Effective Environment Regulatory Compliance in Cement industry

Acts, Rules & Regulations – Cement Plants

Dr.S.Suresh KumarChief Technical Director

Knowledge Lens India Pvt Ltd

CONCENTRATION IN AMBIENT AIR

Pollutant

Time-

weighted

average

Industrial,Residential

, Rural and Other

Area

Ecologically Sensitive

Area (notified by

Central Government)

SulphurDioxide (SO2),

(µg/m3)

Annual * 50 20 - Improved West and Geake Method

24 hours** 80 80 - Ultraviolet Fluorescence

Oxides of Nitrogen as

(NO2) , (µg/m3)

Annual * 40 30 - Modified Jacob & Hochheiser Modified (Na

Arsenite)

24 hours** 80 80 - Chemiluminescence

Particulate Matter (size

less than 10 um) PM10

(µg/m3)

Annual* 60 60 - Gravimetric

- TOEM

24 hours** 100 100 - Beta attenuation

Particulate Matter (size

less than 2.5 um) or

PM2.5 (µg/m3)

Annual* 40 40 - Gravimetric

- TOEM

24 hours** 60 60 - Beta attenuation

Ozone (O3) 8 hours* 100 100 - UV Photometric

- Chemiluminescence

1hour** 180 180 - Chemical method

Lead (Pb) (µg/m3) Annual* 0.50 0.50 - ASS/ICP Method after sampling using EPM

2000 or equivalent Filter paper

24 hours** 1.0 1.0 - ED-XRF using Teflon filter

Ammonia(NH3) (µg/m3) Annual* 100 100 - Chemiluminescence

24 hours** 400 400 - Indophenol blue method

CarbonMonoxide (CO) 8 hours** 02 02 - Non Dispersive Infra Red (NDIR)

1 hour 04 04 - Spectroscopy

NATIONAL AMBIENT AIR QUALITY STANDARDS

10/10/2018 2

CONCENTRATION IN AMBEINT AIR

Pollutant Time-weighted average

Industrial,

Residential, Rural

and Other Area

Ecologically

Sensitive Area

(notified by

Central

Government)

Method of Measurement

Benzene (C6H6)

µg/m3

Annual * 05 05

- Gas Chromatography based continuous

analyser

- adsorption and Desorption followed by

GC analysis

Benzo-a-pyrene (BaP)

– Particulate phase

only, ng/m3Annual* 01 01

- Solvent Extraction followed by HPLC/GC

-Analysis

Arsenic (As)

ng/m3 Annual* 06 06

- AAS/ICP method after sampling on EPM

2000 or equivalent filter paper

Nickel (Ni),

ng/m3Annual * 20 20

- AAS/ICP method after sampling on EPM

2000 or equivalent filter paper

*Annual arithmetic mean of minimum 104 measurements in a year at a particular site taken twice a week 24

hourly at uniform intervals.

** 24 hourly or 8 hourly or 1 hourly monitored values, as applicable, shall be compiled with 98% of the time in

a year. 2 % of the time, they may exceed the limits but not on two consecutive days of monitoring.

10/10/2018 3

S.N

oPollutant

Concn. in Ambient Air

Method of measurementDetection

LimitIndustrial,

Residentia

l & rural

Ecologically

sensitive

area

1 SO2 µg/m3 80 80IS 5182 Pt2 24 hrs monitoring

Flow rate : 0.5 ltr/min ; Abs Sol’n:50 ml8 µg/m3

2 NO2 µg/m3 80 80IS 5182 Pt 6 ; 24 hrs monitoring;

Flow Rate: 0.5 ltr/min ; Abs Sol’n: 30 ml5 µg/m3

3 PM10 µg/m3 100 100 IS 5182 Pt 23; 24 hrs monitoring 5 µg/m3

4 PM2.5 µg/m3 60 60 Gravimetric

5 Ozone µg/m3 100 100

Method of Air Sampling and Analysis (Ed III) ;

8 hrs sampling

Flow Rate: 2 ltr/min ; Abs Sol’n 30 ml

5 µg/m3

6 Lead µg/m3 1 1IS 5182 Pt 22; 16-24 hrs monitoring;

Flow Rate:1.1 m3/min2 ng/m3

7 CO mg/m3 2 2IS 5182 Pt 10, GC-FID (through methanizer)

Grab Sampling in tedler bag (NDIR under d’ment)2.5 mg/m3

8 Ammonia µg/m3 400 400

Method of Air Sampling and Analysis (Ed III)

Indophenol Method ; 24 hrs sampling ;

Flow Rate:2 Ltr/min ;Abs Sol’n 50 ml

9 µg/m3

9 Benzene µg/m3 5 5ASTM D 3686

24hrs monitoring ; Flow rate: 0.5 ltr/min3 µg/m3

10

Benzo(a)pyrine

(particulate phase)

ng/m3

1 1IS 5182 Pt 4(for sampling); USEPA 8270(for analy.)

