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EE 2
EE 2
Cement, in general, adhesive substances of all kinds, but, in a narrower sense, the binding
materials used in building and civil engineering construction. Cements of this kind are finely
ground powders that, when mixed with water, set to a hard mass. Setting and hardening result
from hydration, which is a chemical combination of the cement compounds with water that
yields submicroscopic crystals or a gel-like material with a high surface area. Because of their
hydrating properties, constructional cements, which will even set and harden under water, are
often called hydraulic cements. The most important of these is portland cement.
History Of Cement
The origin of hydraulic cements goes back to ancient Greece and Rome. The materials used
were lime and a volcanic ash that slowly reacted with it in the presence of water to form a hard
mass. This formed the cementing material of the Roman mortars and concretes of more than
2,000 years ago and of subsequent construction work in western Europe. Volcanic ash mined
near what is now the city of Pozzuoli, Italy, was particularly rich in essential aluminosilicate
minerals, giving rise to the classic pozzolana cement of the Roman era. To this day the
term pozzolana, or pozzolan, refers either to the cement itself or to any finely divided
aluminosilicate that reacts with lime in water to form cement. (The term cement, meanwhile,
derives from the Latin word caementum, which meant stone chippings such as were used in
Roman mortar—not the binding material itself.)
Manufacture Of Cement
(4) Grinding the burned product, known as “clinker,” together with some 5 percent
of gypsum (to control the time of set of the cement). powder, or ground dry and then moistened
to form nodules that are fed to the kiln.
Crushing and grinding
All except soft materials are first crushed, often in two stages, and then ground, usually in a
rotating, cylindrical ball, or tube mills containing a charge of steel grinding balls. This grinding
is done wet or dry, depending on the process in use, but for dry grinding the raw materials first
may need to be dried in cylindrical, rotary dryers.
Soft materials are broken down by vigorous stirring with water in wash mills, producing a
fine slurry, which is passed through screens to remove oversize particles.
Blending
A first approximation of the chemical composition required for a particular cement is obtained
by selective quarrying and control of the raw material fed to the crushing and grinding plant.
Finer control is obtained by drawing material from two or more batches containing raw mixes of
slightly different composition. In the dry process these mixes are stored in silos; slurry tanks are
used in the wet process. Thorough mixing of the dry materials in the silos is ensured by agitation
and vigorous circulation induced by compressed air. In the wet process the slurry tanks are
stirred by mechanical means or compressed air or both. The slurry, which contains 35 to 45
percent water, is sometimes filtered, reducing the water content to 20 to 30 percent, and the filter
cake is then fed to the kiln. This reduces the fuel consumption for burning.
Burning
The earliest kilns in which cement was burned in batches were bottle kilns, followed by chamber
kilns and then by continuous shaft kilns. The shaft kiln in a modernized form is still used in some
countries, but the dominant means of burning is the rotary kiln. These kilns—up to 200 metres
(660 feet) long and six metres in diameter in wet process plants but shorter for the dry process—
consist of a steel, cylindrical shell lined with refractory materials. They rotate slowly on an axis
that is inclined a few degrees to the horizontal. The raw material feed, introduced at the upper
end, moves slowly down the kiln to the lower, or firing, end. The fuel for firing may be
pulverized coal, oil, or natural gas injected through a pipe. The temperature at the firing end
ranges from about 1,350 to 1,550 °C (2,460 to 2,820 °F), depending on the raw materials being
burned. Some form of heat exchanger is commonly incorporated at the back end of the kiln to
increase heat transfer to the incoming raw materials and so reduce the heat lost in the waste
gases. The burned product emerges from the kiln as small nodules of clinker. These pass into
coolers, where the heat is transferred to incoming air and the product cooled. The clinker may be
immediately ground to cement or stored in stockpiles for later use.
In the semidry process the raw materials, in the form of nodules containing 10 to 15 percent
water, are fed onto a traveling chain grate before passing to the shorter rotary kiln. Hot gases
coming from the kiln are sucked through the raw nodules on the grate, preheating the nodules.
