CEMENT INDUSTRY

GRUPO 5
PILAR DELICADO HERRERAS
REBECA DIEZ MORALES
CRISTINA MARTN SERRANO

GENERAL INFORMATION ABOUT

CEMENT INDUSTRY

Cement is a basic material for building and

civil engineering construction.

Cement is a finely ground, non-metallic, inorganic

powder when mixed with water forms a paste that sets
and hardens.

World cement production has grown steadily since the

early 1950s, withincreased production in developing
countries, particularly in Asia.

CEMENT PRODUCTION IN THE UE

AND THE WORLD

Producers in the European Union have increased cement

output per man/year from 1700 tonnes in 1970 to 3500
in 1991.

As a result of the introduction of larger scale production

units.

The number of people employed in the cement industry

in the European Union is now less than 60000.

EMISSIONS
The emissions from cement plants which cause greatest
concern are:

Nitrogen oxides (NOx)

Sulphur dioxide (SO2)
Dust
Carbon oxides (CO, CO2)
Volatile organic compounds
Polychlorinated dibenzodioxins (PCDDs) and
dibenzofurans (PCDFs)
Metals and their compounds

APPLIED PROCESSES AND

TECHNIQUES

It begins with the decomposition of calcium

carbonate (CaCO3) at about 900C to leave
calcium oxide (CaO, lime) and liberate gaseous
carbon dioxide (CO2).

CALCINATION

MAIN PROCESS ROUTES FOR THE

MANUFACTURE OF CEMENT

There are four main process routes:

1) Dry process: raw materials are ground and
dried to raw meal in the form of a flowable
powder.
2) Semi-wet process: the slurry is first dewatered
in filter presses.

MAIN PROCESS ROUTES FOR

THE MANUFACTURE OF CEMENT
3) Semi-dry process: dry raw meal is pelletised
with water and fed into a grate preheater before
the kiln or to a long kiln equipped with crosses.
4) Wet process, the raw materials (often with high
moisture content) are ground in water to form a
pumpable slurry.

SUB-PROCESSES

Winning of raw materials

Raw materials storage and preparation
Fuels storage and preparation
Clinker burning
Cement grinding and storage
Packing and dispatch

TECHNIQUES TO CONSIDER THE

DETERMINATION OF BAT

Consumption of raw materials

Use of energy

To optimise the input of energy.

Process selection

Reduce the total consumption of raw materials.

The selected process will affect the releases of all

pollutants, and will also have a significant effect on the
energy use.

General techniques

Optimisation of the clinker burning process is usually done

to reduce the heat consumption, to improve the clinker
quality and to increase the lifetime of the equipment
Reduction of emissions, such as NOx, SO 2 and dust, are
secondary effects of this optimisation.

TECHNIQUES TO CONSIDER
THE DETERMINATION OF BAT

Careful selection and control of substances entering

the kiln can reduce emissions.

Specific techniques

Control NOx emissions

Control SO2 emissions
Control dust emissions
Control other emissions to air

DUST EMISSIONS

Main point sources:

Kiln systems
Clinker coolers
Cement mills

Techniques for controlling it:

Electrostatic precipitators
Fabric filters
Fugitive dust abatement

ELECTROSTATIC PRECIPITATORS

Generate an electrostatic field.

The particles become negatively charged and

migrate towards positively charged collection
plates.

The collection plates are vibrated periodically,

dislodging the material so that it falls.

CONDITIONS

High temperatures (up to approximately 400C).

High humidity.

ELECTROSTATIC PRECIPITATORS

Efficiency is affected by:

Flue gas flow rate

Strength of the electric field
Particulate loading rate
SO2 concentration
Moisture content
Shape and area of the electrodes

ELECTROSTATIC PRECIPITATORS

Electronics precipitators can reduce levels

down to 5-15 mg/m3 as monthly average.

Besides dust, the EP also removes

substances that adsorb to the dust particles,
such as dioxins and metals if present.

