CHAPTER 1: INTRODUCTION

1.1 Background
A substance that sets and hardens and can bind other materials together is known as
cement. The word "cement" traces to the Romans , who used the term opus
caementicium to describe masonry resembling modern concrete that was made from
crushed rock with burnt lime as binder. The volcanic ash and pulverized brick
supplements that were added to the burnt lime, to obtain a hydraulic binder, were later
referred to as cementum, cimentum, cäment, and cement.
Cements used in construction can be characterized as being either hydraulic or non-
hydraulic, depending upon the ability of the cement to be used in the presence of
water.
Non-hydraulic cement will not set in wet conditions or underwater, rather it sets as it
dries and reacts with carbon dioxide in the air.
Hydraulic cement is made by replacing some of the cement in a mix with activated
aluminium silicates, such as fly ash.
Portland Cement is the most common type of cement in general use around the
world because it is a basic ingredient of concrete, mortar, stucco and most non-
specialty grout. It is a fine powder produced by grinding Portland cement clinker
(more than 90%), a limited amount of calcium sulfate (which controls the set time)
and up to 5% minor constituents (as allowed by various standards).

 History of the origin of cement

An early version of cement made with lime, sand, and gravel was used in
Mesopotamia in the third millennium B.C. and later in Egypt. It is uncertain
where it was first discovered, but these concrete was used by Roman engineers.
 Cement industry in the world
Largest cement production country in the world is China which produces 54%
of the total cement production in the world. After then India which produces
7% of the total cement production in the world.
  Nepal Cement Production
The actual production data of existing cement industries both integrated and clinker
based as shown in economic survey report 2006/07 are 613,643 tonnes in 2005/06 and
644,325 (production data for 8 months only) are low.
The use of cement in Nepal as binding material came into effect in Nepal from the
beginning of early 1950's.
Largest cement industry installed in Nepal are as follows and which of them Himal
Cement Company is dissolved. Largest running cement cement industry in Nepal is
udayapur cement industry limited which produces 277,200 metric tone cement per
year.
Installed capacity (MT)
Name of industry Clinker Cement
S.
MT/PA MT/PA
No.
Himal Cement
1. Dissolved Dissolved
Company
Hetauda Cement
2. 247,500 259,875
Industries Ltd.
Udayapur Cement
3. 264,000 277,200
Industries Ltd.
Total 511,500 537,075
1.2 Cement Raw Materials
The first step in the manufacture of portland cement is to combine a variety of raw
ingredients so that the resulting cement will have the desired chemical composition. It is
important to have the correct proportions of calcium, silicon, aluminum, and iron. Table
lists just some of the many possible raw ingredients that can be used to provide each of
the main cement elements.

Examples of raw materials for portland cement manufacture

Calcium Silicon Aluminum Iron

Limestone Clay Clay Clay
Marl Marl Shale Iron ore
Calcite Sand Fly ash Mill scale
Aluminum ore
Aragonite Shale Shale
refuse
Blast furnace
Shale Fly ash
dust
Sea Shells Rice hull ash
Cement kiln dust Slag

1.3Cement Manufacturing Process

From the limestone quarry to the delivery of the end product, follow every step in the
cement manufacturing process.
Step 1: extraction of raw materials

The raw materials needed to produce cement (calcium carbonate, silica, alumina and
iron ore) are generally extracted from limestone rock, chalk, clayey schist or clay.
These raw materials are extracted from the quarry by blasting. They are then crushed
and transported to the plant for manufacturing cement.

Step 2: raw grinding and burning

Very fine grinding produces a fine powder, known as raw meal, which is preheated
and then sent to the kiln. The material is heated to 1,500°C before being suddenly
and dramatically cooled by bursts of air. This produces clinker, the basic material
required for the production of all cements.
Step 3: cement grinding and shipping
A small amount of gypsum (3-5) % is added to the clinker to regulate how the
cement will set. The mixture is then very finely ground to obtain "pure cement".
During this phase, different mineral materials, called "cement additives", may be
added alongside the gypsum. Used in varying proportions, these additives, which are
of natural or industrial origin, give the cement specific properties such as reduced
permeability, greater resistance to sulfates and aggressive environments, improved
workability, or higher-quality finishes. Finally, the cement is stored in silos before
being shipped in bulk or in bags to the sites where it will be used.

