Comprhensive Industry Document On Vertical Shaft Kiln Based Mini Cement Plants

COMPREHENSIVE INDUSTRY DOCUMENT ON VERTICAL SHAFT KILN
BASED MINI CEMENT PLANTS
CONTENTS
Fig. 3 Lurgi Sinter Grate
the material as the kiln rotates at 1

to 2 rpm. Various chemical reactions
(Calcination, sintering, cooling)
takes place as the material
temperature goes upto 1440°C. Hot
gases having transferred the heat to
material escape in counter flow i.e.
from lower end to upper end through
suspension preheater and dust
collectors to atmosphere. Clinker is
discharged into clinker cooler, which
may be rotary, planetary or moving
grate type. Clinker is then
transported to storage yard and
finally ground with gypsum. Control
is maintained through various
control instruments and inspection
of burning conditions. (Fig. 4)
6.5 Vertical Shaft Kiln
The use of vertical shaft kiln process

for cement manufacturing dates
back to the year 1824 when
Portland cement was invented.
However, because of its non-
continuous operation, this process
was found uneconomical and
produced clinker of non-uniform
quality.
Later after the development of

continuous pan type noduliser, a
significant advance was achieved
and the shaft kiln performance
improved considerably thus
permitting its adoption and
production of uniform quality of
clinker on a continuous basis.
Cement manufacture by using
Modern Vertical Shaft kiln is
reportedly being carried out in
different countries like China, India,
West Germany, Australia, Italy,
Indonesia, Nepal, Bhutan etc. In
fact, a wide variety of processes
have been adopted for the
manufacture of cement through
Vertical Shaft Kiln and it would be
desirable to mention some of these
in the following sections.
6.5.1 Black Meal Process
This is the most popular type of

process used for manufacture of
cement through Modern Vertical
Shaft Kiln in which the fuel (usually
low volatile coal or coke breeze) is
interground with the raw mix for
efficient and uniform burning. Most
of the cement plants using Vertical
Shaft Kiln like CRI - Modern Vertical
Shaft Kiln, Vertical Shaft Kiln
supplied by M/s. Loesche of West
Germany etc are mainly based on
the black meal process.
In this process, the vertical shaft

kilns are fed with raw mix of
appropriate composition in the form
of nodules. The feed operation
usually requires crushing of
limestonne to about -15 mm size in
storage bins, proportioning of raw
materials and grinding in a roller or
ball mill, homogenizing and
nodulizing in pan type nodulizer.
The successful operation of shaft
kiln, to a great extent, depends upon
the size of nodules, their uniformity,
porosity and thermal stability. The
noduliser consists of an inclined disc
or pan rotating about its axis. Raw
meal is charged into noduliser by
means of screw conveyor and water
is sprayed, while all the parameters
are maintained at optimum
conditions. A specially designed
rotating scraper continuously cleans
the bottom and the collar of the
drum of the raw meal deposited.
The nodules slide down the chute
and are charged in the
 FOREWORD
 EXECTIVE SUMMARY
 1. INTRODUCTION
2. OBJECTIVES OF THE STUDY
3. GROWTH OF MINI CEMENT PLANTS
4. WORLD SCENARIO OF MINI CEMENT
5. COMPARISION OF LARGE AND MINI CEMENT PLANTS
6. CEMENT MANUFACTURING TECHNOLOGIES
7. TYPES OF MINI CEMENT PLANTS IN INDIA
8. TYPES OF MINI CEMENT PLANTS IN CHINA
9. TYPES OF MINI CEMENT PLANTS IN COUNTRIES

OTHER THAN CHINA AMD INDIA
10. OPERATION OF A CRI-MODERN VERTICAL SHAFT KILN
11. RAW MATERIALS AND THEIR CONSUMPTION FACTOR
12. ELECTRICAL ENERGY AND THERMAL ENERGY
13. FIELD STUDIES
14. EMISSION STANDARDS FOR CEMENT SECTOR
15. DUST COLLECTION SYSTEMS
16. SOURCES OF AIR POLLUTION
17. GUIDELINES TO CONTROL THE DUST EMISSION
ANNEXURES
 Annexure- 1 List of VSK Mini Cement Plants
Annexure- 2 Emission Data of Plant No. 3
 EXHIBITS
 Exhibit - 1 Distribution of Mini Cement Plants in India
Exhibit - 2 Flow sheet of Plant- 1
Exhibit - 3 Location of Noise measurement - Plant- 1
Exhibit - 4 Flow sheet of Plant-2

Exhibit - 6 Flow sheet of Plant-3
 Exhibit - 14 Flow sheet of Plant-7
 EXECUTIVE SUMMARY
1. Presently in India there are 333 vertical shaft kiln (VSK) based mini cement
plants of various capacities ranging from 20 to 300 tonnes per day (TPD) of
various technologies set up in different parts of the country. The distribution is in
the form of clusters.
2. Out of 333, only 193 VSK based mini cement plants are in operation having
operating capacity of 3.47 million tones per annum.
3. Mini cement plant is basically air polluting industry. The air pollution is mainly in
the form of particulate matter emission.
4. To assess the present environmental scenario of Indian Vertical Shaft Kiln
(VSK) based Mini Cement Plants, a questionnaire was prepared and sent to 279
VSK Mini Cement Plants.
The Mini Cement Plant clusters were divided into two regions namely southern
region and northern region. Two plants from southern region and six plants from
northern region were selected for the study. The two plants in A.P are based on
CRI-MVSK technology having the installed capacity of 200 TPD with two VSKs
of 100 TPD each. Six plants selected in Behror, Rajasthan are based on Saboo
VSK Technology having the installed capacity ranging from 20 to 50 TPD.
5. In-depth study was pursued in eight plants. The data in these plants were
collected with respect to history of the plant, manufacturing process and flow-
sheet, sources of air pollution, stack emission monitoring, analysis of particulate
mater for particle size distribution, raw materials quality and its effect on air
pollution, pollution control devices adopted and their design, economics, noise
pollution etc.
6. The methodology adopted for collection of data and information includes :
a. Visit to VSK mini cement plants
b. Discussion of various environmental related issues with the
management.
c. Environmental monitoring was carried out for the following:
i. Ambient Air Quality in downwind and upwind directions

ii. Fugitive dust at various working areas.
iii. Stack emission : Stacks of VSK : Particulate matter, SO2
Stacks of Other Sections : Particulate matter
iv. VSK flue gas analysis: Monitoring of O2, CO2, CO and N2
v. Particle size distribution of particles emanated from VSK.
vi. Noise monitoring near various processing equipment.
2. In plant no. 1 all the sections were provided with necessary pollution control
devices. The particulate matter emission from raw mill, cement mill and VSK is
69, 86 and 348 mg/Nm 3 respectively. It was observed that by changing the raw
mix design, the particulate matter emission from VSK can be brought down to
95 mg/Nm 3 .
Ambient air quality monitoring was conducted for RSPM, SPM, SO2and NO x in
up wind and down wind direction. The value of RSPM, SPM, SO2and NO x in
the up wind direction is 280, 641, 12 and 7 �g/m 3 respectively. The value of
RSPM, SPM, SO2and NO x in the Down wind direction is 310, 899, 14 and 8
�g/m 3 respectively.
3. In plant no.2, Air Pollution Control Devices were provided only in raw mill and
cement mill sections. The particulate matter emission from raw mill, cement mill,
VSK no. 1 and VSK no. 3 is 153 mg/Nm 3 , 67 mg/Nm 3 , 167 mg/Nm 3 and 73
mg/Nm 3 respectively.
Ambient air quality monitoring was conducted for RSPM, SPM, SO2and NO x in
up wind and down wind direction. The value of RSPM, SPM, SO2and NO x in
the up wind direction is 142, 910, 7 and 6 �g/m 3 respectively. The value of
RSPM, SPM, SO2and NO x in the Down wind direction is 275, 1205, 9 and 7
4. In plant no. 3, the average value of particulate matter emission from VSK is 119
mg/Nm 3 . Ambient air quality monitoring was conducted for RSPM, SPM,
SO2and NO x in up wind and down wind direction. The value of RSPM, SPM,
SO2and NO x in the up wind direction is 151, 170, BDL and 34 �g/m 3
respectively. The value of RSPM, SPM, SO2and NO x in the Down wind
direction is 194, 205, BDL and 65 �g/m 3 respectively.
SO2and NO x in the up wind direction is 144, 507, 17, and 52 �g/m 3
direction is 158, 674, 27 and 66 �g/m 3 respectively.
SO2and NO x in the up wind direction is 258, 454, 9, and 33 �g/m 3
SO2and NO x in the up wind direction is 121, 238, 15 and 116 �g/m 3
SO2and NO x in the up wind direction is 137, 410, 10 and 128 �g/m 3
9. In plant no. 8, the particulate matter concentration at inlet and out let of dust
settling chamber of VSK is 584 and 104 mg/Nm 3 respectively. Ambient air
quality monitoring was conducted for RSPM, SPM, SO2and NO x in up wind and
down wind direction. The value of RSPM, SPM, SO2and NO x in the up wind
direction is 177, 967, BDL and 155 �g/m 3 respectively. The value of RSPM,
SPM, SO2and NO x in the Down wind direction is 289, 1313, BDL and 164
10. Few CRI-MVSK (Cement Research Institute of India - Modern Vertical Shaft
Kiln) cement plants are having pollution control devices in all the sections while
other technology based VSK plants are not having pollution control devices in all
the sections. These plants are having only open type bags as pollution control
devices in all the sections, which needs to be modified.
11. As a guideline following pollution control devices are suggested for various
sections of VSK based mini cement plants subject to compliance of emission
standards:
12. a. Crushing and raw materials proportioning section - Bag Filter.
13. b. Raw mill section - Twin cyclone and Bag Filter
14. c Homogenising Silo - Bag Filter
15. d. Nodulizer - Bag Filter

16. e. VSK stack - Cyclone
17. f. Clinker crusher and discharge section - Bag Filter
18. g. Cement mill and packing house - Bag Filter
19. The above air pollution control devices are indicative in nature. Cement Plant
may explore the possibilities of other devices also. The important thing which is
to be kept in mind is that in all the cases the plant has to meet the prescribed
emission standards.
20. 1.0 INTRODUCTION
21. The capacity of a mini cement plant based on Vertical Shaft Kiln (VSK)
technology is limited to 300 TPD or 99000 TPA and the capacity of a mini
cement plant based on Rotary Kiln (RK) technology is limited to 900 TPD or
2,97,000 TPA (For the plant based on RK technology, the capacity has been
enhanced from 600 TPD or 1,98,000 TPA to 900 TPD or 2,97,000 TPA vide
notification no. 20/99 - Central Excise dated 7 May 1999). These plants are
mainly based on vertical shaft kiln technology (VSK). At present there are 333
VSK mini cement plants of capacities ranging from 20 - 300 TPD of various
technologies located in different parts of the country. During the various
operation of cement manufacturing, dust is emitted which poses problem of air
pollution. Majority of these plants are located in clusters in Andhra Pradesh,
Karnataka, Madhya Pradesh and Rajasthan. Rests of the plants are distributed
in the other parts of the country as shown in Exhibit - 1.
22. 2.0 OBJECTIVES OF THE STUDY

23. In the absence of definite techno-economic control devices, air pollution control
in VSK mini cement plants could not be achieved at the desired level. The
present technologies adopted by most of the plants are not adequate.
Considering the above, it was decided to develop a comprehensive industry
document (COINDS) on VSK mini cement plants.
The present study of VSK mini cement plant deals with manufacturing process,
identification of sources of dust emission, stack emission monitoring, analysis of
particulate matter for particle size distribution, air pollution control devices
adopted, ambient air quality monitoring and section wise suggestions for dust
control system.
24. .0 GROWTH OF MINI CEMENT PLANT
25. The prevailing scenario of acute cement scarcity in mid seventies with
inadequate investment in this core sector, led to the Government policy for
promotion of mini cement plants which could fulfill many objectives in addition to
producing cement to meet the local needs. Taking into account various factors
which were prevailing then, the Government of India came out with the policy for
promotion / establishment of mini cement plants in early 1979. In addition to the
several incentives and concessions offered by the Government for establishing
mini cement plants, the policy also had laid stress on certain socio-economic
objectives to be fulfilled in setting up the mini cement plants.
26. As a result of the Government's encouragement backed by the technological

support extended by the National R&D laboratories in the country, a number of
mini cement plants came up in different parts of the country, mostly on
conventional dry process rotary kiln and vertical shaft kiln technologies of CRI,
Saboo & RRL, Jorhat. The first VSK based (30 tpd CRI-MVSK) mini cement
plant became operational in early 1981, whereas the first (200 tpd) mini cement
plant based on rotary kiln technology went on stream in 1982. In addition, some
VSK plants mostly in small-scale sector came up, whose plant and machinery
were supplied by M/s. Shree Engineers, Jodhpur.
Status of mini cement plants at a glance as on 31 March 2001 and 31 March

2006 is given in Table 1 and Table 2 respectively. Thus, it could be seen that
during the Xth Five Year Plan, there has been an addition of 8 plants based on
Rotary Kiln Technology, increasing the operating capacity from 5.96 MTPA to
6.4 MTPA. Number of mini cement plants in the country, installed capacity,
location, year of commissioning of various technologies is listed at Annexure I.
Table 1: Status of Mini Cement Plants at a Glance as on March 31, 2001
Sl. No. Technology Cement Plants
Originally Set up In operation
Nos. Installed Capacity Nos. Installed Capacity

(MTPA) (MTPA)
1 Rotary Kiln 31 4.003 24 3.411
2 CRI-MVSK 101 3.354 30 1.179
3 RRL-VSK 31 0.286 - -
4 Saboo-VSK 202 3.449 78 1.378
Total 365 11.092 132 5.968
27. Table 2: Status of Mini Cement Plants at a Glance as on March 31, 2006
Operating Capacity
Originally Set Up No. of Cement Plants
(MTPA)
Closed
In operation
Rotary kiln: 39 26 13 2.93
Verticlal Shaft Kiln: 333 140 193 3.47