16-24 hrs monitoring; Flow Rate 1.1 m3/min0.47 ng/m3

11 Arsenic ng/m3 6 6IS 5182 Pt 22 ; 16-24 hrs monitoring;

Flow rate: 1.1 m3/min2 ng/m3

12 Nickel ng/m3 20 20IS 5182 Pt 22

16-24 hrs Monitoring; Flow Rate : 1.1 m3/min2 ng/m3

EMISSION STANDARDS FOR DIESEL ENGINES FOR GENERATOR SETS

Engine Power (P) Date

CO HC NOx PM Smoke

g/kWh 1/m

P ≤ 19 kW

2003.7 5.0 1.3 9.2 0.6 0.7

2004.7 3.5 1.3 9.2 0.3 0.7

19 kW < P ≤ 50 kW

2003.7 5.0 1.3 9.2 0.5 0.7

2004.7 3.5 1.3 9.2 0.3 0.7

50 kW < P ≤ 260 kW 2003.7 3.5 1.3 9.2 0.3 0.7

260 kW < P ≤ 800 kW 2004.7 3.5 1.3 9.2 0.3 0.7

Emissions from new diesel engines up to 800 kW used in generator sets have been

regulated by the Ministry of Environment and Forests, Government of India [G.S.R.

371 (E), 17 May 2002]. The emission standards are listed below.

Parameter Area Category Total engine rating of the

plant (includes existing as

well as new generator sets)

Gerator sets commissioning date

Before 1/7/2003 Between 1/7/2003

and 1/7/2005

On or after

1/7/2005

Nox (as NO2) (AT 15% O2), dry basis, in ppmv A Upto 75MW

1100 970 710B Upto 150MW

A More than 75MW

1100 710 360B More than 150MW

NMHC (as C) (at 15% O2), mg/Nm3 Both A and B 150 100

PM (at 15% O2), mg/Nm3 Diesel Fuels - HSD

& LDO

Both A and B75 75

Furnace Oils - LSHS

& FO

Both A and B150 100

CO (at 15% O2), mg/Nm3 Both A and B 150 150

Sulphur content in fuel A <2%

B <4%

Fuel specification For A only Up to 5MW Only Diesel Fuels (HSD, LDO) shall be used.

Stack height (for generator sets commissioned after

1/7/2003)

Stack height shall be maximum of the following, in meter:

i.14 Q 0.3, Q = Total SO2 emission from the plant in kg/hr

ii.Minimum 6 m above the building where generator set is installed.

(iii) 30 m.

EMISSION STANDARDS FOR DIESEL ENGINES (ENGINE RATING MORE

THAN 0.8 MW (800 KW) FOR POWER PLANT, GENERATOR SET

APPLICATIONS AND OTHER REQUIREMENTS

CEMENT PLANT WITHOUT COPROCESSING

PARAMETER STANDARDS

Rotary Kiln - Without Co processing

Date of Commissioning Concentration not to Exceed in mg/Nm3

SO2 in mg/Nm3 Irrespective of date of commissioning100, 700 and 1000 when pyritic sulphur in thelimestone is less than 0.25%, 0.25 to 0.5% andmore than 0.5% respectively.

Oxides of Nitrogen (NO2) in mg/Nm3

After the date of Notification (25.8.14) (1) 600

Before the date of Notification (25.8.14)

(2) 800 for rotary kiln with In Line Calciner (ILC)technology.

(3) 1000 for rotary kiln using mixed stream ofILC, Separate Line Calciner (SLC) and suspensionpreheater technology or SLC technology aloneor without calciner.

The timeline for implementation of emission standards for all the parameters i.e.Sulphur Dioxide (SO2), Oxides of Nitrogen (NOx) and Particulate Matter (PM), withrespect to Rotary Kiln without co processing shall be up to the 31st March, 2017.