Dust emission from cement kilns can be a serious nuisance. In populated areas it is usual and
often compulsory to fit cyclone arrestors, bag-filter systems, or electrostatic dust precipitators
between the kiln exit and the chimney stack. More than 50 percent of the emissions from cement
production are intrinsically linked to the production of clinker and are a by-product of
the chemical reaction that drives the current process. There is potential to blend clinker
with alternative materials to reduce the need for clinker itself and thus help reduce the climate
impacts of the cement-making process.
Modern cement plants are equipped with elaborate instrumentation for control of the burning
process. Raw materials in some plants are sampled automatically, and a computer calculates and
controls the raw mix composition. The largest rotary kilns have outputs exceeding 5,000 tons per
day.
Grinding
The clinker and the required amount of gypsum are ground to a fine powder in horizontal mills
similar to those used for grinding the raw materials. The material may pass straight through the
mill (open-circuit grinding), or coarser material may be separated from the ground product and
returned to the mill for further grinding (closed-circuit grinding). Sometimes a small amount of a
grinding aid is added to the feed material. For air-entraining cements (discussed in the following
section) the addition of an air-entraining agent is similarly made.
Finished cement is pumped pneumatically to storage silos from which it is drawn for packing in
paper bags or for dispatch in bulk containers.
TYPES OF PROCESSESS:
The three important types of processes are
Dry Process
Wet Process
Semidry Process
Dry Process:
In the dry process, the raw materials are dried using impact dryers, drum dryers, paddle-
equipped rapid dryers, or air separators, before grinding, or in the grinding process itself.
Wet Process
In the wet process, water is added during grinding.
Semidry Process
In the semidry process the materials are formed into pellets with the addition of water in a
pelletizing device
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Gaseous atmospheric emissions of CO2, NOx, SO2, Volatile Organic Compounds (VOCs)
and others Carbon dioxide is released during the production of clinker, a component of
cement, in which calcium carbonate (CaCO3) is heated in a rotary kiln to induce a series of
complex chemical reactions (Conneely et al., 2001). Specifically, CO2 is released as a by-
product during calcination, which occurs in the upper, cooler end of the kiln, or a pre
calciner, at temperatures of 600-900°C, and results in the conversion of carbonates to oxides
Sulphur oxides and nitrogen oxides generated from the kiln and drying processes. Sulphur
dioxide is generated from the sulphur compounds in the ores and the combusted fuel and
varies in amount produced from plant to plant. The efficiency of particulate control devices
is inconclusive as the result of variables such as feed sulphur content, temperature,
moisture, and feed chemical composition, in addition to alkali and sulphur content of the raw
materials and fuel. The combustion of fuel in rotary cement kilns generates nitrogen oxides from
the nitrogen in the fuel and incoming combustion air The amount emitted depends on several
factors including fuel type, nitrogen content, and combustion temperature.
Both sulphur dioxide and some of the nitrogen oxide react with the alkaline cement and are
removed from the gas stream.
Volatile organic carbon compounds (VOCs) are a class of chemicals that are emitted directly to
the air as a result of evaporation or another type of volatilization. Sources include stored
gasoline, stored solvents and other industrial chemicals, and certain industrial processes.
Incomplete combustion of fuels of many types is also an important source of
VOC discharge to the ambient air
ii)Dust:
Dust emissions originate mainly from the raw mills, the kiln system, the clinker cooler, and the
cement mills. A general feature of these process steps is that hot exhaust gas or exhaust air
is passing through pulverised material resulting in an intimately dispersed mixture of gas and
particulates. The nature of the particulates generated is linked to the source material itself, that is,
raw materials (partly calcined), clinker or cement (Karstensen., 2006 & 2007).
iii)Noise:
Noise emissions occur throughout the whole cement manufacturing process from preparing
and processing raw materials, from the clinker burning and cement production process, from
material storage as well as from the dispatch and shipping of the final products
The heavy machinery and large fans used in various parts of the cement manufacturing process
can give rise to noise and/or vibration emissions, particularly from: chutes and hoppers, any
operations involving fracture, crushing, milling and screening of raw material, fuels, clinker and
cement; exhaust fans; blowers; duct vibration.
The heavy machinery and large fans used in various parts of the cement manufacturing process
can give rise to noise and/or vibration emissions, particularly from:
chutes and hoppers;
any operations involving fracture,
crushing,
milling and
screening of raw material, fuels, clinker and cement;
exhaust fans;
blowers;
duct vibration.
iv)Bad odour:
Foul smell is sometimes a direct result of the gases emitted during cement manufacturing.