166
Total 372 206 6.40
28. 4.0 WORLD SCENARIO OF MINI CEMENT PLANT

29. The Chinese cement industry has seen a rapid growth over the last five
decades. The production of cement was less than 3 Million tonnes in 1952, but
in 1999 the total production of cement reached 573 Million tonnes. Thus, China,
accounting for about one third of the global cement production ranks first in the
world today in terms of cement output.
30. The total installed capacity of the Chinese cement industry is estimated at 700
Million tonnes from over 7000 cement plants, which means that the average
capacity of each cement plant is about 1,00,000 tonnes per annum. In China,
the cement industry has a multiple ownership structure and a major part of the
industry belongs to the Ministry of Agriculture under its Administration of Town
and Village Industrial Enterprises (TVIE). The cement plants belonging to this
sector are small and based on Vertical Shaft Kilns (VSK), which traditionally
have consumed high levels of raw materials, fuel and power and therefore
cause serious environmental pollution.
31. During the last five years, there have been planned efforts to look at the energy
and environmental issues of these plants with the help of international
organizations like UNIDO, IVAM Environmental Research and University of
Amsterdam. These international bodies have undertaken the study for cleaner
production technology and energy conservation measures in these cement
plants.
32. As previously mentioned, the Chinese cement industry still uses the VSK
process as its principal technology. However, in the last two decades, there has
been the introduction of modern preheater and precalciner kiln systems at
medium and large sized plants. The sum total effect has been the existence of a
mix of technologies and there are now over 13,000 VSK plants in China.
33. Currently, the modern large cement plants with precalciner technology cover
less than 10 percent of the total cement output of the country. About 12 percent
of the output comes from a plethora of small and medium size rotary kiln plants.
The total output from the VSK plants constitutes about 78 percent. According to
a regulation issued in 1997, the VSKs with a capacity of 44,000 tonnes per
annum or less were to be discontinued by the end of 2000, barring only a few
regions where the deadline is 2005. By the end of 1999, it had been officially
reported that the VSK plants with an aggregate production capacity of about 20
Million tones per annum had been closed down. The production and distribution
of Vertical Shaft Kiln (VSK) mini cement plants worldwide are given in Table 3.
34. 5.0 COMPARISON OF LARGE AND MINI CEMENT PLANTS
Cement is one of the most important building materials. The total cement
production in the world reached 1950 million tonnes in 2003. A major
percentage of this total production is from large-scale plants with capacities
ranging from 2000 to 20,000 tpd and transported to the place of use in bulk or
bags.
35. Large capacity plants are appropriate for deriving the benefits from economies
of scale in locations where:
36. - Large enough deposits of the basic raw material i.e. limestonne is available.
- Infrastructural needs such as power and transportation system are sufficient.
- Cement consumption is substantially concentrated.
- Transportation costs are low
- Capital-intensive technology is preferable from socio-economic
considerations.
Table 3: Global Survey of Vertical Shaft Kilns in Operation
Sl No
Country No. of VSK No. of Active Production (X10 3
Cement Plants Kiln TPA)
1 Kenya 1 2 100
2 Brazil - - -
3 Iraq 1 2 292
4 Bhutan 3 4 74
5 Indonesia 1 2 110
6 Lao Peoples Dem Rep. 1 1 65
7 Nepal 4 5 150
8 Germany 2 15 1200
9 Italy 1 1 60
10 Slovak Republic 1 4 150
11 France 5 20 1500
12 Russia 1 6 310
13 China 107 221 25202
14 USA - - -
15 Australia - - -
16 Madagaskar 1 2 200
17 European Union - - 400
18 CEMBUREAU - - 400
19 Central America - - -
20 South America - - -
37. Mini cement plants are appropriate for other areas particularly in cases like :
38. - Small countries, which intend to develop their own cement industry to cater to
their limited needs, thus becoming independent of imports.
39. - Large countries with low population density and/or low per capita cement
consumption.
40. - Only scattered limestonne deposits, which cannot sustain large-scale cement
plants, are available.
41. - Large cement plants cannot be set-up due to infrastructural constraints �

specially hilly and remote regions.
42. - Areas where local and regional market will absorb the production of a mini
cement plant only and that industrial size plants could not operate at economic
production rates.
43. - Socio-economic consideration justifies a Labour intensive technology rather

than a capital intensive one.
44. Mini cement plants have following advantages
45. - Lowers capital investment per unit production without sacrificing quality of
either the plant or the product.
46. - Helps realise quicker returns on capital invested because of lower gestation
periods.
47. - Brings cement industry within the financial access of smaller entrepreneur and
thus enlarge entrepreneurship in the country.
48. - Contributes to uplifting local economy and development as well as to formation

of rural cooperatives as owners of cement plant.
49. - Creates employment opportunities in rural areas on a well dispersed basis
50. - Enables development of cement industry in terrains where movement of heavy

machinery and cement are difficult.
51. - Makes it possible to exploit small deposits of limestonne as well as limited

quantities of calcareous industrial wastes.
52. - Avoids wasteful movement and thus helps to bring down the average unit cost
of transportation of cement in the country as well as strain on Nation's
transportation system.
53. - Eliminates packing charges where the utilisation point is localised by resorting
to bulk supply.
54.
55. 6.0 CEMENT MANUFACTURING TECHNOLOGIES
56. The various technologies, which have been tried for adoption in mini cement
plant, are:
57. i) Fluidized Bed Process (Fuller Pyzel)

ii) Reba Process
iii) Travelling Grate (Lurgi sinter grate)
iv) Rotary kiln and
v) Vertical Shaft Kiln
58. In a nutshell, in all these five alternative schemes of technological lines, there is
an upper and lower threshold of size beyond which either it is technologically
not feasible or economically not viable. Down scaling of plants under any
particular technology even within these threshold results in
59. - Increase in investment per annual tonne of installed capacity

- Increase in the cost of production per tonne.
60. So when the technical and economical threshold is reached for any given
technology line, other technology lines may still give technically feasible and
economically viable results.
61. The conventional rotary kiln is normally uneconomical below 300 to 600 tpd and
so the technology lines like Sintergrate and Reba evolved, but they could not
succeed due to inherent defects.
62. A brief process description for all these technological lines which were tried or
adopted for manufacture of cement in small scale are given in the following
sections:
63. 6.1 Fluidised Bed Process
64. Of these the fluidised bed or Pyzel process is the least popular because the
number of plants working on this process are extremely few even on global
basis and not much is known except for some broad principles of working. This
process, invented by Robert Pyzel, has been developed in USA by Fuller. A 100
tpd pilot plant based on this technology is reported to be in operation on
experimental basis for the last six years with M/s. Scientific Design Company,
New York, USA. (Fig. 1)
65. 6.1.1 Process Details
66. The plant consists of a fluidised bed reactor; raw meal consisting of finely
ground feed mixture is pneumatically conveyed to the fluidised bed alongwith
fuel and preheated air. The temperature of the fluidised bed is maintained at
approximately 1315°C by introducing the fuel directly into the fluidised bed.
67. Cement clinker being almost refractory, coarse clinker particles of 0.8 to 8 mm
can be maintained in granular form in suspension, when finely ground raw mix is
pneumatically blown in, raw cement phases are formed on the hot surface of
characteristically round clinker particles, so that they grow in size continuously.
68. The Specific heat consumption reported without any heat recovery system is
2600 Kcal/kg of clinker and with heat recovery system 1046 Kcal/kg of clinker.
69. Energy requirement for production of clinker alone by the fluidised bed reactor is
55 Kwh/t as against 20-25 Kwh/t of clinker in case of rotary or shaft kilns.
70. Fuels like gas, oil, coal, anthracite and coke could be used in this process.
71. This process stands a good chance for a promising market in USA as there are
very strict environmental protection specifications regarding oxides of sulphur
and nitrogen. At the same time special 'low alkali' cement specifications
72.
73.
Fig. 1 FLUID BED PROCESS
necessitate the rejection of large quantity of dust in rotary kiln burning operation.
This dust with high alkali content can be used as a cement raw mix in the Pyzel
reactor.
74. The specific advantages of Pyzel process have been claimed where there is (a)
high alkali problem; (b) strict environmental protection regulations regarding
oxides of sulphur and nitrogen from exit gases; (c) disposal problem of kiln dust
with high alkali content; and (d) using different fuels like gas, oil, coal, anthracite
and coke.
75. The high investment cost for the heat recovery systems and stringent controls
through an elaborate instrumentation and automation and non-availability of
highly skilled personnel for the operation of the reactor, go against the very
philosophy of mini cement plant. Due to the inherent technological problems in
stabilising the operation of plants based on the above process and also due to
the reported high investment cost per annual tonne of installed capacity, mini
cement plants based on the above technology have not been reported to be a
commercial success anywhere in the world.
76. 6.2 Reba Process
77. In this process, the feed operation requires crushing of limestonne to - 15 mm

size, storing in bays/bins, proportioning of raw materials and final grinding in a
roller/ball mill, homogenisation of raw meal and storage.
78. The fuel used is oil or gas. The homogenised raw meal is fed to a noduliser
where nodules are formed with addition of water and are then fed to a
combustion chamber. The nodules are dried in the preheating zone and heated
in the calcining zone to about 1100°C. The granulated material is then sintered
at about 1450°C and cooled in the shaft cooler. The flow of gases is in opposite
direction to flow of material and thus air used to cool the clinker heats up and is
used as secondary air together with primary air when burning the fuel.
79. Reba process has not so far been operated on solid fuel, i.e. coal and as such
no operational data are available on such applications.
80. It was claimed by the firm M/s. Ready Mix Cement Engineering of FRG that the
Reba Kiln installations for production of cement in the range of 50-200 tpd still
have low investment costs and less energy consumption. The heat consumption
is estimated to be approximately 730 Kcal/kg of clinker. Furthermore, the
electrical energy consumption should correspond to that of rotary kilns. The
energy consumption for burning of materials alone is claimed to be 14 Kwh/t.
81. It is understood that the Reba process has been tried successfully only for
burning of lime and the firm is yet to establish the technology for burning of
cement clinker on a commercial basis. Further, the quality of limestonne and
fuel tried are of very rich quality, i.e., very high percentage of lime in limestonne
of the order of above 52% and coal with every low ash content (10%) and high
calorific value and till date the technology has not been proved using cement
grade limestonne and coals with high ash content. No commercial plants are
known to be in operation in the world on this technology. (Fig. 2)
82. 6.3 Travelling Grate (Lurgi Sinter Grate)
83. In this process, the feed operation requires crushing of limestonne to - 15mm
size in a crusher/mill, storing the materials of -15 mm size in gantry/storage
bins, proportioning of raw materials and final grinding in closed circuit ball
mill/roller mill, homogenisation of raw meal and storage, crushing and screening
of coal to -5 mm size in closed circuit operation and storing of crushed coal in
bin.
84. The raw meal and crushed coal are then extracted from respective bins
according to requirement and conveyed to a drum type nodulizer. In addition,
the noduliser is also fed with 15% of -5mm size burnt clinker to form core of
nodules and 15% water spray. The nodules are conveyed by a belt conveyor to
moving sinter bed made of cast iron grate base. A 75 mm thick layer of + 5 mm
and -10 mm burnt clinker is first spread over this bed and then the fresh nodules
fall over this. The sinter bed passes through various zones over some distance
where suction is maintained through ID fan. Light diesel oil is fired over the bed
in hood fixed about 200 mm above the bed height and the resulting clinker is
discharged through a rotating arm type breaker in red hot condition over an
open pan type horizontal conveyor where it undergoes cooling. (Fig. 3)
85. 6.4 Small Rotary Kiln
86. Here the kiln feed and fuel preparation requires crushing and grinding
operations, like:
- Crushing of limestone and additives in a hammer mill or 2-stage, viz., jaw
crusher and hammer mill to -15 mm size.
- Storing the crushed raw materials in storage yard/bins.
- Proportioning and grinding the raw materials in a roller/ball mill.
- Homogenising and storage of raw meal in blending and storage sections.
- Fuel, viz, coal (VM 25-30%) is pulverised in a separate section (combined coal
drying-cum-grinding section).
87. Blended and homogenised raw meal is then fed to the suspension preheater of
counter current type, where it is preheated and partially calcined by the kiln hot
gases passing in counter current. Raw meal enters the kiln at a temperature of
700°C - 800°C. The exit gases from the preheater are then passed through the
dust collection system and discharged to atmosphere. Dust collected is
recycled.
88. Pulverised coal mixed with primary air is fired from the lower end of the rotary
kiln through coal burners. Secondary air is supplied through clinker cooler to
make up for the combustion air. A flame at around 1660°C is maintained. This
heat
89.
COMPRHENSIVE INDUSTRY DOCUMENT ON VERTICAL SHAFT KILN BASED MINI
CEMENT PLANTS
10.0 OPERATION OF A CRI-MODERN VERTICAL SHAFT KILN
As already explained, in the black meal process, the cement raw materials
are interground with the fuel and the resultant raw meal is blended and then
converted into nodules of sufficient uniformity, strength and porosity in an
inclined disc type noduliser by the addition of required quantity of water.
The nodules are fed to vertical shaft kiln where the pyroprocessing takes
place.
10.1 Before Lighting up
The kiln should be checked for

a) Rotary Grate: The grate segments and crown with cutter teeth should be
intact and in position. A full revolution should be given to the grate to ensure
it does not touch lining plates anywhere.
b) Lining plates should not be loose.
c) Refractory Lining: The lining must be checked and repaired wherever

necessary. If the thickness of lining in burning zone gets reduced below
80mm, it must be replaced.
d) All starters/main switches of the electrical installation should be checked

whether they are all in working condition.
e) Roots Blower: In accordance with the manufacturer's recommendations,