Figure: Cement Manufacturing Process

Cement produces by two process, they are :

1.dry process
2.wet process
Fig : cement manufacturing by dry process

Fig : cement manufacturing by wet process

1.4 Energy Consumption and Cleaner Production

Main sources of energy used in the Cement industries in Nepal are electricity and
coal. Coal is mainly used in the kilns for calcination in limestone based units and in
some cases also used for electricity generation in plants having co-generation system.
Approximate share of electrical energy used in Nepal's cement industry is 9 %;
thermal energy amounts to 91 %.

Fig : energy use in cement industry in Nepal

Baseline study undertaken by GIZ/NEEP in 2012 for the Cement sector has found the
specific energy consumption to be considerably above the regional benchmark.

Tabel: Specific energy comsuption in Nepalese Cement industries (GIZ/NEEP,

2012)

 Cleaner production
Cleaner Production is the continuous application of an integrated, preventive
environmental strategy towards processes, products and services in order to
increase overall efficiency and reduce damage and risks for humans and the
environment.
Cleaner production helps to improves products and services,company images,workers
health and safety conditions. It lowers risks and reduces waste treatment and disposal
costs. It saves costs on raw material, energy and water which makes company more
profitable and competitive.

1.5Environmental Impact/Health
Probable Emission
Cement manufacture causes environmental impacts at all stages of the process. These
include emissions of airborne pollution in the form of dust, gases, noise and vibration
when operating machinery and during blasting in quarries.

CO2 emissions

Cement manufacturing releases CO2 in the atmosphere both directly when calcium
carbonate is heated, producing lime and carbon dioxide and also indirectly through the
use of energy if its production involves the emission of CO2.

Nitrogen oxides (NOx)

The clinker burning process is a high-temperature process resulting in the formation
of nitrogen oxides (NOx). The amount formed is directly related to the main flame
temperature (typically 1850 – 2000 °C). Nitrogen Monoxide(NO) accounts for about
95 %, and nitrogen dioxide (NO2) for about 5 % of this compound present in the
exhaust gas of rotary kiln plants.

Sulfur dioxide (SO2)

Sulfur is input into the clinker burning process via raw materials and fuels. Depending
on their origin, the raw materials may contain sulfur bound as sulfide or sulfate.

Heavy metal emissions in the air

In the origin and the composition of the raw materials used, the high-temperature
calcination process of limestone and clay minerals can release in the atmosphere gases
and dust rich in volatile heavy metals, thallium, cadmium and mercury are the most
toxic. Heavy metals (Tl, Cd, Hg, ...) are often found as trace elements in common
metal sulfides (pyrite (FeS2), zinc blende (ZnS), galena (PbS), ...) present as secondary
minerals in most of the raw materials.

Heavy metals present in the clinker

The presence of heavy metals in the clinker arises both from the natural raw materials
and from the use of recycled by-products or alternative fuels. Nickel, zinc and lead are
commonly found in cement in non-negligible concentrations.
 Environmental impact of concrete

The environmental impact of concrete, is complex. Some effects are harmful, others
are beneficial. A major component of concrete is cement, which has its own
environmental and social impacts . The cement industry is one of the primary
producers of carbon dioxide, a major greenhouse gas. Concrete is used to create hard
surfaces which contribute to surface runoff that may cause soil erosion, water
pollution and flooding. . Concrete is a primary contributor to the urban heat island
effect, Concrete dust is a major source of dangerous air pollution. The presence of
some substances in concrete, which have adverse effect on health due to toxicity and
radioactivity. Wet cement is highly alkaline and should always be handled with proper
protective equipment.

Conversely, concrete is one of the most powerful tools for proper flood control, by
means of damming, diversion, and deflection of flood waters.