EPs are not installed if emissions at startups

and shut downs are very high.

FABRIC FILTERS

Fabric membrane which is permeable to gas

but which will retain the dust.

As the dust cake thickens, the gas pressure

drop across the filter increases
Periodic
cleaning

The use of modern fabric filters can reduce

dust emissions to below 5 mg/m3.

Also removes substances that adsorb to the

dust particles, such as dioxins and metals.

FUGITIVE DUST ABATEMENT

Fugitive emission sources mainly arise from

storage and handling of substances and from
vehicle traffic at the manufacturing site.

Some techniques for fugitive dust abatement

are:

Open pile wind protection

Water spray and chemical dust suppressors
Paving, road wetting and housekeeping
Mobile and stationary vacuum cleaning
Ventilation and collection in fabric filters
Closed storage with automatic handling system

COMPARISON

BEST AVAILABLE TECHNIQUES

FOR THE CEMENT INDUSTRY

The BAT for the production of cement clinker is

considered to be a dry process kiln with multistage preheating and precalcination.

Process control optimisation.

The use of modern, gravimetric solid fuel feed

systems.

Preheating and precalcination to the extent

possible, considering the existing kiln system
configuration.

The use of modern clinker coolers.

BEST AVAILABLE TECHNIQUES

FOR THE CEMENT INDUSTRY

Heat recovery from waste gas.

Power management systems.

Grinding equipment and other electricity based

equipment with high energy efficiency.

Careful selection and control of substances

entering the kiln can reduce emissions.

BAT FOR REDUCING DUST

EMISSIONS

The combination of the above described general

primary measures and:

Minimisation/prevention of dust emissions from

fugitive sources.
Efficient removal of particulate matter from point
sources by application of:
- Electrostatic precipitators with fast measuring and
control equipment to minimise thenumber of CO
trips.
- Fabric filters with multiple compartments and burst
bag detectors.

The BAT emission level associated with these

techniques is 20-30 mg dust/m3 on a daily
average basis.

EMERGING TECHNIQUES IN THE

CEMENT INDUSTRY

Fluidised bed cement manufacturing

technology

Staged combustion combined with

SNCR

FLUIDISED BED CEMENT

MANUFACTURING TECHNOLOGY

Consists of a suspension preheater (SP), a

spouted bed granulating kiln (SBK), a fluidised
bed sintering kiln (FBK), a fluidised bed
quenching cooler (FBK) and a packed bed
cooler.

SP: conventional 4-stage cyclone preheater.

Granulating kiln: granulating the raw meal into

granules of about 1,5-2,5 mm diameter at a
1300C.

FLUIDISED BED CEMENT

MANUFACTURING
TECHNOLOGY

The sintering of the granules is completed at

a 1400C.

The fluidised bed quenching cooler quickly

cools the cement clinker from 1400 to
1000C.

The cement clinker is cooled down to about

100C in the packed bed cooler.

Configuration of the
20 tonnes
clinker/day
fluidised bed
cement kiln
system:

FLUIDISED BED CEMENT

MANUFACTURING TECHNOLOGY

The final target of the technical

development of the fluidised bed cement
kiln system are:

Reduction of heat use by 10-12%.

Reduction of CO2 emission by 10-12%.
A NOx emission level of 380 mg/m3 or less
(converted to 10% O2).

To maintain the current SOx emission level.

Reduction of construction cost by 30%.

Reduction of installation area by 30%.

STAGED COMBUSTION COMBINED

WITH SNCR

In theory, a combination of staged

combustion and SNCR could be
comparable to SCR in performance, that
is NOx emission levels of 100-200
mg/m3.

This combination is considered very

promising by suppliers but is not yet
proven.

CEMENT INDUSTRY
GRUPO 5
PILAR DELICADO HERRERAS
REBECA DIEZ MORALES
CRISTINA MARTN SERRANO