oil must be checked. Filters must be cleaned. The weights in the safety
valve are to be adjusted to suit to the anticipated kiln bed resistance.
f) Chimney's dampers, rotary feeder, kiln hood doors, discharge gates must
be checked for their mechanical operation and lubrication.
g) All the flanges of the kiln, bottom hood cup, chutes, discharge gates etc.
should be properly sealed so that the combustion air does not leak through
the gaps between the joints.
10.2 Lighting up of the Kiln
The kiln should be filled with either the clinker already manufactured, or
limestonne chips or brickbats upto a level of 1-1.5 metres from the conical
portion. Care should be taken that the material is dust free and while filling
the refractory lining is not damaged. In order to remove the dust, the roots
blower has to be run for about 15 minutes after every 1-metre depth of new
material is loaded or better if the blower is run continuously while the kiln is
loaded with the chips or clinker. After every 2 metres depth of new material
has been loaded, the grate is set in motion, to ensure that the material is
moving down the shaft evenly. Above this material, about 100 kg of dry
firewood is now stacked uniformly over this bed in two or three layers. The
chimney damper has to be opened partly and the air by-pass valves/ball
valves are to be kept open in the kiln air duct. The firewood so spread
would be lighted up using torches and after an incandescent bed is formed,
steam coal is charged into the kiln. There will be an uniform incandescent
bed of fire after few minutes. Now charging of the nodules can commence.
One should refrain from adding a new charge of nodules until the edges of
the fire can be just seen. When the bed level reaches to about 50 cm.
below the conical portion, the discharge gate is to be operated slowly.
10.3 Normal Kiln Operation
Stabilised kiln operation as obtained after the initial lighting up may now be
continued under the following instructions:
1. Uniform discharge rate should be maintained as far as possible by

adjusting the grate speed whenever necessary.
2. The nodule size, feed rate and bed level must be maintained.
3. The bed should always be covered with the nodules by continuously

feeding them on a circle some distance away from the refractory lining so
that the nodules themselves distribute both over the periphery and in the
centre. A glowing ring on the periphery and continuous steam emerging
from the centre of bed indicates good fire and good combustion conditions.
The temperatures of various zones should be periodically recorded.
4. It is necessary to ascertain frequently that the entire bed is descending

uniformly. This is ensured by cleaning the sides frequently with the help of a
rod with flattened tip. While cleaning the sides, care must be taken not to
damage the refractory of kilns.
5. Once the kiln is stablised neither the process parameters nor the raw mix
composition should be changed frequently.
10.4 Kiln Controls
10.4.1 Feed
Strict controls should be observed on the preparation of feed right from the
raw material stage. The table feeders/weigh feeders should be monitored
periodically so that the component ratios conform to the values for raw mix
design. Blending operation is carried out till a uniform blending with the
desired T C content is obtained. The T C in raw mix should not vary beyond
± 0.20% of the desired value.
The nodules should be checked for appropriate size, porosity, moisture and
strength on hourly basis. The feed rate and discharge rate should be
synchronised to maintain constant bed level.
10.4.2 Combustion Air
The combustion air can be regulated by adjusting the valve on by-pass

pipe. The measurement is done with the help of two instruments provided
on the burner's platform; one from the orifice plate to give combustion air
flow and the other connected at the bottom for measuring the pressure at
the inlet to the kiln which gives an idea of the bed resistance. If during a
normal operation both the instrument readings are constant, the burner
should understand that the kiln is filled with properly burnt clinker. In case
the inlet pressure varies the burner gets indication that the bed resistance is
varying and necessary corrective action should be applied.
10.4.3 Discharge Rate
Under stabilized operating conditions, the discharge and feed rates should
be synchronised to maintain constant bed level. If there are too big lumps or
too loose a clinker near the grate, the discharge rate will fall or increase.
Depending on the case, immediately the grate speed is to be changed;
otherwise the bed level would rise or burning zone would collapse
destroying the entire kiln operation in next few hours. Intermittent discharge
is not desirable. The rotary grate speed should not be abruptly changed and
it should be done gradually step by step.
10.4.4 Temperature
A normal kiln operation is also judged from, in addition to the above, the
temperatures of flue gases, clinker, burning zone, cooling zone and also of
the kiln shell from outside. The temperature of the kiln is judged from the
thermocouple based temperature indicators and also crosschecked by
touching the kiln shell around periphery at various heights to feel the
uniform temperature gradient. The desired temperature profile for a VSK is
shown in Fig. 8.
1 0.5 Kiln Disorders
10.5.1 Bridging
When the clinker produced is so lumpy that it does not contain any loose
material, there are chances that the lumps form a bridge and rest over the
sides of the conical portion of kiln resulting in rise in fire bed. In such a case
the feed should either be slowed down or stopped and air reduced. The bed
should be given some disturbance in clearing the sides and poking from
burner's platform. If necessary the roots blower should be stopped and then
the feed. The bed should be able to descend with some effects. The cause
should be investigated and the process parameters immediately rectified in
order to avoid repetition of this.
10.5.2 Side Discharge
Sometimes if the clinker produced is suddenly too loose it would pass

through the bigger lumps and get discharged quickly. Even red-hot yellow
nodules (clinker) may discharge representing that at a certain position there
is no bed to support the burning zone. The burning zone seems to collapse
and loose fire. In such a condition, the grate speed should be reduced or it
should be stopped, to reduce discharge for some time and the burning zone
built up slowly even though the level may rise. The discharge may be
reduced till the trouble is overcome. The underburnt clinker may be
separately stocked and appropriately blended with the good clinker at the
time of grinding after ascertaining a suitable proportion. The kiln process
parameters should be immediately attended to. This may be a result of
maintaining the bed level too low inside the cone.
10.5.3 Lump Formation
Sometimes a big lump may be noticed in the burning zone, which is very
strong and as big as kiln internal diameter. This may not descend. This
generally occurs due to melting on account of a very high temperature
there. The raw mix composition should be immediately examined and feed
should be accordingly corrected. The fuel with low ash fusion or too much
of fuel will cause this. The lump so formed should be broken with poking
rods and grate speed should be adjusted to ensure its descent. At the same
time too much poking should be avoided. The lumps that descend though
big, give no trouble as they would get crushed and discharged as soon as
they reach the rotary grate.
10.6 Operational Optimisation and Training with Simulator
Achieving the rated output at high and consistent quality clinker is the real
task for the burners. For this all the input parameters are to be maintained
at an optimum level and the kiln operations should be monitored
continuously. Even a slight disturbance to any of the input parameters for a
short duration will destabilize the steady state and disturb the entire
process.
In this connection, understanding the interdependency of the input

parameters to the other operational and process parameters in a
quantitative way is very much essential for the process optimization of the
kiln. CRI-MVSK simulator is an extra-ordinary powerful tool for imparting
training to the plant operating personnel in the quickest way possible
without causing any damage to the plant, machinery or process and can
also be utilized for optimization of CRI-MVSK plant operation, including
optimum Raw Mix Design and proportioning almost at the flick of a button.
The CRI-MVSK Simulator is a device, which shows the working of complete

vertical shaft kiln section of a cement plant without any physical
connections to the plant, wherein all the inputs, the process as well as the
output are electronically generated within a computer. The simulator
through a specially developed software programme simulates the actual
operating conditions of a vertical shaft kiln cement plant on an ordinary
desktop IBM-PC compatible computer. A mimic diagram of the vertical shaft
kiln section of a cement plant is displayed on the computer screen with all
values of process parameters, which keep on changing with respect to time
just as in an actual plant. The operator can adjust or change any process
parameter as per his wish and see the effect of the same on the plant
operation. All the disturbances normally encountered in the kiln operation
either due to changes in raw materials / fuel quality and / or improper
operation can be created on the simulator and the operator can be trained
to effectively deal with such situations. Working on CRI-MVSK simulator
does not require any knowledge of working on a computer terminal or
computer programming.
The simulator consists of a colour graphic monitor, which shows the live
mimic of the nodulizer - vertical shaft kiln section. The operation data on
vertical shaft kilns based on CRI-VSK Technology are given in Table 4.
Table 4: Operation Data on Vertical Shaft Kiln based on CRI-MVSK

Technology
Sl. No. Name of the item Units Value

1 Nodule Size mm 6 to 12
2 Moisture in nodules % 12 to 14
3 Raw meal fineness % 6 to 14
4 Retained on 170 mesh % 12 to 13
5 Fuel in raw meal mm 200 to 400
6 Bed level from the top of kiln °C 80 to 200
6.1 Temperature of °C 1400 to 1450
6.2 Chimney °C 30 to 100
6.3 Burning zone Kcal/kg of clinker 950 to 1050

7 Clinker discharged mm WG 150 to 600
8 Heat input NM 3 /kg of fuel 10
9 Bed Resistance gm/cc 1080 to 1180
10 Quality of air hrs. 8 to 10
11 Litre weight rph 0.2 to 5
12 Resistance time mm WG 1 to 3
13 Rotary grade speed mm 100
14 Chimney draft Kwh per tonne of clinker 80 to 90
15 Maximum size of clinker lump Kwh per tonne of cement 30 to 40
15.1 Energy consumption
15.2 Clinker (upto kiln section)
Cement grinding alone
(Only cement mill section)
COMPRHENSIVE INDUSTRY DOCUMENT ON VERTICAL SHAFT KILN

BASED MINI CEMENT PLANTS
8.0 TYPES OF MINI CEMENT PLANTS IN CHINA
China uses minor variations in the process with the vertical shaft kiln technology. There are some
plants which use black meal process as in India, there are others which use semi-black meal process
in which only a part of the total coal required is interground with the raw meal and the balance is
added in coarse fraction later prior to nodulisation. Some plants use compound mineralizers also for
lowering the firing temperature. Different types of discharge grates have been used in the vertical
shaft kiln, like roller grate, flat grate, conical grate, reciprocating grate etc. Non-mechanised kilns use
stationary grate. Since the Chinese plants, because of this design and operational features, emit
sizeable amounts of dust, dust collection equipment like electrostatic precipitators, bag filters, etc. is
being installed. The smallest and the largest sizes of mechanized vertical shaft kilns in China have
diameters of 1.7 metres and 3.6 metres producing about 35 tonnes per day and 300 tonnes per day
against design capacities of 45 tonnes per day and 380 tonnes per day respectively.
A number of mini cement plants in China have been facing problems of non-uniform cement quality,
poor management and operational skills, higher cost of production, high heat consumption,
environmental pollution, etc. The Government of China has therefore decided to slowly disband the
old non-mechanised plants numbering about 2000 and take up modernization of those plants which
can produce cement of good quality through mechanization (at the rate of about 300 plants a year).
9.0 TYPES OF MINI CEMENT PLANTS IN COUNTRIES OTHER THAN INDIA AND CHINA
Although the latest information regarding the exact number of mini cement plants operating in different parts of
the world are not available. Table 3 shows a global survey of vertical shaft kilns under operation in different
countries.
So far as mini cement plants based on CRI-MVSK technology are concerned, M/s. Penden Cement Authority of
Bhutan, have installed a 50 tpd CRI-MVSK plant at Gomtu and later expanded it to 100 tpd by installation of
another 50 tpd CRI-MVSK line. One more cement plant of M/s. Lakhi Cements Pvt. Ltd. 100 TPD CRI-MVSK
cement plant installed at Gomtu, Bhutan. One mini cement plant of 160 TPD capacity based on Vertical Shaft Kiln
of size 2.4 metre dia and 8-metre height supplied by M/s. Loesche, West Germany is already under operation at
the works of M/s. Himal Cement Company, Nepal. Another mini cement plant of 30-tpd capacity based on CRI-
MVSK is presently in operation at Anboo-Khaireni in Nepal. This plant purchased 100 TPD (2x50 TPD) CRI-
MVSK cement plant of Penden Cement Authority and expanded upto 200 TPD.
Fig. 7C Flow Sheet of Dry Process Rotary Kiln Cement Plant M/s. Loesche of West Germany have supplied more
than 14 mini cement plants based on black meal VSK process in more than nine countries. The first multiple VSK
plant supplied by M/s. Loesche had gone into operation in 1955 at the cement plant of M/s. Portlandzemtnfabrik
Blaubeuren Gebr. Spohn Ag at Blaubeuren, Germany. Later on M/s Loesche have supplied plants based on VSK
to various countries like Japan, New Zealand, Austria, Spain, Italy, Nepal, Brazil, Madagascar and Indonesia. In
the latest design of 400 tpd (2x200 tpd) plant at Kupang in Indonesia, pre-blending techniques for controlling of
the variation in quality of limestonne and clay were employed. Different fuels of various mixtures have been used
at Paggau ranging from anthracite dust to coke breeze and petrol coke, the application of which in all the cases
have been reported to be a success. In addition to above, M/s Maerz Ofenbau of Zurich also supplied mini
cement plants based on VSK technology on turnkey basis. M/s. Maerz are the exclusive licencee for the
manufacture of Prerov machinery designed mini cement plants with as many as 16 cement shaft kilns operating in
different parts of the world. The heat consumption in these plants is claimed to be about 900-Kcal/Kg clinker.
11.0 RAW MATERIALS AND THEIR CONSUMPTION FACTOR
Raw materials to be used in Vertical Shaft Kiln mini cement plants and their consumption factors (material
balance) per tonne of clinker and cement are given below in Table 5.
Table 5: Raw Materials Consumption Factor
Sl. No. Raw Materials Consumption factor
Per tonne of clinker Per tonne of

cement
1 Limestonne 1.25 to 1.30 1.19 to 1.24
2 Clay 0.10 to 0.30 0.095 to 0.285
3 Additives like iron ore, Bauxite, 0.05 to 0.10 0.048 to 0.095

Laterite etc.
4 0.13 to 0.22 0.124 to 0.209
Low Volatile fuel like coke breeze,
5 saleable low volatile coal, Pet Coke, � 0.03 to 0.05
Jhamma Coal etc.
Gypsum
12.0 ELECTRICAL ENERGY AND THERMAL ENERGY
The electrical energy consumption for various sections and thermal energy consumption of Vertical Shaft
Kiln mini cement plants are given below:
12.1 Electrical Energy
The electrical energy requirements for different sections are given below in Table 6.
Table 6: Electrical Energy Reuirement
Sl. No. Section Electrical Energy in Kwh/tonne of

materials
1 Crushing 1 to 3
2 Raw mill 28 to 35
3 (including mill auxiliaries) 20 to 25
4 VSK 12 to 15
5 RK 25 to 35
6 Coal Mill 35 to 40
Cement Mill
(Including mill auxiliaries)
12.2 Thermal Energy
Thermal energy requirement varies from 850 - 950 K.cal/kg of clinker.
13.0 FIELD STUDIES
Indepth study was conducted at 8 VSK mini cement plants including identification of sources of air pollution (stack
& fugitive), stack emission monitoring, constituent of flue gases in terms of O2, CO2, CO and N2 etc, pollution
control technology adopted, annual operation and maintenance cost, water requirement and ambient air quality
monitoring.
Most of the VSK mini cement plants are not equipped with pollution control devices in all the sections due to the
involvement of capital cost especially in Saboo and RRL VSK mini cement plants. A few CRI-MVSK cement
plants of higher capacity are only having pollution control devices in all the sections of unit. Many VSK mini
cement plants are closed except the plants located in Jammu & Kashmir and North Eastern region.
The study was conducted at 2 VSK cement plants in Andhra Pradesh and 6 VSK cement plants in Rajasthan. The
indepth studies conducted in all the 8 VSK mini cement plants are given in the subsequent paragraphs.
13.1 Plant - 1
13.1.1 History
1 Name of the plant : Plant - I

