BF - 2 - Part 2 - ENVIRONMENTAL IMPACT - 2010 - 04 - 15

CEMEN
Block 2 : Environment
2: Environmental Impact
Environmental Impact
CPDP - Buildin v.04.2010 2

Environmental Impacts
Work in four Groups and list all
Environmental Impacts on a Flip-
Chart; summarise and priorise!
Time: 10 min.

Environmental and CO2

A Green house

Temperature Change

Source of CO2 in Cement Plant
 Direct  Indirect
 Calcination  Power utilization
 Combustion

CO2 from fossil fuels
2,5 t
CO2
1 t coal
0,091 t
CO2
1 t SSW

Stakeholder Relation

Definition
Neighbours
Authorities /
Clients Government
Stakeholder
employees
Supplier
Banks

Environmental impact
2
of cement manufacturing

Impact of plant activities
DUST
Emissions
° SO2, NOx, CO, CO2
° DUST (trace elements, spec. Hg, Tl, Cd)
MEASUREMENT
VIBRATIONS
NOISE
DUST
Risk Material in the cement process
AVOID the use
Environment Legal approvals usually forbid the use of

radioactivity materials, hospital waste, PCB oils, etc.
2
CO2 exercise

Group exercise
The angry group of neighboors

Reference material
3
for the participant’s presentation

4 Air emissions

Impact of plant emission on local environment
EU Ambient air
directive 1999/30/EG
Emissio
Emissio Immissio
Immissio Limits for PM10,
nn nn NOx, SO2, Pb,
Benzol,
As, Cd, Ni and PAH
Plant permit Proposal 2003
EU - Waste incineration
directives for cement ind.
Specific laws in each
country
3
Limits
 limit = highest legally permitted value/concentration
 measurable distinction of acceptable/unacceptable concentrations
 control tool for legal stewardship
 most important indicator for the translation of ecological-political

decisions
 benchmark
3
EC-directive 76/2000 (waste inc.at cem. ind.)
valid 28.12.2005
< 40% haz. Waste > 40% haz. Waste
DA DA
in [mg/Nm³, dry, 10%O2]
Dust 30 10
SO2 + SO3 50+exempt. 50
NO + NO2 800 200/400
NH3 - -
C org 10+exempt. 10
CO -. 50
HCl 10 10
HF 1 1
av 0,5-8hrs.
Cd + Tl 0,05
Hg 0,05
Sb + As + Pb
+ Cr + Co +
0,5
Cu + Mn + Ni
+V
av 6-8hrs.
2,3,7,8-TCDD-
Äquivalent
0.1 [ng/Nm³]
3
What is dust?
 Fine particles in the air
 Commonly found as mineral particles, solid ashes, black smoke,

aerosols, …
 Particle size can be given from nanometre till millimetre
3
Sources of dust
 Fugitive sources  Point sources

 Blasting  Any dedusting installations (stack,
cooler, storage filters etc.)
 Material storages and handling by trucks,
loader, conveyors…
 Wind erosion
 Spillages in the raw mix and clinker
3
Impact on Health Environment
 > PM10 Visual impression and
 Eye irritation
 Difficulty in breathing aesthetics of the plant
 < PM10
Soil contamination e.g. by
 Chronic coughing heavy metals
 Heart and blood circulation
 Heart attack, cancer  Limitation of photo-synthesis
 Soil neutralisation
Hair
50µm
100 x
smaller
Sand
particle
90µm
3
Abatement technologies
 Fugitive sources
 Housekeeping
 Excellent maintenance
 Closed storages
 Paved roads & green areas
 Point sources
 Fabric filters and Electrostatic Precipitators
(ESPs)
 Lafarge objective
 < 50mg/Nm³ in 2010
 Best available technology (BAT)

 20 – 30 mg/Nm³
3
What is SO2?
 Colourless penetrative smelling gas, highly soluble in water
 Source
 Industry, power plants and traffic are the main sourced for SO 2
emissions
 Cement industry: SO2 from fuels are trapped in the preheater.
Almost all SO2 emissions are linked to pyrite in our raw materials
evaporated at the top of the preheater
3
Impact on health and environment
 Long term exposure ( max. 40µg/m³) causes

adverse health effects
 Eyes and respiration problems
 On environmental side: acid rain (SO2 is

transformed with moisture to sulphuric acid).
3
 Process optimisation
 Raw mill online operation
 Selective mining
 Absorbent addition
 Wet scrubber
Best available technology (BAT)

