Team Name

Solution Seekers

Model proposal of an eco-friendly cement factory.

Team Members Supervised by

Abdullahil Muhsee Dr. Bulbul Ahmed
Dept. of Civil Engineering Associate Professor
Md Marjan Jahan Tazin Dept. of Civil Engineering
Dept. of Mechanical Engineering RUET
Abid Hussain
Dept. of Civil Engineering

Name of the Institution

Rajshahi University of Engineering & Technology

Level
(University) – Engineering
 Unit 1

Pictures Related to the Project

Fig. 1, Model Generation of the Eco-friendly Cement Factory on

SolidWorks

Fig. 2, Pilot Reactor Mechanism for Carbon Dioxide Removal

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Fig. 3, Handcrafted layout of the Eco-friendly Cement Factory

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Fig. 4, Eco-Friendly Cement Factory Working Principle

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 Unit 2
Theoretical Information Related to the Project

The following project has merged the field of civil and mechanical
engineering. This unit will give a comprehensive idea about the project.

2.1 50-50 Mixing of Limestone and Sand

In a conventional cement factory, the sand and limestone are mixed at a
proportion of 30-70 percent. However, if the proportion is done at 50-50
mixing, the temperature can be reduced for preparing clinker can be
reduced from 1450 degree Celsius to 1200 degree Celsius. But the
variation of the proportion does not affect the final strength of the concrete
made from the modified cement (reference is given later).

2. 2 Carbon Dioxide Removal Mechanism (Pilot Reactor)

Cement factories emit massive amounts of carbon dioxide while
producing cement. This carbon dioxide is a biproduct of the fuel
combustion, limestone, and burning of sugarcane bagasse.
There are other biproducts of combustion besides carbon dioxide, such
as H2O (Vapor), SOx, and NOx for complete combustion and CO, PM,
etc., for incomplete combustion. But the project only focuses on removing
carbon dioxide, a greenhouse gas. This is done by a device called Pilot
Reactor. The working principle of the pilot reactor is given below (follow
fig. 2 whiling studying the principle)
1. The exhaust emissions go to the first column of the pilot reactor
named Absorber. These emissions come from combustion chamber
of sugarcane bagasse and the preheater.
2. When the exhaust gas enters the column, a substance named
monoethanolamine or MEA (liquid) is sprayed from the top. As the
gas tends to go upward due to natural circulation, gas and MEA
carries a crossflow. As MEA is sprayed, the surface area is massive.
Thus, the chemical reaction of capturing carbon dioxide is done
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 effectively. But the maximum removal of carbon dioxide is around
5%.
3. Then the reduced carbon dioxide gas is released to the atmosphere
from the top of the absorber column, and carbon dioxide rich MEA
is condensed below the column.
4. To reuse MEA, the condensed MEA is pumped to another column
named separator where MEA is gradually heated to 110 degrees
Celsius. At that temperature, MEA’s absorbability reduces and
releases carbon dioxide. The carbon dioxide gas is then collected
from the top of the separator column and lean mixture of MEA-CO2
is condensed at the bottom of the column.
5. This lean mixture is then pumped to the top of absorber column for
the reuse. But this has heat energy that can be used to preheat the
rich mixture of MEA. For this, a shell and tube heat exchanger are
used called regenerator.

2.3 Waste Management

For waste management, sugarcane bagasse is used. Sugarcane bagasse
has been burned to create ash. This ash is replaced with the final cement
by 5%. This replacement does not affect the final cement quality (The test
results are in feasibility section). Moreover, using SBA in production
reduces the overall cost of cement production as well. The cost analysis
is provided later.

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2.4 Supply Chain

Fig. 5, Annual generation report of Sugarcane Bagasse in Bangladesh

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 Unit 3
Test Results and Cost Analysis

3.1 Experimental Setup

Fig. 6, Experimental Setup for (Cement+ SBA) Property Analysis

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3.2 Test Results
300
C-100-SBA-0 50 C-100-SBA-0
250 C-97-SBA-3 C-97-SBA-3
C-94-SBA-6 40 C-94-SBA-6
200 C-91-SBA-9 C-91-SBA-9
30
150

100 20

50 10

0 0
Initial setting time Final setting time Normal consistency (%)
(min) (min)

(a) Setting Time (b) Normal Consistency

Fig. 7, Physical Properties of Cement and Cement with Different

Percentages of SBA

The setting time decreases with the increases of % of SBA in cement. This
is because of hydration process occurs quickly in higher percentages of
SBA in cement. Similar types of results have been found in the previous
researches.