2 Location : Tirupati, Andhra Pradesh
3 Installed Capacity (TPD) : 200 (2 x 100 TPD)
4 Year of Commissioning : April 1996
5 Technology adopted : CRI - MVSK Technology
6 Machinery Supplier : NCB's licensee
M/s Promac Engineering
Industries, Bangalore.
7 Actual Cement Production : 57,083 Tonne / Annum
8 Future Expansion : Yes
9 Types of Cement Manufactured : Slag Cement (BIS: 445 - 1989)
The above plant is put up in order to utilize the slag generated by their steel plant, situated in the same premises.
The quality of granulated slag generated by their steel plant is as per Bureaau of Indian Standards. The slag
consumption was upto 50% depending upon the quality of clinker produced.
The specific thermal energy consumption is 900 K.Cal/ Kg of clinker and specific electrical energy consumption is
110 Kwh / tonne of cement.
Actual production from VSK (average) on the day of monitoring was 85 TPD.
13.1.2 Manufacturing Process and Flow Sheet
CRI - MVSK technology is based on the black meal process in which all the raw materials, viz, limestonne, clay,
fuel (coke breeze, Jhama coal or any suitable low volatile coal) and other corrective materials are ground together
to a fineness of 10% retained on 170 mesh as in dry process and intimately blended to satisfy the chemical
requirements for the raw meal. The homogeneous raw meal is formed into nodules of the desired size by adding
water in a pan nodulizer and fed into the vertical shaft kiln through a revolving feed hopper. As the material
passes down the kiln, it is dried, heated and then burnt into clinker. The clinker is then cooled and discharged
from the kiln by a rotary grate at the bottom of the kiln through a triple airlock discharge device or gamma ray
controlled material Block Tube (MBT). The combustion air to the kiln, which is provided by a Roots blower, also
serves the purpose of cooling the clinker and thus avoids wastage of heat. The clinker then passes on to a
cement mill where it is ground with about 5% gypsum to produce cement of standard quality.
Flow Sheet of Plant - I is shown in Exhibit - 2.
13.1.3 Sources of Air Pollution
Sources of air pollution are shown in Table 7.
Table 7: Sections Causing Air Pollution
Section Type of Pollution Control Equipment
1. Crushing Bag Filter
2. Raw Materials Bag Filter
Proportioning Bag Filter
3. Raw Mill Bag Filter
4. Blending Bag Filter
5. Nodulisation Wet Scrubber
6. VSK Bag Filter
7. Clinker discharges --
8. Clinker tunnel Bag Filter
9. Cement Mill Bag Filter
10. Packing
(Note: Wet scrubber was not connected)
13.1.4 Stack Emission
The stack emission monitoring was conducted at all the important sections and details are given in Table 8 and 9.
Table 8 : Stacks Emission Monitoring Results at outlet of APCD
Raw Mill Cement Mill

S. No. Parameters Kiln (outlet)
(outlet) (outlet)
With intermittent After stabilization
feeding with continuous
feeding
1. Stack dimension (m) 0.50 0.50 1.2 1.2
2. Stack cross sec (m 2 ) 0.196 0.196 1.131 1.131
3. Flue gas temp ( 0 C) 42 48 85 85

4. Exit velocity of flue gas (mps) 8.76 7.66 3.31 3.31
5. Flow rate (m 3 / hr) 6181 5405 13436 13436
6. PM (mg/Nm 3 ) 1) 45 1) 70 1) 580 1) 358
7. Emission rate (kg / hr) 2) 66 2) 96 2) 559 2) 340
8. SO 2 (mg/Nm 3 ) 3) 96 3) 92 3) 550 3) 346
Avg. 69 Avg. 86 Avg. 563 Avg. 348
0.43 0.46 7.56 4.67
- - 7 7
Table 9: Other Stacks Emission Monitoring Results
Particulate Particulate Particulate Particulate

Matter Conc. Matter Conc. Matter Conc. Matter Conc.
(mg/Nm 3 ) (mg/Nm 3 ) (mg/Nm 3 ) (mg/Nm 3 )
Section
Sample I Sample I Sample I Average
Raw mill (Bag Filter Inlet) 873 852 843 856
Cement mill (Bag Filter Inlet) 185 176 164 175
Packing plant (loading activities not

52 60 50 54
continuous)
Raw mill tunnel exhaust 70 81 77 76
TALD gate (Bag Filter Inlet) 800 815 815 810
TALD gate (Bag Filter Outlet) 315 325 332 324
The efficiency of bag filters in raw mill and cement mill was found to be 92% and 95% respectively.
13.1.5 Ambient Air Quality
The ambient air quality was monitored in respect of suspended particulate matter, respirable particulate matter,
SO2, NOx and CO The sampling was done at two locations in upwind and downwind directions on 8-hourly
frequency and 24 hours average value is computed.
The ambient air quality monitoring results are given in Table 10.
Table 10: Ambient Air Quality Monitoring Results
Sl. No. Parameters Down Wind Direction ( �g/m 3 ) Up Wind Direction ( �g/m 3 )
1 RSPM 310 280
2 SPM 899 641

3 SO 2 14 12
4 NO x 8 7
5 CO Traces Traces
13.1.6 Analysis of Particle Size Distribution of Particulate Matter
The particle size analysis of the dust collected in thimbles at the VSK Kiln is as given below:
µ Size 0-3 3-5 5-10 10-20 20-40 40-60 60-90 90-105
% 10.70 6.20 8.50 19.50 7.10 26.90 20.39 0.71
13.1.7 Raw Mix Design and its Effect on Emission
The plant is using 5 component mixes for clinker manufacture. The raw materials used are two type of limestonne
high & low grade, clay, Iron dust and coke breeze. The chemical composition of the above materials and the raw
meal is given in Table 11. The raw materials consumption factor per tonne of cement is given below:
Limestonne - I : 0.50
Limestonne - II : 0.89
Clay : 0.07
Additive : 0.03
Coke breeze : 0.18
Table 11: Chemical Composition of Raw Materials & Raw Meal
Materials LOI% SiO 2 % Al 2 O 3 % Fe 2 O 3 % CaO% MgO%

Limestonne � I 39.40 6.71 2.07 0.93 48.45 1.30
Limestonne � II 35.07 13.60 3.10 1.40 44.40 0.70
Clay 10.00 55.0 17.00 8.00 5.00 2.00
Additive 4.00 3.00 3.00 85.00 -- --
Coke Breeze 82.00 7.35 2.60 5.10 1.25 0.15
Raw meal 40.00 12.23 3.30 3.60 38.40 0.85
The modulii values obtained of the raw meal is given below:
SM : 1.77
AM : 0.92
LSF : 0.92
%LC : 31.00
The Cement quality obtained is shown below:
Compressive strength
3 days : 340 - 380 Kg / cm2

7 days : 440 - 480 Kg / cm2
28 days: 550 - 600 Kg / cm2
Soundness
Le Chatlier expansion (mm): 2.7

Autoclave (%) : 0.3
To study the effect of different raw materials proportions on clinker quality and particulate matter emissions, using
the same quality raw materials and only changing the raw mix design (RMD), stack emissions were measured.
The present RMD had been changed to new RMD having following Modulii values and increased liquid content
which is given below:
_ SM__ __AM__ __LSF__ __%LC__
1.55 0.66 0.88 36.88
When the material with new RMD was fed to the kiln, the quality of clinker was improved, the stack emissions
were observed as given below:
Stack Emission Data with New Raw Mix Design

a) Stack dimension (m) : 1.2
b) Stack cross section area (m2) : 1.131
c) Flue gas temp. (°C) : 84
d) Flue gas velocity (m/sec) : 3.31
e) Flow rate (m3/hr) : 13436
f ) Particulate Matter Emission (mg/Nm3) : 95
g) Emission rate (kg/hr) : 4.00
Thus, it is observed that if the kiln is fed with proper nodules of optimum RMD and proper process parameters are
strictly followed as per the norms, particulate matter emission from VSK is well below the stipulated norms.
13.1.8 Process Parameters of VSK
The process parameters of Vertical Shaft Kiln are given below:

a) Nodule Size (mm) : 6-10
b) Moisture (%) : 13-14
c) Fuel in Kiln Feed (%) : 11
d) Rotary Grate Speed : 600-750
(Dyno drive rpm)
e) Clinker Temperature (°C) : 60-80
f) Bed length from top (mm) : 300-500
13.1.9 Air Pollution Control Devices adopted and Design Efficiency
The air pollution control devices installed in various sections are given in Table 7. The design parameters like fan
capacity, drive hp, no. of bags in various sections alongwith the capacity of equipment are given in Table 12.
Table 12: Design Parameters of Air Pollution Control Devices installed at Various Sections
Capacity Fan Capacity Drive

S. No. Section No. of Efficiency
(tph) (m 3 /hr) (HP) Bags
1 Crushing 30 4000 10 32 70
2 Raw Materials - 6600 15 56 74

Proportioning
3 Raw Mill 11 18000 100 144 92
4 Blending 75 T. Cap. 4000 10 32 70
5 VSK - -------- Wet Scrubber ---------
6 Clinker Discharge - 4000 10 32 70

(TALD)
7 Cement Mill 12 13300 25 96 95
8 Packing 20 7000 15 60 73
13.1.10 Economics
The capital cost of air pollution control devices along with its maintenance cost per annum for various sections are
given in Table 13.
Table 13: Capital and Operation & Maintenance Cost of Air Pollution Control Devices
S. No. Section Air Pollution Capital Cost (Rs. Operation and

Control Devices Lakh) Maintenance Cost /
Annum (Rs.)
1 Crushing Ordinary Bag Filter 1.50 25,000
2 Raw Materials Ordinary Bag Filter 1.50 25,000

Proportioning
3 Raw Mill Pnu-jet bag filter 3.50 1,00,000
4 Raw Meal Blending Pnu-jet bag filter 3.50 1,00,000
5 Raw Meal Storage Ordinary Bag Filter 1.50 1,00,000
6 VSK Wet Scrubber 3.50 35,000
7 Clinker Discharge (TALD) Ordinary Bag Filter 1.50 25,000
8 Cement Mill Pnu-jet bag filter 3.50 1,00,000
9 Packing Ordinary Bag Filter 1.50 25,000
13.1.11 Environmental Standards
The limit stipulated by Andhra Pradesh Pollution Control Board for particulate matter emission is 115 mg/Nm3.
Ambient air quality standard for SPM is 500 mg/m3.
13.1.12 Noise Pollution
Detrimental and unpleasant sound energy transmitted from one area to another is classified as "Noise". The noise
is generated in various sections has been measured as shown in Table 14. The major sources of noise
generation are raw mill and cement mill. The distance between source of noise and point of measurement is
approximately 3 m. About 3 persons were working near each mill. The location of noise measurement is indicated
in the plant layout and shown at Exhibit - 3.
Table 14: Noise Level
Sl. No. Sections Noise Measurements (dBA)

Day Time Night Time
1 Near DG Set 59 55
2 Second Gate 43 41
3 Colony 42 36
4 Cement Mill 91.8 91.0
5 Near Kiln Shed 46 43
6 Near Laboratory 45 43
7 Crusher Control Rooms 57 45
8 Near Packing 47 43
9 Near Raw Mill 93.4 92.4
13.1.13 Water Requirement
Water required for a 200-tpd CRI-MVSK cement plant is 200 KL/day for the process and domestic purpose. The
water quality of the plant is shown in Table15.
Table 15: Water Quality
pH : 5.5 � 9.0
Suspended Solids : 200 mg/l
Total dissolved solid : 2100 mg/l
13.1.14 Solid Waste
There is practically no solid waste generation in the plant.
13.2 Plant - 2
13.2.1 History
1 Name of the plant : Plant - 2
2 Location : Near Vijayawada, A.P.
3 Installed Capacity (TPD) : 300 (3 x 100 TPD)
4 Year of Commissioning : 2x100 = 200 TPD, 1991
1x100 = 100 TPD, 1997
5 Technology adopted : CRI - MVSK Technology
6 Machinery Supplier : NCB's licencee
M/s Promac Engineering
Industries, Bangalore &
M/s. Kay Iron Works Pvt. Ltd.,
Yamunanagar.
7 Actual Cement Production : 69,000 Tonnes / Annum
8 Future Expansion : No
The specific thermal energy consumption is 1050 Kcals / kg of clinker and specific electrical energy consumption
is 115 Kwh / tonne of cement.
The actual production for both the kilns (average) on the day of monitoring was 70 TPD.
Manufacturing process is same as explained earlier in Plant-1. The flow sheet of Plant-2 is based on crane layout
for handling raw materials, fuel, clinker & gypsum which is shown in Exhibit-4.
Sources of Air pollution are shown in Table 16.