 Health Impact
Cement dust causes lung function impairment, chronic obstructive lung disease,
restrictive lung disease, pneumoconiosis and carcinoma of the lungs, stomach and
colon. Other studies have shown that cement dust may enter into the systemic
circulation and thereby reach the essentially all the organs of body and affects the
different tissues including heart, liver, spleen, bone, muscles and hairs and ultimately
affecting their micro-structure and physiological performance.
1.6 Rationale of Study
Study about the cement production and its impact on surrounding environment is
concerned about
 impact on health of people
 impact on natural vegetation
 air ,noise pollution level
 water pollution
 land pollution
 impact on biodiversity, flora and fauna
 impact on wildlife
 impact on agriculture
 impact on human settlement

1.7 Objectives
 To know the general cement manufacture process
 Study on environmental impact cause by cement industry
 Study about polluting agents like coal, diesel
 To suggest mitigation measure for reduction of pollution

1.8 Limitations
CHAPTER 2: LITERATURE REVIEW

Cement industry is listed in the main industrial sector which adversely affect to
the environment and human settlement. So many studies are related with
cement industry.

KEMA (2005) study entitled “INDUSTRIAL CASE STUDY:

THE CEMENT INDUSTRY”
The goals of this case study includes:
• Develop an understanding of the key processes and associated energy consumption
in the cement industry.
• Identify key energy efficiency opportunities and associated technical potential for
the cement industry.
• Identify key barriers that preclude cement customers for adopting energy efficient
practices and equipment.
• Examine how current PGC-funded programs can better address these customers’
barriers to implementation of more energy efficiency measures.

Kuldeep Sharma, Ujjawal Jain & Anupam Singhal studied about cement industry and
its impact entitled “TREATMENT OF WASTE GENERATED FROM CEMENT
INDUSTRY AND THEIR TREATMENT” This study mainly focuses on overview
of the pollution of air and water and solid waste in cement industries and the main
sources of environmental pollution in cement industries.

G.Murali, C.M. Vivek Vardhan, Siji Raju and Deepthi Susan Zachariah
studied entitled “Influence of various industrial effluents on concrete
structures” They study about Population explosion in urban area has
raised the demand for water resulting in its scarcity. With industrialization,
the quantum of wastewater generated too has soared up warranting
appropriate measures for utilization of the same. An attempt has been made
in this direction towards utilization of industrial effluents in construction
industry.
M. Tariq, M. Ali and Z. Shah (2003) studied entitled “ Characteristics of industrial
effluents and their possible impacts on quality of underground water”
This study was conducted to evaluate various industrial effluents of Hayatabad
Industrial Estate (HIE), Peshawar, and assess the possible impacts of such effluents
on quality of underground water. These results suggested that effluents discharged
from various industries showed variable characteristics and are potential threat to
underground water contamination.

EPA/ EPR
According to Environment Protection Act / Environment Protection Regulation 1997
(2053/2054)

 Limestone and clinker based cement industry which have capacity to produce
upto 50 metric ton per hour should be done initial environmental examination.
 Limestone and clinker based cement industry which have capacity to produce
more than 50 metric ton per hour should be done environmental impact
assessment.

Prevention and Control of Pollution

According to Environment Protection Act 1997 (2053)

Nobody shall create pollution in such a manner as to cause significant adverse impacts
on the environment or likely to be hazardous to public life and people’s health, or
dispose or cause to be disposed sound, heat radioactive rays and wastes from any
mechanical devices, industrial enterprises, or other places contrary to the prescribed
standards.

1. If it appears that anyone has carried out any act contrary to sub-section (1) and
caused significant adverse impacts on the environment, the concerned agency may
prescribe necessary terms in regard thereto or may prohibit the carrying out of such
an act.
2. If it appears that the use of any types of substance, fuel, tools or device has
caused or is likely to cause significant adverse impact on the environment, the
ministry may, by a notification in the Nepal Gazette, forbid the use of such
substance, fuel, tools or device.
3. Other provision relating to the prevention and control of pollution shall be as
prescribed.
CHAPTER 3: MATERIALS AND METHODOLOGY
The entire study program was designed, approved by supervisor and conducted as per
stated plan (chart 2.1) to maintain the quality of the work.

Chart 2.1: Study Flow Chart

Literature Review

Site Identification

Field Visit & Data Collection

Result & Report Preparation

Draft Report

Final Report

Dissemination
Study site map

Ma
p of udayapur district

Map of limestone quarry site jalpachilaune v.d.c.