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 Fig. 8, Cube Test Result with SBA Mixed

Fig. 9, Cylindrical Concrete Test Result with SBA Mixed

From the graphs, it can be seen that the best result is obtained from 3
days test. Therefore, cost analysis is done for this particular result.

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3.2 Cost Analysis
To make an implementation of our project idea, collaboration with
industrialists is needed. Therefore, our project is built virtually and tested
in labs for validation.
For the cost analysis, in the case of cement production in our project,
around 87 BDT can be saved due to using sugarcane bagasse ash.
Tables are given below that contains the cost analysis of the final cement
production when sugarcane bagasse ash is used.

Table 1: Cost of 1 cubic-meter concrete production

Material Quantity Price (BDT)

Cement 259.086 kg 2124
Sand 0.41 cum 729
Coarse 0.84 cum 5638
Total 8491

Table 2: Cost of 1 cubic-meter concrete production with 3% replacement

of cement by sugarcane bagasse ash

Material Quantity Price (BDT)

Cement 246.132 kg 2018
Sand 0.41 cum 729
Coarse 0.84 cum 5638
Sugarcane Bagasse Ash 12.954 kg 19.2
Total 8404

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3.3 Feasibility of the Test Result
This project has been reviewed by our honorable teacher Dr. Bulbul
Ahmed, Assistant Professor, Department of Civil Engineering. The
following sustainability analysis is taken from research journals and lab
testing.
▪ SBA contains 58.6% - 59.55% Si𝑂2, 7.32% - 7.55% 𝐴𝑙2𝑂3, and
9.45% - 9.83% 𝐹𝑒2𝑂3 [5].
▪ SBA gives proper amount of Si𝑂2, 𝐴𝑙2𝑂3, and 𝐹𝑒2𝑂3 which is in line
with ASTM C618-17a requirement [6].
▪ As the failure load lies between 511.2 KN and 306 KN, sugarcane
bagasse ash increases the strength of cement bricks [7].
▪ SBA meets the requirements for a pozzolanic action.

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 Unit 4
SDG Goals Fulfilment

SDG or Sustainable Development Goals are 17 goals given by United

Nations. These goals address the major development challenges faced
by people in Bangladesh. Bangladesh Government is working to fulfil the
goals by 2030.
The following project of ours fulfil 9th and 13th goal of SDG. The following
goals are:
1. Industry, Innovation, and Infrastructure: Developing quality,
reliable, and sustainable resilient infrastructure.
2. Climate Action: Using technologies that reduces environmental
effects.
Our project covers these two goals from SDG list.

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 Unit 5
Conclusion

The following project covers three sides, including

1. Reducing air pollution done by cement factory
2. Reducing biodegradable waste by utilizing it
3. Reducing construction cost

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 Unit 6
References

[1] Manoj Katiyar, [2019] Concrete with Alternative Aggregates – Green

Concrete.
[2] The Business Standard Report. [3] Zhao et al (2017) Evaluation of
dioxins and dioxin-like compounds from a cement plant using
carbide slag from chlor-alkali industry as the major raw material. J
Hazard Mater 330:135–141. [4] Ara Cho, Hong-Seok Jang, Seok
Roh, Environmental Toxicology and Pharmacology, Volume 36,
Issue 3, [2013] Detrimental effects of cement mortar and fly ash
mortar on asthma progression
[3] Ahmed Sagban Saadoon, Abdulnasser Mohammed Abbas,
Abdulamir Atalla Almayah, ‘Revisional Study of Green Concrete’
Basrah Journal for Engineering Sciences, Vol. 19. No.2, September
2019.
[4] Kiyasudeen K, Ibrahim MH, Quaik S, Ismail SA. Prospects of
organic waste management and the significance of earthworms.
Applied Environmental science and Engineering for a sustainable
future. Springer International Publishing Switzerland Standard
Specification for Coal Fly Ash and Raw or Calcined Natural
Pozzolan for Use in Concrete.
[5] Amany Michael, Rania Rushdy, Ain Shams Engineering Journal,
Volume 12. Issue 3, [2011], “Investigating the economic and
environmental effect of Sugarcane Bagasse Ash in Cement Bricks.
[6] Shaikh Mohammad Shamim Reza, Sherajul Islam, ISSN: 2309-
1185, Journal of Environmental Treatment Techniques, Volume 7,
2019, “Utilization Potential of Waste from Sugarcane Factory of
Bangladesh as Partial Replacement of Cement in Concrete.”

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