Section
Type of Pollution Control Equipment
1. Crushing -
2. Raw Materials Proportioning -
3. Raw Mill Pnu � jet Bag Filter
4. Blending -
5. Nodulisation -
6. VSK -
7. Clinker discharges -
8. Clinker tunnel -
9. Cement Mill Pnu � jet Bag Filter
10. Packing -
The stack emission monitoring was conducted at all the important sections and details are given in Table 17 and
Table 18.
Table 17: Stacks Emission Monitoring Results at outlet of APCD
Parameters Raw Mill

Cement Mill Kiln (outlet)
(outlet) (outlet)
I* III
1. Stack dimension (m) 1.03 0.315 1.3 1.3
2. Stack cross sec (m 2 ) 0.834 0.078 1.328 1.328
3. Flue gas temp ( 0 C) 48 42 105 62
4. Exit Velocity of flue gas (m/s) 8.85 8.76 3.4 4.5
5. Flow rate (m 3 / hr) 26571 2460 16255 21514
6. PM (mg/Nm 3 ) 1) 161 1) 82 1) 171 1) 75

7. Emission rate (kg / hr) 2) 148 2) 69 2) 166 2) 82
8. SO 2 (mg/Nm 3 ) 3) 150 3) 50 3) 164 3) 62
Avg. 153 Avg. 67 Avg. 167 Avg. 73
4.07 0.166 2.72 1.58
- - 6 6.5
* many leakages in stack
Table 18: Other Stack Emission Monitoring Results
Section Particulate Matter Emission (mg/Nm 3 )

1. 1300
Raw Mill (Bag Filter Inlet)
2. 1200
3. 1118
Avg. 1206
Bag Filter Efficiency
The dust concentration at raw mill bag filter inlet was measured to estimate the efficiency of the dust collector
which was found to be 87.3%.
The Ambient Air Quality was monitored in down wind and up wind directions. The ambient air quality monitoring
results are given in Table 19.
Table 19: Ambient Air Quality
Sl. No. Parameters Down-wind Direction �g/m 3 Up-wind Direction �g/m 3

1 RSPM 275 142
2 SPM 1205 910
3 SO 2 9 7
4 NO x 7 6
5 CO Traces Traces
13.2.6 Analysis of Particle Size Distribution of Particulate Matter
The particle size analysis of the dust collected in thimbles at the VSK Kiln is as given below:
µ Size 0-3 3-5 5-10 10-20 20-40 40-60 60-90 90-105
% 9.98 6.56 8.86 19.40 7.20 26.75 20.44 0.81

13.2.7 Raw Mix Design
The plant is using 6 component mixes for clinker manufacture. The raw materials used are two types of
limestonnes, coke breeze, clay, iron ore and bauxite. The chemical composition of the above materials and the
raw meal is given in Table 20.
T able 20: Chemical Composition of Raw Materials & Raw Meal
Materials LOI% SiO 2 % Al 2 O 3 % Fe 2 O 3 % CaO% MgO%

Limestone 38.88 8.61 1.12 1.74 48.05 1.06
Low Grade 37.76 10.32 1.27 2.22 46.91 1.10
Limestone 69.76 17.61 2.46 6.53 2.34 0.78
Coke Breeze 13.13 48.23 8.45 16.95 8.24 3.25
Clay 1.73 1.28 89.25 6.28 0.99 0.25
Iron Ore 10.41 28.58 33.52 27.73 0.89 0.16
Bauxite 39.77 12.49 4.15 4.15 37.79 1.10
Raw Meal
The raw materials consumption factor per tonne of cement is given below:
Limestone - 1.28
Coke Breeze - 0.21
Clay - 0.09
Iron Ore - 0.025
Bauxite - 0.058
The cement quality obtained is shown below:
Compressive Strength
3 days : 270 - 330 Kg / cm2

7 days : 340 - 360 Kg / cm2
28 days: > 480 Kg / cm2
The raw mix design adopted by the plant is properly implemented with appropriate process parameters.
The process parameters of Vertical Shaft Kilns (Kiln 1 & Kiln 2) are given below:
Kiln 1 Kiln 2
a) Nodule Size (mm) : 8-12 8-12
b) Moisture (%) : 13-14 13-14
c) Fuel in Kiln Feed (%) : 13.0-13.50 13.0-13.50
d) Rotary Grate Speed : 600-800 600-800
(Dyno drive rpm)
e) Clinker Temperature (°C) : 65-85 65-85
f) Bed level from top (mm) : 300-500 300-500
13.2.9 Pollution Control Devices adopted and Design Efficiency
The pollution control devices installed in various sections are given in Table 16. The design parameters like fan
capacity, drive hp, no. of bags in various sections alongwith the capacity of equipment are given in Table 21.
13.2.10 Economics
The capital cost of air pollution control devices along with its operation and maintenance cost per annum for
various sections were not made available. It was informed that 32 & 22 Nos. of polyster needle woven bags per
annum were changed in Raw Mill & Cement Mill Pnu-jet bag filters respectively.
13.2.11 Environmental Standards
The environmental standards stipulated by AP Pollution Control Board are already given in the details of Plant No.
1.
The noise measurements taken at various locations in the plant are shown in Table 22. The major sources of
noise generation are raw mill and cement mill. The distance between source of noise and point of measurement is
approximately 3m. The numbers of persons working near the mills are 3 each. The location of noise
measurement is indicated in the plant layout and shown at Exhibit-5.
Table 21: Design Parameters of Existing Air Pollution Control Devices
Capacity Fan Capacity Drive Efficiency

S. No. Section No. of Bags
(tph) (m 3 /hr) (HP) (%)
1 Crushing 35 - - - -
2 Raw Materials - - - - -
Proportioning
3 Raw Mill 22 Not working - 325 polyester 90

needle bags
4 Blending 132t each (2 - - - -

Nos.)
5 VSK 300 TPD - - - -
6 MBT 5 - - - -
7 Cement Mill 13 16000 25 92 85
8 Packing with 2 spouts - - - - -
Table 22: Noise Level
Sl. No. Sections Noise Measurements (dBA)
Day Time Night Time
1 Near DG Set 63 52
2 Colony 32 25
3 Raw Mill 93.5 92.5
4 Cement Mill 88.4 87
5 Near Laboratory 38 36
6 Crusher Control Rooms 48 43
7 Near Packing 45 43

Water required for the plant is 200 KL/day mainly for the process purposes. Water is used for nodulisation, raw
mill trunion bearing cooling and cement mill shell cooling.
13.2.14 Solid Waste
There is practically no solid waste generation in the plant.
13.3 Plant - 3
13.3.1 History
1. Name of Plant : Plant - 3

2. Location : Behror, Rajasthan
3. Installed Capacity : 50 TPD
Actual output obtained : 40 TPD
(Average) on the days of
monitoring
4. Year of Commissioning : 1993
5. Technology Adopted : Semi Dry Process
Saboo VSK Technology
6. Actual Cement Production : 2,880 Tonnes/ Annum
7. Future Expansion : No
8. Types of cement : Ordinary Portland Cement Manufactured (OPC)
Saboo VSK Technology based on black meal process in which all Raw Materials viz. Limestone, Clay, Coke
Breeze, and Iron ore are ground together to a fineness of 10% residue on 170 mesh (90m) as in dry process and
immediately blended to satisfy the chemical quality requirement for the Raw Meal. The homogenous Raw Meal is
formed into nodules of desired size (6 to 12 mm diameter) by adding water in a pan noduliser and fed into Vertical
Shaft Kiln through revolving feed hopper inside VSK arrangement. As the material passes down the kiln, it is
dried, calcined and burnt into clinker. The clinker is then cooled and discharged by a rotary grate at the bottom of
the kiln through discharge arrangement. The combustion air is supplied through Roots Blower, also serves the
purpose of cooling the clinker and thus avoids wastage of heat. The cooled clinker then passes on to cement mill
where it is ground with about 5% Gypsum to manufacture Cement of Standard Quality.
Flow sheet of Plant - 3 is shown in Exhibit - 6.
Sources of Air Pollution are shown in Table 23.
Sl. No. Section Types of Pollution Control Equipment

1. Crushing Bags
2. Raw Materials Proportioning Bags
3. Raw Mill Bags
4. Blending Bags
5. Nodulisation Bags
6. VSK Wet Scrubber
7. Clinker Discharge Bags
8. Clinker Tunnel -
9. Cement Mill Bags
10. Packing -
The stack emission monitoring carried out in important sections is given in Annexure II. Three samples of
particulate matter emissions were taken at VSK stack and these values are varying from 96 to 140 mg/Nm3.
Particulate matter emissions rate varies from 1.69 to 2.47 Kg / hr. SO2 concentration in the flue gas vary from 6 to
7 mg/Nm3. The details of the stack (VSK chimney) are given below:
· Stack dimension Dia (m) / height (m) : 0.9 / 4.0

· Stack cross sectional area (m2) : 0.6362
· Flue gas temp. (°C) : 60
· Exit gas velocity of flue gas (Average)(m/sec) : 8.60
· Flow rate (m3/hr) : 17618
Flue gas analysis was carried out with "Flue Gas Analyser". The flue gas analysis indicates presence of Carbon
Monoxide to the extent of about 4091 ppm. The flue gas analysis for O2, CO2, CO and N2 is given at Annexure
II.
Fugitive dust emissions were measured near Raw Mill and are given in Annexure II. Ambient air quality
monitoring was carried out in upwind and downwind directions and results are given in Annexure II.
13.3.6 Analysis of Particulate Matter for Particle Size Distribution
Particle size distribution of the collected dust in thimbles (VSK Flue Gas) was carried out and the values are given
in Annexure II.
13.3.7 Raw Materials
The plant is using 4 component mixes for clinker manufacture. The raw materials used are limestonne, clay, coke
breeze and Iron ore. The raw mix design followed by the plant is given below.
Limestonne = 73%
Clay = 12%
Coke breeze = 13%
Iron Ore = 2%
13.3.8 Consumption Factor of Raw Materials
The raw materials consumption factor per tonne of clinker and cement are given below in Table 24.
Sl. No. Raw Materials Consumption Factor
Per tonne of Per tonne of cement

clinker
1 Limestonne 1.219 1.158
2 Clay 0.200 0.190

3 Coke Breeze 0.217 0.206
4 Iron Ore 0.033 0.031
The specific thermal energy consumption is 1056 Kcals/Kg of clinker. Whenever there is no power supply, the
plant is being operated with Diesel Generator set.
The process parameters of Vertical Shaft Kiln are given below :
a) Nodule Size (mm) - 6-12

b) Moisture (%) - 12-14
c) Fuel in Kiln Feed (%) - 13
d) Clinker Temperature (°C) - 50-80
e) Bed Length from top (mw) - 300-500
Noise levels were monitored at varius sources in the plant and are given in Annexure II. The distance between
source of noise and point of measurement is approximately 3 m. The number of persons working near the
sources is 3 each.
The average quantity of water required for this VSK cement plant is 10,000 litres / day as reported by the plant.
13.3.12 Solid Waste
Solid waste generation is practically nil.
13.3.13 Manpower
The total manpower deployed, as reported by plant authorities, is 21 staff and 30 contract labours.
13.4 Plant - 4
13.4.1 History

monitoring
6. Actual Cement Production : 9907 Tonnes / Annum

8. Types of cement : OPC
Manufactured
Saboo VSK Technology based on black meal process in which all Raw Materials viz. Limestonne, Clay, Coke
Breeze, and Iron ore are ground together to a fineness of 10% residue on 170 mesh (90m) as in dry process and
immediately blended to satisfy the chemical quality requirement for the Raw Meal is formed into nodules of
desired size (6 to 12 mm diameter) by adding water in a pan noduliser and fed into Vertical Shaft Kiln through
revolving feed hopper inside VSK arrangement. As the material passes down the kiln, it is dried calcined and
burnt into clinker. The clinker is then cooled and discharged by a rotary grate at the bottom of the kiln through
discharge arrangement. The combustion air is supplied through Roots Blower, also serves the purpose of cooling
the clinker and thus avoids wastage of heat. The cooled clinker then passes on to cement mill where it is ground
with about 5% Gypsum to manufacture Cement of Standard Quality.
Sources of air pollution for this plant are shown in Table 25

1. Crushing -
2. Raw Materials Proportioning -
3. Raw Mill 3 Bags
4. Blending 2 Bags
6. VSK Wet Scrubber
7. Clinker Discharge -
8. Clinker Tunnel -
9. Cement Mill 6 Air Filter Bags
10. Packing 2 Bags
The stack emission monitoring carried out in important sections is given in Annexure III. Three samples of
particulate matter emissions were taken at VSK stack and values observed are 430, 119 and 129 mg/Nm3 with
average of 226 mg/Nm3. Particulate matter emissions rate in kg/hr are 4.33, 1.20 and 1.30 respectively. SO2
concentration in the flue gas varies from 1.5 to 2 mg/Nm3. The details of the stack (VSK chimney) are given
below:
· Stack dimension Dia (m) / height (m) = 0.6096/3.5

· Stack cross sectional area (m2) = 0.3
· Flue gas temp. (°C) = 32
· Exit gas velocity of flue gas (m/sec) = 9.77
· Flow rate (Average - m3/hr) = 10,070
Flue gas analysis was carried out with "Flue Gas Analyser". The flue gas analysis indicates presence of Carbon
Monoxide in traces. The flue gas analysis for O2, CO2, CO and N2 is given at Annexure III.
Fugitive dust emissions were measured at Jaw Crusher and are given in Annexure III. Ambient air quality
monitoring was carried out in upwind and downwind directions and results are given in Annexure III.
in Annexure III.

