burner) Organic liquid waste from Pharma Industry as partial fuel replacement

(Kiln Burner) Polymer sludge from Chemical/Paint Industry)- (Fed to Calciner)

Spent Carbon Proximate Analysis

Free Moisture % 24.4

Inherent Moisture % 3.48

Volatile Matter % 12.4

Fixed Carbon % 42.72

Ash % 40.4

Gross C.V. K.Cal/Kg % 4108

SO3 % 0.32

Name DMF (Liquid)

NON Sterilize Residue

IPA Residue

MDC Residue

Mixed Residue

IPE + ED

Residue Inherent Moisture % 92.23 3.35 10.56 5.26 6.32 4.92

Volatile Matter % 7.32 93.69 84.35 93.41 65 64.74

Fixed Carbon % 0.31 0.88 3.79 0.60 0.53 17.7

Ash % 0.14 2.08 1.30 0.73 28.15 12.64

Gross C.V. K.Cal/Kg 5475 7337 7904 7421 4511 4963

Proximate Analysis of various wastes from a typical Pharma Industry (both solid & liquid)

Properties of Polymer cake /sludge from Chemical/Paint Industry

S.no Test parameters Result Units

1 Bulk Density 0.5612 gm/ml

2 Flash point 95 %

3 Calorific value 6519 Cal/ gm

5 Loss on Drying 21.9 %

6 Loss on Ignition 98.81 %

7 Chlorides 601 mg/ Kg

8 Sulphates 433 mg/Kg

9 %organic content 3.7 %

10 Hexavalent chromium BDL mg/Kg

11 Nickel BDL mg/Kg

12 Zinc BDL mg/Kg

13 Copper BDL mg/Kg

14 Manganese BDL mg/Kg

15 Cyanide BDL mg/Kg

16 Lead <1 PPb

17 Mercury 11 PPb

Impediments in usage of Industrial wastes Absence of statutory law that polluters pay. Polluters sell their waste at high

price or adopts improper disposal method.

Long Wait for Clearances from Statutory Bodies.

Inconsistent availability of waste.

Competition from others in cement industry.

Requirement of huge investment for building infrastructure to handle, store and use industrial wastes along with conventional fuel.

Strong odour which invites protest from public as well as employees.

Problem of Transportation of hazardous wastes in view of high inflammability.

Bio-fuels

Agricultural wastes as renewable bio-fuel

Cashew shell is major bio-fuel. It has very good heat value. The other bio-fuels are rice husk, ground-nut shell, coconut shell, chilli stems, etc.

No processing is needed. Easy to regulate the feed into the kiln.

No adverse smell or health hazard but high volume storage and handling is posing problem

Availability of bio-fuel is erratic and seasonal. Since agriculture is small scale and scattered, procurement of sizable quantity is problem

The cost is high since it is used as fuel in village homes and small scale industries

Fuel GCV Cal/gm

NCV Cal/gm Moisture C H N S ASH O

Saw dust 3952 3798 10.81 43.65 5.83 0.52 0.11 2.05 47.84 Rice Straw 3382 3228 11.01 38.69 5.78 0.59 0.11 14.54 40.29 Ground Nut shell 4091 3937 10.4 44.55 6.02 0.02 0.09 5.16 44.16 Bamboo dust 4127 3973 9.9 46.89 6.77 0.34 0.1 2.09 43.81 Bagasse 4172 4018 8.38 46.73 6.24 0.44 0.01 3.49 43.09 Cane Trash 4032 3878 10.33 43.76 6.19 0.93 0.1 5.91 43.11 Rice husk 4067 3912 12.24 34.52 5.55 1.35 0.15 24.34 34.09 Wheat Straw 3980 3826 7.96 40.21 5.08 0.61 0.11 7.04 46.95 Coir Waste 4312 4158 7.86 45.16 5.26 0.2 0.18 2.14 47.06 Padak Dust 4724 4569 9.81 43.05 5.76 0.4 0.05 0.62 50.12

Calorific Value of Bio- Mass Fuels

Wood Chip as renewable bio-fuel

1. Wild shrub called JULI FLORA which grows uncontrolled in barren uncultivable land offers excellent scope for bio-fuel.

2. Even after trimming the plant up to the root, it grows from root very fast. It grows through out the year.

3. Availability of large barren land and wild growth of Juli-flora in it is abundant. There are many thermal power plants operating on exclusively Juli-flora woodchips as fuel.

4. Absence of viable mechanization for harvesting Juli-flora is problem. The cost of manual harvesting is high.

Wood Chips of Juli-flora plant

Wood Chipper

C3S Size C2S Size % C3S % C2S Liquid%

Normal Clinker

18.0µ 9.9µ 50.6 33.2 15.2

AFR Clinker

18.7

10.5

49.5

34

16.0

Microstructure of Normal Clinker Vs. 5-8% AFR clinker

Similar microstructure except marginal increase in crystal size & liquid content in AFR clinker

Chemical Characteristics of Clinker with use of Spent carbon/sludge

Oxide composition

Clinker-1 (Normal)

Clinker-2 (With AF) Phase

Composition

Clinker-1 (Normal)

Clinker-2 (With AF)

SiO2(%) 21.0 20.7 Bogue Potential Phase

Al2O3(%) 5.6 5.80 C3S(%) 53.4 53.2 Fe2O3(%) 4.65 4.40 C2S(%) 19.9 19.3 CaO(%) 65.1 64.9 C3A(%) 7.1 8.0 MgO(%) 1.05 0.95 C4AF(%) 14.2 13.7 SO3(%) 0.30 0.35 Chemical Parameters

Na2O(%) 0.38 0.55 Liquid Content (%) 28.6 29.0

K2O(%) 0.44 0.61 AM(%) 1.21 1.29 Cl (%) 0.004 0.008 SM(%) 2.04 2.03 F- (%) 0.01 0.03 LSF(%) 0.95 0.94

Mn2O3 (%) 0.05 0.05 F.CaO(%) 1.65 1.80

P2O5 (%) TiO2

0.18 0.15

0.21 0.22

Except marginal increase in Alkalies and minor elements , no difference in chemical/ phase composition observed.

Influence on Clinker Quality Alternative Fuels Such as Plastic fraction potentially contain

minor traces of metals Contents Given in mg/kg if not specifically mentioned

Petcoke Plastic Waste Oil Prepared Domestic Waste

Cd 0.005 2-8 13 3.3

Cl 25 12800 8400 1.23

Cr 1 9 7.6

Hg 0.2 0.3 2 0.15

Ti 0.2

Zn 5 114-177 3000 378

Conclusion

Co-processing of waste derived materials (both hazardous & innocuous) in Cement Kiln is a sound method of safe disposal of and benefits the Environment.

It has been proven that heavy metal elements are safely captured in

clinker phases and the high thermal profile in the kiln ensures cracking of the hazrdous organic compounds of the WDF down to its base molecule methane (CH4) and then is completely combusted. The clinker quality does not suffer on account of WDF usage.

The competitiveness of the cement industry in the near future will

be decided by the extent of Substitution of primary fossil fuels with alternate fuels.

Thank you

Littering of Plastic wastes

Plastic wastes spoil city’s beauty

Plastics choke water bodies

Burning of plastics

Burning plastic wastes in open

Plastic shredder in operation

Shredded Plastic Fluff

Shredding & Feeding of Plastic Waste Directly into the kiln burner

Shredding & Feeding of Plastic Waste Directly into the kiln burner

Coconut Shell