CEMENT PLANT WITH COPROCESSINGPARAMETER STANDARDS

Rotary Kiln - With Co processing of Wastes

Date of Commissioning Concentration not to Exceed in mg/Nm3

PM in mg/Nm3

on or after the date of notification(25.8.2014)

30

before the date of notification (25.8.2014) 30

Oxides of Nitrogen (NO2) in mg/Nm3

After the date of Notification (25.8.14) (1) 600

Before the date of Notification (25.8.14)

(2) 800 for rotary kiln with In Line Calciner (ILC)technology.

(3) 1000 for rotary kiln using mixed stream ofILC, Separate Line Calciner (SLC) and suspensionpreheater technology or SLC technology aloneor without calciner.

SO2 in mg/Nm3 irrespective of date of commissioning100, 700 and 1000 when pyritic sulphur in thelimestone is less than 0.25%, 0.25 to 0.5% andmore than 0.5% respectively.

HCl in mg/Nm3 -- 10

HF in mg/Nm3 1

TOC in mg/Nm3 10 Permitting authority may prescribe separate standards on case to case basis, if TOC does not result from the co-processing of waste.

PARAMETER STANDARDS

Rotary Kiln - With Co processing

Date of Commissioning Concentration not to Exceed in mg/Nm3

SO2 in mg/Nm3

Irrespective of date of commissioning100, 700 and 1000 when pyritic sulphur in thelimestone is less than 0.25%, 0.25 to 0.5% and morethan 0.5% respectively.

Irrespective of date of commissioning100

[when pyritic sulphur in the limestone is less than 0.25%]

Irrespective of date of commissioning

700[when pyritic sulphur in the limestone is

less than 0.25 to 0.5%]

Irrespective of date of commissioning1000

[when pyritic sulphur in the limestone is more than 0.5%]

PARAMETER STANDARDS

Rotary Kiln - With Co processing

Date of Commissioning Concentration not to Exceed in mg/Nm3

Oxides of Nitrogen (NO2) in mg/Nm3

After the date of Notification (25.8.14) 600

Before the date of Notification (25.8.14)800

for rotary kiln with In Line Calciner (ILC) technology.

Before the date of Notification (25.8.14)

1000 for rotary kiln using mixed stream of ILC, Separate

Line Calciner (SLC) and suspension preheater technology or SLC technology alone or without

calciner.

CEMENT PLANT WITH COPROCESSING

PARAMETER STANDARDS

Rotary Kiln - With Co processing of Wastes

Date of Commissioning Concentration not to Exceed in mg/Nm3

Hg and its compounds in mg/Nm3 irrespective of date ofcommissioning

0.05 mg/Nm3

Cd +Tl and their compoundsirrespective of date ofcommissioning

0.05 mg/Nm3

Sb+As+Pb+Co+Cr+Cu+Mn+Ni+V andtheir compounds

irrespective of date ofcommissioning

0.5 mg/Nm3

Dioxins and Furansirrespective of date ofcommissioning

0.1 ngTEQ/ Nm3

CPCB General Emission Standards –Cement Plants

▪ Cement Plants (with co-processing)

▪ Rotary kiln based plants (Particulate Matter from raw mill,kiln and pre-calciner system put together)

▪ 0.125 kg/ tonne of clinker.

PREVENTION AND CONTROL OF FUGITIVE EMISSIONS FROM CEMENT PLANTS

Unloading Section (Limestone, Coal & other Relevant Material)

▪ Control Measures to be Provided : Enclosureshould be provided for all unloadingoperations, except wet materials likegypsum.

▪ Guideline: The enclosures for the unloadingsides could be flexible curtain type materialcovering up to height of dumpers dischargefrom the roof.

▪ Control Measures to be Provided : Watershall be sprayed on the material prior andduring unloading.

▪ Guideline: A dust suppression system shouldbe provided to spray water.

Material Handling Section (Including Transfer Points)

▪ Control Measures to be Provided : All transferpoint locations should be fully enclosed.

▪ Guideline: The enclosures from all sides with theprovision for access doors, which shall be kept, closedduring operation. Spillages should be periodicallyremoved.