Map of cement production site Jaljale , Triyuga Municipality

Study approach

CHAPTER 4: RESULT

 General information
Udayapur cement industry limited is established in 2044 BS. Its raw material
limestone source is at sidali site at jalpachilaune vdc. From this site limestone is
transported by ropeway and by vehicle to jaljale site which is 17 kilometer apart from
quarry site. Its manufacturing site is installed at jaljale, triyuga municipality,
udayapur. In this factory 540 workers are working there. This industry use electricity
and diesel as a energy resource. This industry have capacity to produce 800 metric
ton clinker per day and 840 ton cement per day. Yearly it produces 277200 metric ton
cement.

 Raw materials
For production cement properly, this industry should have these raw materials :

1. Limestone- 330000 metric ton

2. Clay – 57000-82500 metric ton
3. Sand- 2100 metric ton
4. Ore – 400 metric ton
5. Gypsum – 10500 metric ton
6. Water – 1500 cubic meter, per day
7. Electricity – 10000 kilowatt
8. Coal – 50000 metric ton
9. Furnace oil – 12000 kilo liter , for sudden use
10.Diesel – 900 kilo liter
11.Bag – 5544000

This industry manufacture ordinary Portland cement which have capacity to

manufacture 840 ton per day, by using these material in given percentage.

Clinkerization factor = 1.626 ton raw meal (for 1 ton clinker)

Gypsum addition= 5% for 100% clinker

Coal consumption= 125-140 ton per day

Average calorific value of fuel= 5700 k cal/kg of coal

Coal consumption per ton clinker= 25%

Coal consumption per ton cement= 0.25 ton/ton cement

 Energy Consumption & Cleaner Production

Energy resource for this industry is electricity and diesel. No cleaner production
system is installed in this industry.

Energy Total Source

Electricity, (KVA) 6 mw NEA
Diesel, (Kl) 20 KL/Month India

 Workers status
Manpower Unit Approved Male Female
In-direct Nos 60 59 1
Direct Nos 480 460 20
Total Nos 540 519 21

Cement manufacturing process

Process Layout of Cement Production
1. Crushing:
Firstly, major component in the composition of cement Calcium Oxide(CaO) is
obtained from the quarries is crushed to seven inch during primary crushing and
25mm during secondary crushing. It is in the sindali site where industry’s quarry site
is located.
2. Raw mill:
The raw mill is the equipment used to grind raw material into raw mix during the
manufacture of the cement. The raw materials are ground to the desired finest in the
raw mill. The fine powder is fed to the large size continues blending and storage by
use of aero pole. The mineral from the blending silo is dropped by gravity.this site is
located at jaljale site.
4. Clinkerisation:
It is the process where all materials are make a clinker which is used for make a
cement. In this process raw mixture is heated in a cement kiln, a slowly rotating and
sloped cylinder, with temperatures increasing over the length of the cylinder up to a
peak temperature of 1400-1450 °C. this is in the jaljale site.
5. Grinding
Grinding process make a desired setting qualities in the finished product, 5% gypsum
is added to the clinker and the mixture is finely ground to form the finished cement
powder. This is achieved in a cement mill.this is in the production plant at jaljale site.
5. Packing of cement
In udayapur cement industry plastic bag is used for the packaging of the cement. This
is in the production plant at jaljale site from where trucks are loaded cement for
customer.
 Environmental Pollution
1. Cement kiln emissions
 Carbon dioxide
 Nitrogen oxides (NOx)
 Sulfur dioxide (SO2)
 Carbon monoxide (CO) and total carbon
 Benzene, toluene, ethylbenzene, xylene
 Gaseous inorganic chlorine compounds
2. Noise pollution
 Blasting
 Use of heavy equipment
 Operation of machines
 Transportation
3. Dust
 From quarry site
 From stone crushing site
 Leakage from rope way & vehicle
 From manufacturing site
4. Leakage of hazardous substance from industry

Annex
Investment Amount
SN Particulars Existing
1 Land & Land development
2 Building & Civil Construction
3 Plant & Machineries
4 Furniture, Fixtures & Office Equipments
 5 Vehicles
6 Pre-operating Expenses
  Total Fixed Asset Investment
  Total Working Capital Investment
  Total Investment

Potential Manufacturing Cement Type

S. N. Types of Cement Production Quantity
Ordinary Portland
Cement (OPC)
Rapid Hardening
Cement (RHD)
Sulphate Resisting
Cement (SRC)
Portland Slag Cement
(PSC)
Portland Pozzolana
Cement (PPC)
Other