Limestonne = 75%
Clay = 8.75%
Coke breeze = 12%
Iron Ore = 3.75%
The raw materials consumption factor per tonne of clinker and cement are given belowin Table 26.

cement
2 Clay 0.150 0.143
4 Iron Ore 0.063 0.060
The process parameters of Vertical Shaft Kiln are given below :

b) Moisture (%) - 12-14
Noise levels were monitored at various sources in the plant and are given in Annexure III. The distance between
sources is 3 each.
The average quantity of water required for this VSK cement plant is 15,000 llitres / day as reported by the plant.
13.4.12 Solid Waste
13.4.13 Manpower
The total manpower deployed , as reported by them, is 6 staff and 32 contract labours.
13.5 Plant - 5
13.5.1 History
monitoring
6. Actual Cement Production : 10,372 Tonnes / Annum
7. Future Expansion : Yes
8. Types of cement : Ordinary Portland Cement
Manufactured
Breeze, and iron ore are ground together to a fineness of 10% residue on 170 mesh (90m) as in dry process and
dried, calcined and burnt into clinker. The clinker is then cooled and discharged from the kiln through discharge
arrangement. The combustion air is supplied through Roots Blower, also serves the purpose of cooling the clinker
and thus avoids wastage of heat. The cooled clinker then passes on to cement mill where it is ground with about
5% Gypsum to manufacture Cement of Standard Quality.
13.5.3 Sources of Air Pollution (Stack & Fugitive)

1. Crushing Bag Filter
2. Raw Materials Proportioning Bag Filter
3. Raw Mill Bag Filter
4. Blending Bag Filter
5. Nodulisation Hood
6. VSK Dust Setting Chamber
7. Clinker Discharge Hood
8. Clinker Tunnel -
9. Cement Mill Bag Filter
10 Packing Bag Filter
The stack emission monitoring carried out in important sections is given in Annexure IV. Three samples of
particulate matter emisions were taken at VSK stack and the values observed are 400, 359 and 351 mg/Nm3 and
its average is 370 mg/Nm3. Particulate matter emission rate in kg/hr are 7.2, 6.46 and 6.32 respectively. SO2
concentration in the flue gas analysis varies from 5 to 5.5 mg/Nm3. The details of the stack (VSK chimney) are
given below:
· Stack dimension Dia (m) / height (m) = 0.9 / 5.0
· Exit gas velocity of flue gas (Average)(m/sec) = 8.9206
· Flow rate (m3/hr) = 18,011
Flue gas analysis was carried out with "Flue Gas Analyser". The flue gas analysis indicates presence of carbon
monoxide in traces. The flue gas analysis for O2, CO2, CO and N2 is given at Annexure IV.
Fugitive dust emissions were measured near raw mill section and the values are given in Annexure IV. Ambient
air quality monitoring was carried out in upwind and downwind directions and results are given in Annexure IV.
in Annexure IV.
breeze and Iron ore. The raw mix design following by the plant is given below.
Limestonne = 72.40%
Coke Breeze = 12.00%
Clay = 12.30%
Laterite = 3.30%

cement
2 Clay 0.202 0.192
4 Iron Ore 0.055 0.052
The specific thermal energy consumption is 1008 K.cals/Kg of clinker. Whenever there is no power supply, the

b) Moisture (%) - 12-14

Noise levels were monitored at various sources in the plant and are given in Annexure IV. The distance between
sources is 3 each.
The average quantity of water required for this VSK cement plant is 15,000 litres/ day as reported by the plant.
13.5.12 Solid Waste
13.5.13 Manpower
The total manpower deployed at this plant, as reported by them, is 12 staff and 18 contract labours.
13.6 Plant - 6
13.6.1 History

monitoring
8. Types of cement : Ordinary Portland Cement Manufactured (OPC)
Breeze, and laterite are ground together to a fineness of 10% residue on 170 mesh (90m) as in dry process and
Flow sheet of Plant - 6 is shown in Exhibit - 12

1. Crushing 3 Bag
2. Raw Materials Proportioning 2 Bag
3. Raw Mill 3 Bag
4. Blending 2 Bag
5. Nodulisation 1 Bag
6. VSK Cyclone system
7. Clinker Discharge -
8. Clinker Tunnel -
9. Cement Mill 3 Bag
10 Packing 4 Bag
The stack emission monitoriong carried out in important sections is given in Annexure V. Three measurements of
particulate matter emisions were taken at VSK stack and these values vary from 455 to 504 mg/Nm3. Particulate
matter emission rate vary from 0.67 to 0.75 Kg/hr. SO2 concentration in the flue gas vary from 5 to 6 mg/Nm3.
The details of the stack (VSK chimney) are given below:

· Flow rate (Average - m3/hr) = 1,480
monoxide in traces. The flue gas analysis for O2, CO2, CO and N2 is given at Annexure V.
Fugitive dust emissions were measured near Jaw Crusher and are given in Annexure V. Ambient air quality
monitoring wae carried out in upwind and downwind directions and results are given in Annexure V.
in Annexure V.
Limestonne = 72%
Coke Breeze = 11%
Clay = 13%
Laterite = 4%
The raw materials consumption factor per tonne of clinker and cement are given belowin Table 30.
Per tonne of clinker Per tonne of cement

2 Clay 0.185 0.178
4 Iron Ore 0.065 0.062
The specific thermal energy consumption is 888 Kcals/Kg of clinker. Whenever there is no power supply, the plant
is being operated with Diesel Generator set.

b) Moisture (%) - 12-14
Noise levels were monitored at various sources in the plant and are given in Annexure V. The distance between
source at noise and point of measurement is approximately 3 m. The numbers of persons working near the
sources are 3 each.
13.6.12 Solid Waste
Solid waste generated is practically nil.
13.6.13 Manpower
13.7 Plant - 7
13.7.1 History

monitoring
8. Types of cement : Ordinary Portland Cement Manufactured
Breeze, and laterite are ground together to a fineness of 10% residue on 170 mesh (90m) as in dry process and

1. Crushing Bags
3. Raw Mill Bags
4. Blending Bags
6. VSK Dust settling chamber
8. Clinker Tunnel -
9. Cement Mill Bags
10 Packing -
The stack emission monitoring carried out in important sections is given in Annexure VI. Three measurements of
particulate matter emisions were taken at VSK stack and these values varying from 87 to 126 mg/Nm3.
Particulate matter emission rate vary from 0.30 to 0.43 Kg/hr. SO2 concentration in the flue gas analysis vary
from 6 to 7 mg/Nm3. The details of the stack (VSK chimney) are given below:

· Exit gas velocity of flue gas (m/sec) = 1.6319
· Flow rate (m3/hr) = 3392
Stack flue gas analysis was carried out with "Flue Gas Analyser". The flue gas analysis indicates presence of
carbon monoxide in traces. The flue gas analysis for O2, CO2, CO and N2 is given at Annexure VI.
Fugitive dust emissions were measured near raw mill and are given in Annexure VI. Ambient air quality
monitoring was carried out in upwind and downwind directions and results are given in Annexure VI.
Particle size distribution of the collected dust in thimbles (VSK Chimney Flue Gas) was carried out and the values
are given in Annexure VI.
Limestonne = 77.10%
Coke Breeze = 15.70%
Clay = 4.30%
Laterite = 2.90%

cement
2 Clay 0.26 0.247
4 Iron Ore 0.05 0.048
The specific thermal energy consumption is 1248 Kcals/Kg of clinker. whenever there is no power supply, the

b) Moisture (%) - 12-14
c) Fuel in Kiln Feed (%) - 15.7
Noise levels were monitored at various sources in the plant and are given in Annexure VI. The distance between
source of noise and point of measurement is approximately 3 m. The numbers of persons working near the
sources are 3 each.
13.7.12 Solid Waste
Solid waste generated is practically nil.
13.7.13 Manpower
13.8 Plant - 8
13.8.1 History

monitoring
6. Actual Cement Production : 5,121 Tonnes / Annum 7. Future Expansion : No
8. Types of cement : Ordinary Portland Cement
Manufactured (OPC)
Saboo VSK Technology based on black meal process in which all Raw Materials viz. Limestonne, Clay, Pet Coke
and Laterite are ground together to a fineness of 10% residue on 170 mesh (90m) as in dry process and

1. Crushing Bags
3. Raw Mill Bags
4. Blending Bags
6. VSK Dust setting chamber
8. Clinker Tunnel -
9. Cement Mill Bags
10 Packing -
The stack emission monitoring carried out in important sections is given in Annexure VII. Three samples of
particulate matter emissions were taken at VSK stack and these values are varying from 541 to 648 mg/Nm3
before dust setting chamber and 64 to 184 mg/Nm3 after dust setting chamber. Particulate matter emission rate
varies from 0.85 to 1.02 Kg/hr before dust setting chamber and 0.10 to 0.13 Kg/hr after dust setting chamber.
SO2 concentration in the flue gas analysis varies from 7 mg/Nm3 to 8 mg/Nm3. The details of the stack (VSK
chimney) are given below:

· Flow rate (Average - m3/hr) = 1574
monoxide in traces. The flue gas analysis for O2, CO2, CO and N2 is given at Annexure VII.
Fugitive dust emissions were measured near Jaw Crusher and are given in Annexure VII. Ambient air quality
monitoring was carried out in upwind and downwind directions and results are given in Annexure VII.
Particle size distribution of the collected dust in thimbles (VSK Chimney Flue Gas) was carried out and the values
are given in Annexure VII.
Limestonne = 74.70%
Pet Coke = 8.70%
Clay = 13.30%
Laterite = 3.30%

cement
2 Clay 0.15 0.143
4 Iron Ore 0.06 0.057

b) Moisture (%) - 12-14
c) Fuel in Kiln Feed (%) - 8.70
Noise levels were monitored at various sources in the plant and are given in Annexure VII. The distance between
source of noise and point of measurement is approximately 3 m. The numbers of persons working near the
sources are 3 each.

The average quantity of water required for this VSK cement plant is 15,000 lts / day as reported by the plant.
13.8.12 Solid Waste
13.8.13 Manpower
14.0 EMISSION STANDARDS FOR CEMENT SECTOR
The emission standards for cement plants notified under the Environment Protection Act, 1986 are given below in
Table 35.
Table 35: Particulate Matter Emission Standards in India
Emission Limit (mg/Nm 3 )

C apacity
Protected Area Other Area

< 200 TPD 250 400
> 200 TPD 150 250
The emission standards for cement plants including grinding units locared in critically polluted or urban areas with
a population of one lakh and above (including 5 km distance outside urban boundary) is given below.
Particulate matter emission: 100 mg/Nm3
The emission standards for new cement kils including grinding units is given below.
Particulate matter emission: 50 mg/Nm3
15.0 DUST COLLECTION SYSTEMS
Particulate matter, commonly called dust, is the primary emission in the manufacture of Portland cement. For the
control of dust, the Cement Industry employs the following dust collectors.
i) Gravity settling chambers
ii) Cyclones
iii) Fabric filters
iv) Wet Scrubbers
The basic mechanism of removing particulate matter from gas stream may be classified as:
1. Gravitational Settling
2. Centrifugal Impaction
3. Inertial Impaction
4. Direct Interception
5. Diffusion
15.1 Gravity Settling Chambers
Gravity settling chambers will always be of importance for pre-cleaning of high dust laden gases. They work on
the principle of removing dust by reducing the velocity of gas (or) air stream. The gas is directed from the dust
generating equipment into the large volume settling chamber, where the velocity drops low enough to let large
dust particles drop out by gravity. Dust settling chambers are sometimes equipped with deflectors, to charge the
direction of gas flow and so to shorten the settling path of particles, improving collection efficiency. Because of the
simple construction, gravity-settling chambers are the lowest in cost, but at the same time also the least effective
dust collection devices.
The efficiency of gravity settling chamber è 30 � 70%
The gas velocity in the settling chamber è 100 ft/min
The pressure drop è 0.2 � 1.0 mmWG
Schematic of gravity settling chambers for dust removal is shown in Fig. 8.
15.2 Cyclones
15.2.1 Operation
A cyclone consists essentially of two sections: a cylindrical and a conical one. At the top of the cylindrical section
the gas enters tangentially and spirals along the walls downward into the conical section (outside vortex); from
here it starts to occupy the center space of the cyclone, and spirals upwards (inside vortex) to the outlet.
Centrifugal forces push the dust particles towards the wall where they accumulate and descend down by gravity
as well as under the influence of the outer vortex. Most of the particles fall down to the bottom into a hopper from
where they are removed by rotary valves (or) screw conveyors. The ascending gas vortex represents the clean
gas, but it always contains a certain amount of fine particulates. The Inside Vortex occupies only a small part of
the cyclones cross-section, and along its axis there is the so called neutral sector; if the size of this sector is large,
then a considerable amount of dust is taken away with the escaping gases. From this it results that the longer
distance a dust particle has to cover for reaching the boundary gas layer, the less particles are separated in the
cyclone; therefore it can be said that the efficiency of cyclone is inversely proportional to its diameter.
Diameter (inches) 9 16 24 124
Efficiency 96.7% 92.6% 88.2% 57.5%
Cyclones are low cost dust collectors, without moving parts, and can be furnished with refractory linings for high
temperature upto 1800°F.
The pressure drop of cyclones is in the range from 1.2 to 6.5 inches water column and depends on
- The temperature of the gas;
- The size of the cyclone; and on
- The inlet velocity of the gas.
Design proportions of a cyclone dust separator are given in Fig. 9.