200 – 400 mg/Nm³
3
What is NOx?
 NOx is the common term for NO and NO2
 High concentration NO2: red or orange/brown gas, characteristic sharp,

biting odour
 Source
 Traffic and industry
 In the kiln NOx is formed at high temperatures (thermal NOx) and at
lower temperature from the nitrogen in the fuel (fuel NOx)
rner
[mg/m³]
bu
1600 Main
1400
Calciner
1200
1000
800
600
Fuel NOx Thermal NOx
400
200
Prompt NOx
3
0
1027 1227 1427 1627 1827 2027[°C]

 Long-term exposure to concentration levels above 40µg/m³ causes

adverse health effects
 On environment side NOx causes

 Acid rains
 Ground level ozone formation
 Smog formation and contributes to
 Greenhouse effect
3
 Process optimization
 Flame cooling
 Alternative fuels
 Staged combustion
 Selective Non Catalytic

Reduction (SNCR)
 Selective Catalytic Reduction

(SCR)
Best available technology (BAT)
Staged combustion and SNCR 200 – 500 mg/Nm³
SCR (split view) 100 – 200
mg/Nm³
3
What is Hg?
 Mercury is a volatile metal to be found in different
compounds
 It is emitted from combustion process and accumulates in

soils and water
 Source
 Via raw materials and fuels
 It is evaporated in our pyro-process than partly trapped in
the cooler areas as raw mill and filter. Part of the mercury is
released with the kiln exit gas
3
Impact on health
 Mercury emitted by combustion process is transported globally.

Transferred to methyl-mercury by micro organism bio
accumulates especially in fish.
 It adversely affecting humans and wildlife as impacting the

genome, nervous system and brain
3
 Proper temperature control of kiln exit gas keep less than 140°C
 Removal of part of the filter dust
 Control of mercury input to the kiln system
Today no common regulation
EU (linked with waste incineration) < 0.05mg/Nm³ at 10% O2
3
What are Dioxins and Furans?
 Organic compounds having 2 benzene rings with 4 - 8

chlorine atoms
 17 out of 210 types (congeners) are considered as toxic
 Dioxins have been accumulated over decades in our

environments (soils, water, air)
 Source
 Municipal waste incineration
 Home and commercial heating
 Sinter and metal smelting plants
 Back yard burning
 Natural processes as fire
3
Impact on health
 Today studies are still on-going, so far all the limits are based on
animal test
 The World Health Organization set the Tolerable Daily Intake in

1998 at a range of 1 to 4 picograms/kg body weight (1 pg = 10-12
grams)
 Almost all dioxins intake (95%) comes from our daily food
 Uncertainty of the risk for particular cancer and immune system
3
 Proper temperature control of kiln exit and bypass gas keep less
then 200°C
 Stable combustion process
 No organic materials feed as part of the raw mix
 Regular fuel and AF feeding
EU regulation:
< 0.1 ng TEQ[1]/Nm³ at 10% O2

[1] Toxic Equivalent Quantity
3
What are heavy metals?
 Based on their volatilisation properties and toxicology, they can be

classified as followed:
 high volatile elements: Hg gaseous phase > 90 °C
 volatile elements: Tl gaseous phase 450 - 550 °C
 low volatile elements: Cd, Pb gaseous phase 700 - 900 °C
 non-volatile elements: As, Cr, Ni, V, Zn, Co, Cu, Mn --> stay in the
solid/liquid phase
3
 This elements have impact on living being (e.g. essential in small

amounts, inhibitors/catalysts in biochemical reactions), up to toxic
behaviour when in excess.
 Toxic, carcinogenic (lunge, skin, etc.)
 Accumulation in the food chain
3
 Optimization of trapping: low exit temperature, good de-dusting (most

of the emitted heavy metals are particle trapped), good dust
management
 Use only acceptable input materials (secondary materials: secondary

fuel, secondary raw material, secondary cement additives)
3
What is Odour?
 Odour can be percept from pleasant till nauseating. Depending on

the intensity and frequency odour is often seen as a typical
nuisance.
 As typical chemical compounds mercaptans, Ammoniac, SO2, PAH,