Moreover, since cement manufacture has life threatening impacts to plants and animals, the
manufacturing process then directly and indirectly gives rise to offensive smells as the dead
plants and animals decay
Health and Safety Requirements
The air pollution occurs in the excavation activities, dumps, tips, conveyer belts, crushing mills,
and kilns of cement industry. Minimizing air pollution is a mandatory legislative requirement,
which also contributes to minimizing wastage and survival of the industry [37]. Dust particles
emitted at sites other than kilns can be captured using a hood or other partial enclosure and
transported through a series of ducts to the collectors. The dust collected can be fed to the kiln
provided that it is not too alkaline not exceeding 0.6% as per the Na 2O (N) content. However, if
the alkalinity is higher than this value, then the dust must be either discarded or pretreated before
feeding to the kiln. Flexible pulse jet filters, electrostatic precipitators, wet scrubbers, and
baghouse method can be used to collect dust from flue gas [38]. The US Environmental
Protection Agency has reviewed the available and emerging technologies for reducing
greenhouse gas emissions from Portland cement industry. The primary greenhouse gas emitted in
the cement industry is carbon dioxide, but in lower quantities, NOxs and SOxs are also emitted
This involves separation and capture of carbon dioxide from the flue gas, pressurization, and
transportation via pipelines, injection, and long-term storage. In regard to this, several processes
have been developed as detailed below.
Calera Process
This involves capture of CO2 from flue gas and conversion to carbonates. This utilizes a scrubber
containing high-pH water with calcium, magnesium, sodium, hydroxide, and chloride as the
scrubbing liquid. CO2 captured by this water is converted to CaCO 3 and MgCO3, which are
precipitated out of the solution. The precipitates can be filtered, washed, and dried for reuse as
feed material for the kiln to make blended cement. Water used may be seawater or reject brine.
Capture efficiency of over 90% has been reported in a 10 -MW coal-fired pilot plant. It is
interesting to note that when captured carbon is reused, the overall carbon footprint becomes
negative since the carbon emissions avoided from the cement manufacturing process could be
greater than those of carbon emissions from the power plant
Oxy-Combustion Process
In the oxy-combustion process, fuel is burnt with pure or nearly pure oxygen instead of air. Since
there is no nitrogen gas, the fuel consumption is reduced due to the fact that there is no need to
heat and burn nitrogen gas. Since air contains nearly 79% nitrogen gas and any combusted
nitrogen comes as NOx in flue gas, the volume of flue gas and NO x in it is significantly reduced
when pure oxygen is used for combustion [39, 41]. This process should utilize an air separation
process to separate out nitrogen gas, which can be used for other processes such as for inflating
vehicle tires. Nitrogen-removed air basically contains majority of oxygen, and it can be used for
the oxy-combustion process. When oxy-combustion is used, the resulting kiln exhaust contains
over 80% CO2 gas, which can be recovered by the Calera process. There are several technical
issues as laid down in [42] that have to be tackled before implementing this process in cement
industry.
When flue gas is passed through a column containing monoethanolamine, CO 2 gas is selectively
absorbed. High-pressure, low-temperature conditions favour the absorption. When CO 2-rich
MEA solution is subjected to low-pressure, high-temperature conditions, it releases absorbed
CO2 which can be converted to some other product like CaCO 3 or MgCO3 and the solvent
recovered can be reused. One of the problems with this method is that acidic gases such as
SOx and NOx present in the flue gas can react with MEA. Therefore, levels of these gases must
be kept below 0.001% prior to absorption by MEA. Instead of regular amines, hindered amines
can also be used. Hindered amines have special functional to prevent degradation of the amine
[43].
Flue gas contains SOx, which could be separated using limestone-based compounds. They are
then converted to slurries to use as CO 2 absorbents. This way, both SOx and CO2 can be removed
from flue gas
Cryogenic Distillation
Cryogenics is the science that addresses the production and effects of very low temperatures. In
the cryogenic separation, all other gases except CO 2 and N2 have to be removed prior to
subjecting to low-temperature conditions. The triple point for CO 2 is 256.68°C and 7.4 atm, and
when these conditions are maintained, CO2 will condense while N2 will remain as a gas. N2 gas is
then escaped through an outlet at the top of the chamber, and the dense liquid is taken from the
bottom of the chamber. Refrigeration under pressure is an alternative method to cryogenic
distillation but utilizes even harsh conditions such as higher pressures and lower temperatures.
