Everand Logo

Welcome to Everand!

  • Discover millions of ebooks, audiobooks, and so much more with a free trial

    Only $11.99/month after trial. Cancel anytime.

    Designing Green Cement Plants
    Designing Green Cement Plants
    Designing Green Cement Plants
    Ebook623 pages49 hours

    Designing Green Cement Plants

    By S.P. Deolalkar, Anil Shah and Naresh Davergave

    4/5

    ()

    Read preview

    About this ebook

    Cement production is known to be a polluting and energy-intensive industry. Cement plants account for 5 percent of global emissions of carbon dioxide and one of the main causes of global warming. However, cement it is literally the glue of progress. Designing Green Cement Plants provides the tools and techniques for designing new large cement plants that would promote sustainable growth, preserve natural resources to the maximum possible extent and make least possible additions to the Greenhouse Gases that cause global warming.

    Brief and but authoritative, this title embraces new technologies and methods such as Carbon Capture and Sequestration, as well as methods for harnessing renewable energy sources such as wind and solar. The author also discusses the efficient use of energy and materials through the use recycling. In addition, this book also examines thepossibilities of developing green cement substitutes such as Calera, Caliix, Novacem, Aether and Geopolymer cements.

    • Includes the tools and methods for reducing the emissions of greenhouse Gases
    • Explores technologies such as: carbon capture and storage and substitute cements
    • Provides essential data to determining the unique factors involved in designing large new green cement plants
    • Includes interactive excel spreadsheets
    • Methods for preforming a cost benefits analysis for the production of green cements as opposed to conventional OPC
    LanguageEnglish
    PublisherElsevier Science
    Release dateSep 2, 2015
    ISBN9780128034354
    Designing Green Cement Plants

    Related to Designing Green Cement Plants

    Related ebooks

    Construction For You

    View More
    View More

    Related podcast episodes

    Related articles

    Related categories

    Reviews for Designing Green Cement Plants

    4/5

    9 ratings0 reviews

    What did you think?

    Tap to rate

    Review must be at least 10 words

      Book preview

      Designing Green Cement Plants - S.P. Deolalkar

      production

      Section 1

      Green Cement

      Chapter 1

      What is a Green Cement Plant

      Abstract

      Green Cement brings out the philosophy behind the design and operation of cement plants right from the planning stage. Sustainable development is the guiding concept in this.

      The main aspects are: reduction in quantity of emission of green house gases (GHG) that cause global warming; conservation of natural resources like limestone, the main raw material, and fossil fuels like coal; and reuse and recycling of wastes, disposal of which has assumed grave proportions.

      Principal ways available to achieve these goals are making blended cements, using alternate fuels, and using waste heat to generate power/heat. Improving operational efficiencies also helps in this respect, but for plants already operating at high levels of efficiency, the scope is limited.

      In addition to saving of fossil fuels, using renewable energy sources like wind and solar power also helps, as there are no GHG emissions.

      Carbon capture and storage (CCS) is another possibility, where released CO2 is captured and stored. The industry is also exploring substitutes for known forms of cement.

      Keywords

      Green house gases (GHG)

      Green house effect

      Global warming

      Blended and composite cements

      Alternate fuels and raw materials (AFR)

      Renewable energy

      Carbon capture and storage (CCS)

      Cement substitutes

      1.1. Definition of a green cement plant

      The natural color of cement is gray, varying between lighter and darker shades. What then is green about a green cement plant?

      Obviously, green does not refer to the color of the cement. It refers to the philosophy that lies behind the design concepts of new cement plants.

      A green cement plant is one that is designed to conserve natural resources of all kinds and that contributes to the release of the greenhouse gases (GHG) to the atmosphere to the least possible extent consistent with the quality of cement produced.

      1.2. Blended cements

      Release of CO2, a greenhouse gas, is inherent in the process of the manufacture of cement, as CO2 is released from limestone, the basic raw material of cement during the process of calcining. One kilogram of calcium carbonate releases 0.44 kg of CO2. Therefore, in making 1 kg of clinker, approximately 0.51 kg CO2 gets released into the atmosphere.

      The quantity is reduced when computed in terms of cements made from the clinker:

      • OPC: ~ 0.49-0.50 kg/kg

      • PPC: ~ 0.34-035 kg/kg

      • BFSC: ~ 0.19-0.20 kg/kg

      This itself is a factor in reducing GHG emissions. Blended cements release less GHG as compared to OPC per ton of cement.

      1.3. Combustion of fuel

      A vital component of total carbon dioxide released to the atmosphere is the CO2 released in the process of combustion of fuel fired in the kiln and calciner in the clinkerization process. The quantum released is directly related to the quantum of fuel fired and the quantum of carbon in it.

      Again, by the same logic, the obvious way to reduce emissions is to reduce the heat requirement, or what is called specific fuel consumption, and/or to use fuels with less carbon or those that are carbon neutral.

      1.4. Alternate fuels

      Alternate fuels have been successfully used in many countries in kilns and calciners. In Europe the cement industry is progressing toward zero fuel costs. Great possibilities exist for using wastes of industry and agriculture that have heat value as secondary fuels in kilns and calciners.

      Certain modifications and additions are of course required in the existing fuel storing, preparation and firing systems in order to fire secondary fuels alongside of basic fossil fuels.

      Whereas blended cements can be easily made in an existing plant, introduction of alternate fuels would require careful planning and engineering and also capital investment.

      1.5. Electrical energy

      Production of cement also requires a supply of electrical energy, expressed as kwh/ton of cement. Electrical energy is presently produced mostly by burning fossil fuels like coal and oil. Thus reduction of electrical energy by making cement indirectly means a reduction in electrical energy produced and thereby in GHG released to the atmosphere. If 1 kwh is used in a cement plant, the generating station has to produce much more to allow for transmission losses and for its own inputs. In some countries transmission losses are small, say 10%, but in some countries (India for one) they are more than 30%.

      Any saving in electrical energy by the cement plant, howsoever small, has a still greater impact on decreasing GHG emissions when energy generated at thermal power stations is taken into account.

      1.6. Waste heat recovery

      Cement plants can further contribute significantly to reducing GHG emissions by converting waste heat in the exhaust gases from the kiln and cooler into electricity using waste heat recovery systems (WHRS). There is plenty of scope in existing dry process cement plants to produce power from waste heat.

      Due to recent developments in technology it is now possible to generate power even from waste gases in modern cement plants with low heat contents by using the organic Rankine cycle and the Kalina process. It is estimated that between 20 to 30% of the energy required by a cement plant can be generated by installing WHRS. Energy so generated can be used in the plant or fed to the

      Enjoying the preview?
      Page 1 of 1