Professional Documents
Culture Documents
Cement Industry
Innovations Leading the Way Forward
S K Chaturvedi
Joint Director
National Council for Cement and Building Materials, India
60
40 67 65 66
50
20 19 26
11 11 8 8 7 7
0
1995 2000 2005 2008 2012 2015
Minimum
Constituent Content , %
Clinker/ 35 - 65 Clin
Maximum
ker /
OPC OPC Minimum
Fly ash 15 -35
0 20 40 60 80
GBFS 20 - 50
Future Cementing Materials
• Broadening the range of additives for use in composite cement
• Use of combination of fly ash and limestone as the mineral
additives
• Use of blending additives such as rice husk ash, metakaolin,
silica fume, microfine slag/ fly ash, various types of slags
• Geopolymeric Binders
• Performance Improvers in PPC and PSC
• High volume Fly ash Cement
• Portland Limestone Cement
• Multi Component Blended Cement
• Calcined Clay-Limestone Cement
SEM image of alkali activated Bottom ash with
30% GBFS cured for 28 days
Physical Characteristics of Laboratory Prepared Tiles
Sl Dimensions
Warpage Flexural Strength Water Absorption
Period No LxWxH
(mm) (mm) (MPa) (%)
15
Source of waste heat in context of Cement Plant
PREHEATER EXIT GAS COOLER EXIT GAS
300 - 400oC, 180 - 250 200 - 300oC, 80 -
KCAL/KG 130 KCAL/KG
16
Outcome of PAT Scheme
Government of India enacted Energy Conservation
Act in 2001. Under this Act, an innovative scheme
of Perform, Achieve and Trade (PAT) was launched.
During PAT cycle-1 (Apr’14 to Mar’15), which is now
completed, Indian cement industry has shown
commendable performance in surpassing the set
energy targets and achieved 1.480 million tones of
oil equivalent (MTOE), 82% higher than the target.
Waste Heat Recovery system implementation
during PAT Cycle-1 was to the tune of 159 MW
which generated 841.3 Million Units @ 61% Plant
Load Factor.
Despite the progress that has been made in waste
heat recovery in the cement industry, it is important
to keep in mind that the overall efficiency of waste
heat recovery and the economic situation is very
plant-specific. 17
Outcome of Energy Audit Studies Carried Out by NCB
18
Availability of Alternate Fuels in India
Total Availability for
availability co-processing % TSR
Alternate Fuel
(million (million potential
tonnes/year) tonnes/year)
Surplus 150 15 30-32
Biomass
ETP Sludge
The ETP sludge consumption was found to be varying from 4% to 6.5% (on dry basis)
of total fuel used during the period of trials.
With proper handling and feeding higher quantity of ETP sludge can be used up to
10%.
The laboratory results for chemical analysis and heavy metals in the clinker indicate
that ETP sludge has negligible impact on the quality of clinker.
The results of leachability tests from all the clinker samples are also found within
narrow variation indicating no adverse impact on use of ETP sludge. 21
Renewable Energy
Presently, 8 plants have gone for installation of wind
power with rated capacity of around 256 MW.
Replication potential exists for other plants for around
30% renewable energy substitutions.
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