Cryogenic methods have distinct advantages over other separation methods. Since CO 2 is
separated as a liquid, it can be transported via pipelines for sequestration. Also, the recovery and
purity of CO2 is very high (CO2 purity after distillation can exceed 99.95%) [43].
Membrane Separation
Suitable membranes can be used to separate or adsorb CO 2 in the kiln exhaust gas.
Poly(methoxyethoxy)ethanol phosphazene (MEEP) hollow fibre membranes are excellent
CO2 separation and storing membranes, where (methoxyethoxy)ethanol groups attached P have
strong interactions with CO2 [44–46]. One such example is given in Figure
Polymer blends with required properties such as strong interaction with CO 2 can be used as CO2-
selective membranes
Separation of CO2 from a gas mixture by selective adsorption involves both thermodynamics
(adsorption) and kinetics (diffusion selectivity), and designing adsorbents for CO 2 in the
presence of gases such as CH4 and N2 is challenging since all three gases have similar kinetic
diameters of 3.30 Å, 3.76 Å, and 23.64 Å, respectively [55]. In this sense, sorbents such as
zeolites and metal-organic frameworks (MOFs) stand out as adsorbents of CO2.
Environmental Legislation:
Environmental legislation is the collection of laws and regulations pertaining to air quality, water
quality, the wilderness, endangered wildlife and other environmental factors. The umbrella of
environmental legislation covers many laws and regulations, yet they all work together toward a
common goal, which is regulating the interaction between man and the natural world to reduce
threats to the environment and increase public health. As you might imagine, environmental
legislation is a broad topic, mainly because the natural environment encompasses so many
different aspects. So, environmental laws need to consider everything, from the air we breathe to
the natural resources we rely on to the plants and animals that share this world with us
Example
To better understand environmental law, let's look at an example. Let's say that an energy
company wants to build a coal-burning power plant to create electricity for the community.
Where should this power plant be built? What type of pollutants might result from the coal
burning, and what measures will need to be taken to control harmful emissions? If the power
plant is built at the edge of town to lessen air pollution for the human population, how will this
impact lesser species that inhabit the land downwind of the plant? These are all considerations to
be evaluated within the scope of environmental law
Environmental Legislation Timeline:
Debates over how to preserve air and water quality are not new. These topics, along with many
other environmental issues, have been subjected to laws for thousands of years. There's evidence
of early Roman law regarding the handling of water and sewage. In fact, it is speculated that the
Roman Empire lasted as long as it did because they paid so much attention to sewage networks
and extensive freshwater distribution channels. However, the official timeline of environmental
law in the United States did not start until the 20th century. The United States is regarded as a
world leader when it comes to development and application of environmental law, and the 1960s
are when the process got started. This time period in U.S. history was marked by a surge in
economic and industrial growth. Along with an increase in factories and industrial activities,
came a mounting concern about the impact these practices were having on the earth's natural
environment. This was also a time when environmentalism, which is a movement toward
protecting the natural environment against hazards and pollutants, matured into a public and
political force. The new-found awareness and events of the 1960s coalesced to establish the start
of environmental legislation.
Neighborhood Environment:
Considerations should also be given to the characteristics of neighborhood environment and the
sensitivity of other nearby premises to environmental nuisance, e.g. dust, odour, noise. This may
affect the likelihood of triggering environmental complaints in the future. Such considerations
include: • Are there any environment-sensitive premises, e.g. residential buildings, schools,
hospitals, etc., close to the planned site of your company? • Are there any environment-
sensitive tenants (e.g. elderly tenants undertaking activities requiring quiet environment, etc.)
within the building that your company plans to move in?
If your answer to any of the above questions is yes, you will need to exercise extra care in
planning and designing your operation processes and facilities or even consider the use of
suitable environmental control systems. Otherwise, it is likely that your future operation would
attract environmental complaints
(1) Effective arrangements shall be made in every factory for the disposal of wastes and
effluents due to the manufacturing process carried on therein.