15.2.2 Maintenance
Operational problems in cyclone are more due to process factors rather than constructional aspects. Some of the
operational problems in cyclone are given below.
i) Plugging of cyclone either in inlet duct, cyclone body or in exit duct. Plugging of inlet duct can occur when dust
agglomerates due to fineness or presence of moisture particularly when temperature falls below due point of gas.
Plugging of cyclone body occurs when hopper is plugged and dust level rises in cyclone.
ii) Erosion in cyclone is caused by impingement and rubbing of dust particles on cyclone wall due to high dust
loading, high inlet velocity and coarse dust particles.
15.3 Multiple Cyclones or Multicyclones
Multicyclones are enclosed units arranged in banks for parallel flow with feed gas from a plenum chamber and
with a common dust discharge hopper; multicyclone units can contain upto 400 individual cyclones.
Efficiency of Multicyclones è 85 � 94%
Pressure drop è 5 � 7 in of water column
A disadvantage of multicyclones is plugging of small tubes.
Longitudinal section of multicyclone for dust collection is given in Fig. 10.
15.4 Fabric Filters
Particle collection in fabric filter is based on several collecting mechanisms including inertial impaction,
interception, diffusion and gravitational sedimentation. Generally, inertial impaction, interception and diffusion
mechanisms are important for particles below one micron. Gravitational settling and filteration by the packed bed
of accumulated dust on the surface of filter media are decisive factors for coarse particles.
The pressure drop across the fabric filter is about 100-125 mmWG and the collection efficiency is as high as
99.99% depending on the type of fabric used. It is a constant efficiency dust collector and minor variations in
process parameters affect the performance of fabric filter. Bag house filter media and cleaning system constitute
basic components of the fabric filter.
Fabric filter systems typically consist of a tubular bag or an envelope suspended or mounted in such manner that
the collected particles fall into a hopper when dislodged from the fabric. The structure in which the bags hang is
known as bag house. Generally, particle-laden gas enters the bag at the bottom and passes
through the fabric while the particles are deposited on the inside of bag. Large bag houses are constructed with
several compartments, so that one compartment may be isolated for cleaning as needed while the other
compartments are operating. The bags should be arranged in each compartment provided for dust collection and
the dust is removed by rotary or screw valves. The cleaning mechanisms can be mechanical shaking system,
reverse air cleaning system or high pressure pulse jet cleaning system. The cleaning may be accomplished by
shaking the bags or by increasing the air pressure on the bag in a manner that causes the bag to collapse or
otherwise deform sufficiently to dislodge the accumulated dust.
The following advantages makes the fabric filters the best choice in many cases.
i) Very high efficiency
ii) Retention of finest particles
iii) Collection of particulates in dry form
iv) Relatively low pressure drop
Some of the disadvantages using fabric filters are:
i) Their large size
ii) High construction cost
iii) This application only to process temperature generally below 285°C
iv) High operating costs
The main operational problems of fabric filters are :
- Variation in filtration velocity
- Gas temperature below due point causing clogging of bags
- Variation in pressure drop
- Improper gas flow distribution in various compartments
- Cleaning system and its operation
- Flow control systems, inlet ducting, fans etc.
- Fire and explosion hazards.
Schematic diagram of typical bag house is given in Fig. 11.
15.5 Wet Scrubbers
15.5.1 Operation
The basic function of wet scrubbers is to provide contact between the scrubbing liquid, usually water, and the
particulate to be collected. This contact can be achieved in a variety of ways as the particles are confronted with
so called impaction targets � which can be wetted surfaces or individual droplets. Whether the particles
encounter wetted surfaces as in packed Scrubbers or individual droplets as in spray scrubbers, the basic
mechanism are the same as
in filters; inertial impaction, interception and diffusion. Generally impaction and interception are the predominant
mechanisms for particles of diameter above 0.3 m m, and for particles of diameter below 0.3 m m, diffusion
begins to prevail. In addition, diffusiophoretic deposition and electrostatic precipitation also effect particle
collection. Diffusiophoretic deposition can be significant when mass transfer within the scrubber, caused by
condensation of water vapour from the gas onto a cold liquid surface, exerts a force upon the particles and
causes them to get deposit on the surface.
There are many scrubber designs presently available where the contact between the scrubbing liquid and the
particles is achieved in a variety of ways the major types are
i) Spray Towers
ii) Centrifugal scrubbers
iii) Packed beds and plate columns
iv) Venturi Scrubbers

Each type of design has a certain range of applicability. Thus low energy scrubbers such as spray towers are
most often used to handle particles largely about 5-10 m m in diameter.
The effectiveness of the conventional spray tower ranges from 94% for 5 m m particles to 99% for 25 m m
particles.
Schematic diagram of spray tower is given in Fig. 12.
15.5.2 Advantages of Wet Scrubber
- Simultaneous removal of gases and particulates
- Effective performance over a wide loading range
- Equipment occupies only a moderate amount of space compared to dry collectors such as bag house
- Hazards of explosive dust-air mixtures are reduced
- Indifference to the temperature and moisture content of gas
- Corrosive gases may be neutralized by proper choice of scrubbing liquid
15.5.3 Disadvantages of Wet Scrubber
- Relatively high energy cost
- Problem of wet sludge disposal
- Corrosion problems
- Visible wet plume, reduction in buoyancy
- Very small particles (sub-micron sizes) may not be captured

16.0 SOURCES OF AIR POLLUTION
16.1 Introduction
Pollution control aspects are being given increasing attention in recent years. Mini cement plant is
basically air polluting industry. Air pollution, which basically, can be caused by both particulates and
gaseous pollutant, the CRI - MVSK cement plant operation ensures negligible emission of the latter such
as NOx etc as optimised operating conditions of the kiln generally prevents emission of such gases. The
generation of particulates, however, is inherent in the manufacturing process and the associated unit
operations, which is controlled by the application of dust collectors wherever required. The operation of
vertical shaft kiln, which is the heart of process, is such that less emission takes place as the shaft kiln
itself acts as an effective filter.
16.2 Manufacturing Process
The manufacturing process involved in the VSK mini cement plants essentially consists of the following
steps:
· Mining and crushing of limestonne (and additives, if necessary) ;
· Proportioning of raw materials and fuel based on raw mix design ;
· Grinding and blending to obtain fine homogenised black meal;
· Preparation of nodules ;
· Feeding the nodules to vertical shaft kiln wherein the drying, preheating, calcining and sintering takes
place resulting in the formation of clinker;
· Clinker cooling in the kiln;
· Grinding of clinker and gypsum in controlled proportion to produce ordinary portland cement;
· Storage, packing and despatch of cement.
16.3 Dust Generation Sources
The various dust generation sources are given below:
16.3.1 Mining
Mostly mini cement plant sector does not have its own captive mines. They buy limestone mostly from
other agencies. Wherever captive mines are there, mining is generally carried out manually. The level of
dust generation during drilling / blasting and loading of limestonne is generally low. Dust suppression
techniques such as water spray are generally found adequate.
16.3.2 Crushing and Raw Materials Proportioning
In crushing section, generally combinations of primary and secondary crushers are used for size
reduction. Various raw materials, i.e. crushed limestonne, clay, coke breeze, additive are stored in
hoppers. These materials are extracted from individual hoppers and are conveyed to the raw grinding
section. A single cyclone/fabric filter is mostly used to collect dust from both the crushing as well as raw
materials proportioning section and sometimes separate dust collectors for these two sections are also
recommended depending on the specific situation.
16.3.3 Raw Material Grinding
Depending upon the raw material characteristics, air swept ball mills or vertical roller mills are usually
employed for the intergrinding of raw materials and fuel. In both the cases, cyclones and fabrics filters are
used to keep the emission low.
16.3.4 Raw Material Blending and Homogenising
The ground raw meal is blended and homogenised pneumatically in blending silos. The generated dust is
collected in fabric filters to ensure low emission.
16.3.5 Kiln Section
Raw meal is extracted from the noduliser feed hopper and is fed to noduliser where water is also sprayed
to form nodules. In order to collect dust from noduliser a fabric filter is used.
The system design and the technology used in the CRI - Modern vertical shaft kiln (CRI - MVSK) have
adequate in built provision to restrict dust emission from chimney. This is a unique feature performed by
the MVSK, which in addition to clinkerisation also reduce the dust generation significantly. The green bed
of moist nodules, which are constantly distributed on the top by the rotary feeder, would trap most of the
dust particles and only allow gases into the stack. In fact when CRI - MVSKs are operated as per the
norms and procedures, the emission levels are very much within the stipulated norms. In addition, the
principle of natural draft, which is employed in the system, further ensures very little entrainment of dust
particles and even the small particles which may get into the gas stream, would settle down on the bed
due to gravity as the velocity is very less in the stack.
Whilst, in general the operational experiences have proved that the kilns based on CRI - MVSK
technology do not pose any problem in regard to dust emission, a dust collector of simple design has
been developed by NCB which has been successfully installed in CRI - MVSK cement plants. The flue
gases from the VSK is made to pass through the dust settling chambers, wherein the dust particles get
settled in the chamber, the dust so collected can be re-used in the process.
16.3.6 Clinker Handling

Clinker discharged from MVSK through triple air lock discharge gas / material block tube is crushed in a
jaw crusher. Clinker and gypsum stored in separate hoppers are extracted to feed to the grinding mill. A
fabric filter is used to collect dust from discharge gate / material block tube, clinker crusher and clinker
and gypsum extraction points beneath their respective hoppers.
16.3.7 Cement Grinding
In mini cement plants based on CRI-MVSK technology, generally open circuit tube mills are employed for
cement grinding. The mill works on overflow principle and the product is directly conveyed to the storage
silo. Fabric filters are used to facilitate dust collection to ensure very low emissions.
16.3.8 Fugitive Emission
Specific instances of fugitive dust generations include dust blown by wind from raw materials stockpile,
dust caused by vehicular traffic within the factory, dust leakage from conveyors, conveyor transfer points,
silos, storage hoppers and packers etc. Good house keeping, proper maintenance, wetting of dusty
areas, use of enclosed storage wherever feasible etc would eliminate fugitive dust.
17.0 GUIDELINES TO CONTROL THE DUST EMISSION
As a guideline suggested air pollution control devices for various sections of VSK based mini cement plants are
given in Table 36, subject to compliance of emission standards.
Table 36: Section wise Suggested Dust Collectors
Sl.No. Section Type of Dust Collector
1 Crushing and Raw Materials Proportioning Bag filter with proper metallic casing, stack
height and stack monitoring requirement
2 Raw Mill Twin cyclone & Bag filter with proper metallic
casing, stack height and stack monitoring
requirement
3 Homogenising Silo Bag filter with proper metallic casing, stack

4 Noduliser Bag filter with proper metallic casing, stack

5 VSK Cyclone with proper stack height and stack

monitoring requirement
6 Clinker Crusher and Discharge Tube Bag filter with proper metallic casing, stack
7 Cement Mill Bag filter with proper metallic casing, stack

8 Packing House Bag Filter with proper metallic casing, stack

The above air pollution control devices are indicative in nature. Cement Plant may explore the possibilities of
other devices also. The important thing which is to be kept in mind is that in all the cases the plant has to meet the
prescribed emission standards.

Emission Data of Plant No. 3
1 Name of Plant Plant � 3
2 Location/Altitude/Barometric Behror (Rajasthan) / 250m / 10010 mmwg

Pressure
3 Plant Installed Capacity/Actual output50 / 40

obtained on the days of monitoring
(Average) (TPD)
a) Year of Commissioning 1993
b) Process followed Semi Dry black meal process (Saboo VSK Technology
4. Fuel used Coke Breeze
5 Actual production (TPA) 2880
6 Ambient Air Quality (AAQ)
a) Particulate Matter (24 Hrs average) Down wind Up wind

(µg/m3)
Day 1 Day 2 Day 1 Day 2
i) RPM 241 146 198 103
ii) SPM 253 157 209 130

Fugitive dust (SPM) (µg/m3)
b) 7192
(Location : Near Raw Mill)
Gaseous Concentration (µg/m3)
c) Down wind Up wind
(24 hours average)
i) SO 2 BDL 8 BDL 6
ii) NO x 66 65 34 35
7 Stack Emissions
i) Location VSK Chimney
ii) Diameter / height ( m) 0.9 / 4.0
iii) Gas Velocity (m/sec.) 8.6
iv) Gas Flow rate (Nm 3 /hr) 17618
v) Particulate Matter (mg/Nm 3 ) 1) 96 2) 140 3) 122
vi) Emission Rate (kg/ hr) 1) 1.69 2) 2.47 3) 2.15

vii) Exhaust gas temperature (°C) 60
viii) SO 2 (mg/Nm 3 ) 1) 6 2) 7 3) 6.5
8 Stack Flue Gas

Analysis
a) O 2 (%) 13.5
b) CO 2 (%) 4.1
c) CO (PPM) 4091; More CO formation due to insufficient Oxygen
d) N 2 (%) 81.99 (approx.)
e) Temperature DifferenceO
( D T) (°C)
f) Combustion Efficiency (89%

h)
9 Quality (Clinker )
i) Litre Weight (gm/ltr.) 1050 to 1200
ii) Free Lime (%) 1.00 to 1.50
10 Particle Size0-3 3-5 5-10 10-20 20-40 40-80 60-90 90-105 8.5
Distribution Values (%) 4.24 1.16 2.32 5.18 24.9 28.3 25.4
11 Noise Monitoring Data# AB 74 C 98 D 94 E 98 F 92 G 100 H 76 I 90 J 94 K 76

Decibel (dbA) 76
12 Pollution Control
Equipment data
a) Cost (Rs. In Lakh) 4
b) Operation and30,000
maintenance cost per
annum (Rs.)
c) Efficiency ( h ) 60 to 70
d) Capital Investment (Rs.1.50 (1993)

In Crores)
e) Annual Turn over (Rs.1.296

In Crores)
* BDL = Below Detectable Limit

# A - Office; B - Security Gate; C - Jaw Crusher; D � Clinker Yard ; E - Hammer Crusher ; F - Raw Mill Hopper
G - Raw Mill ; H - Raw Meal Silo ; I - VSK Discharge Area ; J � Cement Mill ; K � Boundary of the Plant.
2 Location/Altitude/Barometric Pressure Behror (Rajasthan) / 250m / 10010 mmwg
3 Plant Installed Capacity/Actual (TPD) output50 / 25

obtained on the days of monitoring (Average)
b) Process followed Semi Dry black meal process (Saboo VSK Technology )
5 Actual production (TPA) 8151.40
a) Particulate Matter (24 Hrs average) (µ g/m 3 ) Down wind Up wind
i) RPM 205 110 185 102
ii) SPM 790 557 581 432

Fugitive dust (SPM) (at source) (µ g/m 3 )
b) 16358
(Location : Near Jaw Crusher)
Gaseous Concentration (µ g/m 3 )
(24 hours average)
i) SO 2 25 29 16 18
ii) NO x 78 54 61 42
7 Stack Emissions
iii) Gas Velocity (m/sec.) 9.77 (Average)
iv) Gas Flow rate (Nm 3 /hr) 10,070

viii) SO 2 (mg/Nm 3 ) 1) BDL 2) BDL 3) BDL
8 Stack Flue Gas Analysis I.D. Fan Outlet Kiln hood @ for 3.5TPH nodules feed
a) O2 (%) 20.8 20.8
b) CO 2 (%) 0.1 0.1
c) CO (PPM) 0 0
d) N 2 (%) 79.1 79.1
e) Temperature Difference ( D 0 0
T) (°C)
f) Combustion Efficiency ( η ) 87 89
10 Particle Size Distribution0-3 2.893-5 1.095-10 10-20 20-40 40-80 60-90 90-105 1.9
Values (%) ( m ) 2.87 7.85 44.5 25.4 13.5
#A F
11 Noise Monitoring Data B 75 C 98 D 95 E 98 G 100 H 75 I 90 J 94 K 75
Decibel (dbA) 74 --
12 Pollution Control Equipment