▪ Control Measures to be Provided : Airborne dustat all transfer operations / points should becontrolled either by spraying water or byextracting to bag filter

▪ Guideline: Either water spray system should be providedfor suppressing the air borne dust or dry extraction cumbag filter with adequate extraction volume.

▪ Control Measures to be Provided : Beltconveyors should preferably be closed.

▪ Guideline: This will avoid wind blowing offines.

Coal Storage Section▪ Coal yard / storage area should be clearly earmarked.

▪ The pathways in coal yard for vehicle movement should be paved.

▪ Accumulated dust shall be removed / swept regularly and water the areaafter sweeping.

▪ Coal other than coal stock pile should preferably be stored under coveredshed.

▪ Instead of dust extraction cum bag filter system, If dust suppressionmeasure is used, following additional control measures should be provided.

▪ Wetting before unloading

▪ Spray water at crusher discharge and transfer point

Clinker Cooler Section▪ Air borne fines extracted from clinker cooler shall be separated and

sent to last possible destination directly, if possible.

▪ The unit may need to install necessary provisions for separating fineparticulates from the clinker cooler ESP collection.

▪ Fines separation may be achieved by passing collected dust throughcyclone.

▪ The fines escaping cyclone to be separated,

▪ Cyclone collection (coarse particles) could be recycled.

▪ The fines shall be recycled to the last possible destination (like clinkerday silo) suitable or safely disposed.

Clinker Stock Piles Section

▪ In new cement plant, clinker should be stored preferably in silo.

▪ Clinker should be stored in closed enclosure covered from all sidesand should have a venting arrangement along with a bag filter.

▪ The dust extracted and captured in bag filter should be avoided tofeed back / recycled to the clinker stockpile, if possible

▪ The storage should be done under covered shed

▪ Dry fly ash shall be transported by closed tankers. In case of wet flyash trucks may be used for transportation

▪ Dry Fly ash shall be stored in silos only.

▪ Flyash in the dry form should be encouraged and in wet form shouldbe discouraged.

Storage of Limestone, Gypsum, Flyash and other Additives

▪ All roads on which vehiclemovement of raw materials orproducts take place should bepaved.

▪ Limit the speed of vehicles

▪ Employ preventive measures tominimize dust build up on roads.

▪ Carry out regular sweeping ofroads to minimize emissions.

Roads

Co-Processing refers to the use of waste materials such ascement, lime, steel, glasses, power generation etc….Instead of fossil fuels & natural resources

Cement Kiln Co-processing

Co-processing

▪ Upgrades waste management within the waste hierarchy

▪ Reduces global environmental impacts

▪ Maintains and improves the industrial sector'scompetitiveness

▪ Decreases (largely) the costs of waste management

▪ Improves all technical-economical factors

Co-processing in the Waste Hierarchy

The co-processing of waste has been recognized as a recovery operation under EU legislation.

100% Material Recovery

100% Energy Recovery

Five Main Types of Waste Used as Alternative Fuels

Co-processing in CementWaste materials to be used as alternative fuels :

▪ Used tires,

▪ Meat and bone meal, animal fat,

▪ Plastics,

▪ Packaging waste,

▪ Waste wood, impregnated saw dust,

▪ Paper, cardboard,

▪ Sludge (paper fiber, sewage)

▪ Agricultural and organic waste,

▪ Shale, oil shales,

▪ Coal slurries, distillation residues,

▪ Fine/ anodes / chemical cokes,

▪ Waste oils, oiled water,

▪ Spent solvents.

Waste co-processing Principles

Refuse the listed "banned wastes"

Anatomical Hospital Wastes

Asbestos-containing Wastes

Bio-hazardous Wastes

Electronic Scrap

Entire Batteries

Explosives

High-concentrationCyanide Wastes

Mineral Acids

Radioactive Wastes

Unsorted Municipal Garbage

Pre and Co-Processing: Liquid WastesStandard Installation

Receiving Station (covered) Storage, dosing, pumping the kiln

All on hard, impermeable surface, roof covered.

Fire fighting equipment and water management system.

AFR Pre-Processing

Select the Correct Fuel Feed Points

The Cement Industry and the Preservation of Natural Resources

THANK YOU

Contact usDr.S.Suresh Kumar, Chief Technical Director

Knowledge Lens India Pvt LtdEmail: suresh.kumar@knowledgelens.com

Mobile: 9884836199; 9940157123