(1) An urban local council may through a notice require the owners, tenants and occupiers of
commercial and industrial concerns in any area or areas within its local area to have at
their own cost prepared a scheme for the adequate and safe drainage and disposal of their
wastes and effluent of the quality permitted under the rules or the by-laws and submit it
to the urban local council within the time specified in the notice:
Whoever voluntarily corrupts or fouls the water of any public spring or reservoir, so as to
render it less fit for the purposes for which it is ordinarily used, shall be punished with
imprisonment of either description for a term which may extend to three months, or with fine
which may extend to five hundred rupees, or with bot
Employers manage and conduct their work activities in such a manner as to ensure the
safety, health and welfare of employees.
That a risk assessment is carried out by the employer or person in control of the place of
work.
Transport hazards that exist in the workplace must be assessed as part of this risk
assessment and appropriate steps taken to eliminate or reduce any risks found.
Vehicles are designed, provided and maintained in a condition that is safe and without
risk to health
Safe means of access and egress to and from the vehicle is designed, provided and
maintained
Systems of work are planned, organized, performed, maintained and revised as
appropriate, for example safe systems of work must be available for vehicle loading and
unloading activities Information, instruction, training and supervision is provided for
all employees who operate work related vehicles
Health and Safety Risk Assessments:
One of the largest areas of health and safety that underpins the overall topic is risk
assessments. As the title suggests, risk assessments are designed to assess and address risks
wherever possible. This is required in all workplaces, and is also implemented in areas of life
like medical care, school trips, and university society activities. Risk assessments are carried
out for the benefit of those working within organizations, as well as those who come into
contact with them. Ideally, a risk assessment will be performed before the risk arises. For
example, a nurse who is caring for an elderly patient will assess the risks that they face while
in their care. The nurse may decide that the patient is at risk of experiencing falls. When this
risk is identified, she will then put a solution in place. This approach extends to multiple
workplaces, and is designed to prevent people from becoming injured. The aim of any risk
assessment procedure is to minimize the risks present, not to attempt to eliminate them
altogether. Sometimes it is the case that an incident has occurred, and the risk needs to be
assessed and addressed afterwards. Using the patient analogy again, this could arise if the
elderly patient has fallen over and injured their hip. If that has happened, the nurse and their
medical colleagues must assess why it happened, and implement a measure that prevents it
from happening again. Finally, data must be collected on risk assessments. This is used to
form guidelines and procedures that minimize problems in the future. Those who wish to
carry out a risk assessment can obtain relevant forms and guidelines from the Health and
Safety Executive, which should be specific to the area they are assessing.
Taking Steps:
Once a risk assessment is made it usually requires some action to be taken. This might be
relatively simple. In our example, using a highlight to visually indicate a trip hazard more
clearly might be enough. In other cases, no action may be required at all. However, in some
circumstances, more will be needed - perhaps clearing an area of trip hazards completely and
providing staff with pegs so they can hang their personal belongings away rather than have
them in bags on the floor next to their desks. Taking preventative measures like these is only
part of the process. All staff need to be informed of a risk assessment that affects their
workspace and practices. It is no good, after all, to make a risk assessment that says
walkways must be kept clear of bags and boxes, if staff don't know about such a policy and
fail to act on it. In order to establish that there has been an improvement and that risk has
been reduced, according to the assessment that has been made, a further inspection should be
carried out. There is no hard and fast rule about when this should be. Low risks might be
inspected only annually, but areas that pose higher risks should be more frequently looked at
until the risk is successfully reduced. Setting the timescale for the next assessment is a crucial
part of the way the process works and without it the whole system can fail - with the result
that offices continue to be unsafe and also potentially meaning that employers are in breach
of the law.
Cross-referencing:
Where the plan refers to material in other documents, it should include cross-references that are
clear, complete and that specify the document version and date. Use tables, diagrams and maps
where their inclusion would provide a better understanding and implementation of the
management plan. Link all tables, diagrams and maps into the text through cross-referencing.
References
https://www.researchgate.net/publication/
323029097_Impacts_of_Cement_Industry_on_Environment_-_An_Overview
https://www.hindawi.com/journals/amse/2018/4158682/
https://www.linkedin.com/pulse/environmental-social-impacts-cement-industries-narayanan