Data
b) Operation and maintenance35,000

cost per annum (Rs.)
c) Efficiency ( η ) 70
d) Capital Investment (Rs. In1.40

Crores)
e) Annual Turn over (Rs. In1.40

Crores)
2 Location/Altitude/Barometric Pressure RIICO Ind. Area, Behror Distt. Ajmer (Rajasthan) 250m /
10010 mmWG
3 Plant Installed Capacity/Actual output50 / 30

obtained on the days of monitoring
(Average) (TPD)
5 Actual production (TPA) 10,371
a) Particulate Matter (24 Hrs average) ( µ Down wind Up wind

g/m 3 )
i) RPM 435 395 288 227
ii) SPM 802 998 486 422

Fugitive dust (SPM) ( µ g/m 3 )
b) 18575
(Location : Middle of raw mill section)
Gaseous Concentration ( µ g/m 3 )
(24 hours average)
i) SO 2 12 12 9 9
ii) NO x 63 58 34 33
7 Stack Emissions

iv) Gas Flow rate (m 3 /hr) 18011
Vii Emission Rate (kg/ hr) 1) 7.2 2) 6.46 3) 6.32
viii) SO 2 (mg/Nm 3) 1) 5.5 2) 5.0 3) 5.0
8 Stack Flue Gas Analysis
a) O 2 (%) 20.5
b) CO 2 (%) 0.0
c) CO (PPM) 0.0
d) N 2 (%) 79.5
e) Temperature Difference ( D T) (°C) 0
f) Combustion Efficiency (η) 97.0
9 Quality data (Clinker )
ii) Free Lime (%) 1.25
10 Particle Size Distribution Values (%) ( m ) 0-3 3-5 5-10 10-20 20-40 40-80 60-90 90-105
6.30 1.89 14.33 51.80 12.8 9.90 2.60 0.40
F
11 Noise Monitoring Data Decibel (dbA) # AB 74C 95D E G 96H I 92 J 95 K
89 94 100 93 75 76
12 Pollution Control Equipment Data
b) Operation and maintenance cost per annum (Rs.) 45,000
c) Efficiency ( η ) 70 to 80
d) Capital Investment (Rs. In Crores) 1.15 (1993-94)
e) Annual Turn over (Rs. In Crores) 1.35 to 1.40

2 Location/Altitude/Barometric Pressure Behror (Rajasthan) / 250m / 10010 mmWG
3 Plant Installed Capacity/Actual output obtained20 / 15

on the days of monitoring (Average) (TPD)
a) Particulate Matter (24 Hrs average) (µ g/m 3 ) Down wind Up wind
i) RPM 220 215 131 211
ii) SPM 644 260 256 219

Fugitive dust (SPM (µ g/m 3 )
b) 28701
(Location : Near Jaw Crusher)
Gaseous Concentration (µ g/m 3 )
(24 hours average)
i) SO 2 10 11 19 10
ii) NO x 160 139 120 112
7 Stack Emissions
ii) Diameter / height ( m) 0.8 / 4.8m
iii) Gas Velocity (m/sec.) 0.8827 (Avg.)

Vii Emission Rate (kg/ hr) 1) 0.75 2) 0.68 3) 0.67
viii) SO 2 (mg/Nm 3 ) 1) 5 2) 6 3) 28
8 Stack Flue Gas Analysis
a) O 2 (%) 20.5
b) CO 2 (%) 0.4
c) CO (PPM) 0
d) N 2 (%) 79.1
e) Temperature Difference ( D T) (°C) 0
f) Combustion Efficiency (η) 97
i) Litre Weight (gm/ltr.) 1020
10 Particle Size Distribution Values (%) ( m ) 0-3 3-5 5-10 10-20 20-40 40-80 60-90 90-105
11.8 4.10 9.50 19.60 6.30 27.20 2.90 0.60
F
11 Noise Monitoring Data Decibel (dbA) # AB C 98D E 100 G H 75I 90 J K
76 79 96 100 102 95 78
12 Pollution Control Equipment Data
a) Cost (Rs. In Lakh) 0.70
b) Operation and maintenance cost per annum (Rs.) 20,000
c) Efficiency (η) 70
d) Capital Investment (Rs. In Crores) 0.60 (1985)
e) Annual Turn over (Rs. In Crores) 0.35
2 Location/Altitude/Barometric Pressure Behror (Rajasthan) / 250m / 10010 mmWG
3 Plant Installed Capacity/Actual output obtained50 / 27

on the days of monitoring (Average) (TPD)
a) Particulate Matter (24 Hrs average) ( µ g/m 3 ) Down wind Up wind
i) RPM 21 303 20 253
ii) SPM 21 830 20 800

b) 58615
(Location : Near Raw Mill)
(24 hours average)
i) SO 2 12 19 08 12
ii) NO x 119 186 95 160
7 Stack Emissions
i) Location Above setting chamber in VSK Chimney
ii) Diameter / height ( m) 0.9 / 4.5m

viii) SO 2 (mg/Nm 3 ) 1) 6 2) 7 3) 6.5
8 Stack Flue Gas

Analysis
a) O 2 (%) 19.0
b) CO 2 (%) 1.0
c) CO (PPM) 0.0
d) N 2 (%) 80.0
e) Temperature 0
Difference ( D T) (°C)
f) Combustion Efficiency96
(η)
10 Particle Size0-3 10.50 3-5 4.75 5-10 10.15 10-20 20-40 8.30 40-80 27.10 60-90 23.10 90-105 0.60
Distribution Values (%) 15.50
(m)
E F
11 Noise Monitoring Data# AB 75 C 96 D 95 G 100 H 75 I 90 J 94 K 75
Decibel (dbA) 75 96 92
Equipment Data
a) Cost (Rs. in Lakh) 2
annum (Rs.)
d) Capital Investment1.50 (1992)

(Rs. In Crores)
e) Annual Turn over (Rs.1.44

In Crores)
# A - Office; B - Security Gate; C - Jaw Crusher; D � Clinker Yard ; E - Hammer Crusher ; F - Raw Mill Hopper G
- Raw Mill ; H - Raw Meal Silo ; I - VSK Discharge Area ; J � Cement Mill ; K � Boundary of the Plant.
2 Location/Altitude/Barometric Behror (Rajasthan) / 250m / 10010 mmWG

Pressure
3 Plant Installed Capacity/Actual50 / 21

output obtained on the days of
monitoring (Average) (TPD)
5 Actual production trend (TPA) 5,121
a) Particulate Matter (24 Hrs average) Down wind Up wind

( µ g/m 3 )
i) RPM 225 352 219 134
ii) SPM 1255 1371 1002 932

b) 34961
(Location : Near Raw Mill Section)
(24 hours average)
i) SO 2 BDL* 06 BDL* 06
ii) NO x 175 152 168 141
7 Stack Emissions

ii) Diameter / height ( m) 0.61
iii) Gas Velocity (m/sec.) 1.65 Avg.
v) Particulate Matter (mg/Nm 3 ) Dust Setting Chamber
Before After
1) 648 2) 564 3) 541 1) 184 2) 65 3) 64
vi) Emission Rate (kg/ hr) 1)1.02 2)0.89 3)0.85 1)0.13 2)0.10 3)0.10
viii) SO 2 (mg/Nm 3 ) Outlet
1) 8 2) 7 3) 7
8 Stack Flue Gas Analysis Above dust settling chamber
a) O 2 (%) 20.8
b) CO 2 (%) 0.1
c) CO (PPM) 0.0
d) N 2 (%) 79.1
e) Temperature Difference0
( D T) (°C)
f) Combustion Efficiency (η) 97
9 Quality data (Clinker )
10 Particle Size Distribution0-3 10.033-5 4.705-10 11.1510-20 20-40 40-80 60-90 90-105
Values (%) ( m ) 16.45 7.80 27.15 22.10 0.62
E F
11 Noise Monitoring Data# A 93 B 74 C 90 D 105 G 96 H 97 I 61 J 95 K 74
Decibel (dbA) 94 96
Equipment Data
a) Cost (Rs. in Lakh) 5
annum (Rs.)
d) Capital Investment (Rs. In1.50 (1993)

Crores)
e) Annual Turn over (Rs. In1.00

Crores)
# A - Office; B - Security Gate; C - Jaw Crusher; D � Clinker Yard ; E - Hammer Crusher ; F - Raw Mill
Hopper G - Raw Mill ; H - Raw Meal Silo ; I - VSK Discharge Area ; J � Cement Mill ; K � Boundary of the
Plant
National Ambient Air Quality Standards
Pollutants Time- Concentration in ambient air Method of measurement

weighted
average Industrial Residential, Sensitive
Areas Rural & other Areas
Areas
SulphurDioxide (SO2) Annual 80 µg/m3 60 µg/m3 15 µg/m3 - Improved West and Geake
Average* Method
- Ultraviolet Fluorescence
24 hours** 120 µg/m3 80 µg/m3 30 µg/m3
Oxides of Annual 80 µg/m3 60 µg/m3 15 µg/m3 - Jacob & Hochheiser Modified
Nitrogen as Average* (Na-Arsenite) Method
(NO2)
24 hours** 120 µg/m3 80 µg/m3 30 µg/m3 - Gas Phase Chemiluminescence
Suspended Annual 360 µg/m3 140 µg/m3 70 µg/m3 - High Volume Sampling,
Particulate Matter Average* (Average flow rate not less than
(SPM) 1.1 m3/minute).
24 hours** 500 µg/m3 200 µg/m3 100 µg/m3
RespirableParticulate Annual 120 µg/m3 60 µg/m3 50 µg/m3 - Respirable particulate matter
Matter (RPM) (size Average* sampler
less than 10 microns)
24 hours** 150 µg/m3 100 µg/m3 75 µg/m3
Lead (Pb) Annual 1.0 µg/m3 0.75 µg/m3 0.50 µg/m3 - ASS Method after sampling
Average* using EPM 2000 or equivalent
Filter paper
24 hours** 1.5 µg/m3 1.00 µg/m3 0.75 µg/m3 .
Ammonia1 Annual 0.1 mg/ m3 0.1 mg/ m3 0.1 mg/m3 .
Average*
24 hours** 0.4 mg/ m3 0.4 mg/m3 0.4 mg/m3 .
CarbonMonoxide 8 hours** 5.0 mg/m3 2.0 mg/m3 1.0 mg/ m3 - Non Dispersive Infra Red
(CO) (NDIR)
1 hour 10.0 mg/m3 4.0 mg/m3 2.0 mg/m3 Spectroscopy
Annual Arithmetic mean of minimum 104 measurements in a year taken twice a week 24
* hourly at uniform interval.
24 hourly/8 hourly values should be met 98% of the time in a year. However, 2% of
** the time, it may exceed but not on two consecutive days.

Comprhensive Industry Document On Vertical Shaft Kiln Based Mini Cement Plants

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COMPREHENSIVE INDUSTRY DOCUMENT ON VERTICAL SHAFT KILN

BASED MINI CEMENT PLANTS

the material as the kiln rotates at 1

6.5 Vertical Shaft Kiln

The use of vertical shaft kiln process

Later after the development of

6.5.1 Black Meal Process

This is the most popular type of

In this process, the vertical shaft

2. OBJECTIVES OF THE STUDY

3. GROWTH OF MINI CEMENT PLANTS

4. WORLD SCENARIO OF MINI CEMENT

5. COMPARISION OF LARGE AND MINI CEMENT PLANTS

6. CEMENT MANUFACTURING TECHNOLOGIES

7. TYPES OF MINI CEMENT PLANTS IN INDIA

8. TYPES OF MINI CEMENT PLANTS IN CHINA

9. TYPES OF MINI CEMENT PLANTS IN COUNTRIES

10. OPERATION OF A CRI-MODERN VERTICAL SHAFT KILN

11. RAW MATERIALS AND THEIR CONSUMPTION FACTOR

12. ELECTRICAL ENERGY AND THERMAL ENERGY

13. FIELD STUDIES

14. EMISSION STANDARDS FOR CEMENT SECTOR

15. DUST COLLECTION SYSTEMS

16. SOURCES OF AIR POLLUTION

17. GUIDELINES TO CONTROL THE DUST EMISSION

 Annexure- 1 List of VSK Mini Cement Plants

Annexure- 2 Emission Data of Plant No. 3

Annexure- 3 Emission Data of Plant No. 4

Annexure- 4 Emission Data of Plant No. 5

Annexure- 5 Emission Data of Plant No. 6

Annexure- 6 Emission Data of Plant No. 7

Annexure- 7 Emission Data of Plant No. 8

 Exhibit - 1 Distribution of Mini Cement Plants in India

Exhibit - 2 Flow sheet of Plant- 1

Exhibit - 3 Location of Noise measurement - Plant- 1

Exhibit - 4 Flow sheet of Plant-2

Exhibit - 6 Flow sheet of Plant-3

Exhibit - 7 Location of Noise measurement - Plant- 3

Exhibit - 8 Flow sheet of Plant- 4

Exhibit - 9 Location of Noise measurement - Plant- 4

Exhibit - 10 Flow sheet of Plant- 5

Exhibit - 11 Location of Noise measurement - Plant- 5

Exhibit - 12 Flow sheet of Plant- 6

Exhibit - 13 Location of Noise measurement - Plant- 6

 Exhibit - 14 Flow sheet of Plant-7

Exhibit - 15 Location of Noise measurement - Plant- 7

Exhibit - 16 Flow sheet of Plant- 8

Exhibit - 17 Location of Noise measurement - Plant- 8

i. Ambient Air Quality in downwind and upwind directions

14. c Homogenising Silo - Bag Filter

15. d. Nodulizer - Bag Filter

17. f. Clinker crusher and discharge section - Bag Filter

18. g. Cement mill and packing house - Bag Filter

20. 1.0 INTRODUCTION

22. 2.0 OBJECTIVES OF THE STUDY

24. .0 GROWTH OF MINI CEMENT PLANT

26. As a result of the Government's encouragement backed by the technological

Status of mini cement plants at a glance as on 31 March 2001 and 31 March

Table 1: Status of Mini Cement Plants at a Glance as on March 31, 2001

Sl. No. Technology Cement Plants

Originally Set up In operation

Nos. Installed Capacity Nos. Installed Capacity

1 Rotary Kiln 31 4.003 24 3.411