H2S can be given
 Sources
 Chemical and petrochemical industry, agriculture and animal farms
 In cement industry incomplete combustion, aerosols (-SO2) and
storage of alternative fuels and materials may form odour
3
 The sense for odour is one of our most sensitive once. As the
sense of hearing humans can not escape. The associated health
impact are stress and psychosomatic diseases
3
 Process control
 Proper stack height
 Bio-filters
 Thermal treatments of exit gas
In some courtiers guidelines for odour immissions

exists. The reasonability is scaled by the hours of
odour per year.
3
Noise?
 Unwanted or damaging sound, that is, sound which interferes

with what people are trying to do, or sound which has an
adverse effect on health or safety
 Sources
 Quarry: blasting, drilling machine, loaders, trucks
 Raw material preparation: crushing, sieving, milling
 Burning: shell cooling, kiln drive, stack
 Conveying: belt conveyors, bucket elevators
 Others: traffic on plant area
3
 Damage of the ear lamellas, hearing loss
 Stress and psychosomatic diseases
 Emission (1 m distance): Limit defined according to the
national work place safety regulations
 Immission (influence of “receptors”): Limit defined
according to the „sensitivity“ of the area
3
Typical quantities

 Personal safety equipment

 ear plugs
 head phones
 Organizational measures
 Reduction of sound formation and
transmission
 re-scheduling
 maintaining (lubricate,
cleaning,...)
 closing of doors, windows
 Technical methods (silencer, in-

housing, flexible pipes, sound
shield, sound insulation, double
glass etc.)
3

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CEMEN

CPDP - Buildin v.04.2010 2

CPDP - Buildin v.04.2010 3

CPDP - Buildin v.04.2010 4

CPDP - Buildin v.04.2010 5

CPDP - Buildin v.04.2010 7

CPDP - Buildin v.04.2010 8

CPDP - Buildin v.04.2010 9

CPDP - Buildin v.04.2010 1

CPDP - Buildin v.04.2010 1

CPDP - Buildin v.04.2010 1

Environment Legal approvals usually forbid the use of

CPDP - Buildin v.04.2010 1

CPDP - Buildin v.04.2010 1

CPDP - Buildin v.04.2010 1

CPDP - Buildin v.04.2010 1

 limit = highest legally permitted value/concentration

 measurable distinction of acceptable/unacceptable concentrations

 control tool for legal stewardship

 most important indicator for the translation of ecological-political

< 40% haz. Waste > 40% haz. Waste

 Commonly found as mineral particles, solid ashes, black smoke,

 Particle size can be given from nanometre till millimetre

 Fugitive sources  Point sources

 Best available technology (BAT)

 Colourless penetrative smelling gas, highly soluble in water

 Long term exposure ( max. 40µg/m³) causes

 Eyes and respiration problems

 On environmental side: acid rain (SO2 is

 Raw mill online operation

Best available technology (BAT)

 High concentration NO2: red or orange/brown gas, characteristic sharp,

CPDP - Buildin v.04.2010 3

 Long-term exposure to concentration levels above 40µg/m³ causes

 On environment side NOx causes

 Selective Non Catalytic

 Selective Catalytic Reduction

 It is emitted from combustion process and accumulates in

 Mercury emitted by combustion process is transported globally.

 It adversely affecting humans and wildlife as impacting the

 Removal of part of the filter dust

 Control of mercury input to the kiln system

Today no common regulation

EU (linked with waste incineration) < 0.05mg/Nm³ at 10% O2

 Organic compounds having 2 benzene rings with 4 - 8

 17 out of 210 types (congeners) are considered as toxic

 Dioxins have been accumulated over decades in our

 The World Health Organization set the Tolerable Daily Intake in

 Uncertainty of the risk for particular cancer and immune system

 Stable combustion process

 No organic materials feed as part of the raw mix

 Regular fuel and AF feeding

< 0.1 ng TEQ[1]/Nm³ at 10% O2

 Based on their volatilisation properties and toxicology, they can be

 This elements have impact on living being (e.g. essential in small

 Toxic, carcinogenic (lunge, skin, etc.)

 Accumulation in the food chain

 Optimization of trapping: low exit temperature, good de-dusting (most

 Use only acceptable input materials (secondary materials: secondary

 Odour can be percept from pleasant till nauseating. Depending on

 As typical chemical compounds mercaptans, Ammoniac, SO2, PAH,

 Proper stack height

 Thermal treatments of exit gas