Clinkerization Factor =
Gypsum Addition =
Coal Consumption =
Average Calorific Value of Fuel =
Coal consumption per tonne Clinker =
Coal consumption per tonne Cement =
Broad Equipment Specification for Cement Plant
Equipment Capacity

Limestone crushing storage and transportation, (MT)

Raw material grinding, (TPH)
Homogenizing silo, (MT)
Preheater, Kiln and Cooler, (TPD)
Coal grinding, (TPH)
Clinker silo, (MT)
Gypsum storage, (MT)
Cement grinding, (TPH)
Cement storage, (MT)
Cement packing and dispatch, (TPH)
Truck Loading, (truck/day)
Backup Power Supply, (MW)

S. N. Sites Existing Area

Bigha Hectares
1. Plant Site 131.75
2. Mine Site
3. Spoil disposal yards close to the mine
4. Quarters for the plant operators and administrators
 5. Quarters for the mine operators and administrators
6. Repair and maintenance garage at the mine area
7. Workshop and inventories at the plant site

Available Auxiliary facilities within the industrial boundary:

 About a 45 Km long access road from Plant site to the mine

 Crushing plant, chute and loading yard close to the mine area
 Spoil disposal yards close to the mine
 Quarters for the plant operators and administrators
 Quarters for the mine operators and administrators
 Repair and maintenance garage at the mine area
 Workshop and inventories at the plant site
 Clay mine/quarry site
 Water supply to plant site
 Water supply to Mine site
 Electrical power supply to Plant
 Electrical power supply to Mine
 Backup/ Captive electrical power supply to plant
 Back up electrical power supply to mine

 Number of working days =

 Working Shift/day =

Equipment / machineries

A Raw Material Crushing Section

S. N. Particulars Unit Quantity / Number
1 Jaw Crusher with Hopper, Base Frame, Air Compressor etc. Set
with Full set
2 Hammer Crusher with Base Frame, Hopper etc with Full Set
Set
3 Belt Conveyors with all fittings Set
Sub Total
B Raw Material Mill-Grinding Section 
1 Raw Mill Full Unit with Hoppers Set
2 Belt Conveyors Set
3 Air Slide Set
4 Bucket Elevators Set
5 Screw Elevators Set
6 Raw Mill Separator, Bag Filter, Compressor, etc. Set Each
C Blending and Storage Section
1 Blending Silos with Compressors Set
2 Bucket Elevators Set
3 Get Value, Blending Blower, Gate valve separator, etc. Set Each
D Horizontal (Rotary) Kiln Section 
1 Horizontal Kiln with Burner, Motor Pump Set
2 Plate Conveyors Set
3 Rollers, Cooling bed, discharge hood, etc. Set
E Clinker Handling, Cement Mill and Packing Section
1 Table Feeders No.
2 Discharge Chutes No.
3 Gypsum Feeders No.
4 Belt Conveyor No.
5 Bucket Elevators (Chain) No.
6 Slide Gates No.
7 Cement Mill No.
8 Screw Conveyors No.
9 Cement Storage Silo with all fittings No.
10 Rotary Vane Feeder No.
11 Vibrating Screen (Close Type) No.
12 Packing Machine No.
13 Spillage Hopper No.
14 Spillage Screw Conveyor No.
15 Bag Handling Conveyor No.
F Coal, Clinker and Gypsum Crushing Unit
1 MS Feed Hoppers No.
2 Sliding Dampers No.
3 Feeders No.
4 Belt Conveyors No.
5 Coal Mill with lining including full accessories No.
6 Storage Tank with all findings No.
H Pollution Control Equipment
1 Bag Filters, Cyclone (for section A, B, C, E, F, G)    
2 Mechanical Dust Collectors (For Section D)    
3 Wet Scrubber (for Section D) Lot
4 Electrostatic Precipitator (for Section D) Lot
K Material Handling Equipment
1 Loaders No.
L Generators No.
M Mines Equipment 
1 Excavator No.
2 Loaders No.
3 Dump Truck No.
4 Rock Breaker Machine No.

Man Power Unit Approved

In-direct Nos
Direct Nos
Total Nos

Energy Total Source

Electricity, (KVA)
Diesel, (Kl)