Humboldt Wedag India has been at the forefront of technological developments taking place in the cement industry of Indian subcontinent. ASHOK DEMBLA and BALESH SINGH open up a window for us on various aspects of developments.
The Indian cement industry continues to be second largest producer of this commodity in the world. This sector is expected to continue its fast-paced growth and attain installed capacity of 850 million tonnes (MT) per annum by 2030 and 1,350 MT by 2050. The industry has made tremendous strides in technology assimilation and upgradation.
Single production lines of over 12,000 TPD (tonnes per day) with multi-stream pre-heaters and calciner, thermal energy consumption of 685 Kcal/Kg clinker, or electrical energy consumption of 70 kWh/ton of cement were unimaginable two decades ago when these figures hovered at around 850 Kcal/Kg clinker and 110 KwH /ton of Cement respectively.
Some of the important plants supplied
by Humboldt Wedag India which are achieving results comparable to best figures in the Industry and sometimes best in the Industry are;
I)First 4-stage Preheater Technology - The first plants with 300 tpd capacity and 600 tpd capacity, came in from Humboldt in Andhra Pradesh at the end of the 1960's.
II)Roller Press Technology - First plants again came from Humboldt in Diamond Cement, Rajashree Cement and Vikram Cement, in the year 1986-87 which have now been upgraded.
III)V Separator Technology -This technology came as a boon for energy-savings and reliability for semi-finish grinding technology in the year 1995.
IV) Alternative Fuels - Extended PYROCLON?and KHD's Combustion Chamber came as excellent technology to use pet coke, city waste and other waste derived fuels.
V)5 & 6 Stage Preheater Technology - The first of these type of plants came on line in India e.g. Diamond Cement, Vikram Cement and Rajashree Cement in order to reduce thermal energy consumption.
VI)Latest Generation Grate Coolers - The KHD Grate Cooler got its start at Vikram Cement. Later came the PYROSTEP? Cooler and now PYROFLOOR? cooler. In addition there has been many innovations in Burner Technology, where the original KHD design has become the world standard.
Energy, Efficiency and Environment
KHD-Humboldt Wedag buzz word for Technology is Energy, Efficiency and Environment. Energy: The COMFLEX? grinding system consumes less energy compared to other process circuits.. More and more customers began to use this roller press-based system in the finish-grinding mode for Slag, Limestone, and clinker.
Potential in saving with selection of KHD Roller Press circuit than the VRMs:
Potential in saving with Selection of KHD Pyro process Technology.
It is proven that KHD COMFLEX? circuits consist of Roller Press gives more efficiency than other Grinding Systems. Under normal operation conditions our STUDDED roller surfaces are maintenance free for more than years
Status of Emissions and CEMS - present Status and Challenges
Emissions are released from cement kilns, coming from the physical and chemical reactions of the raw materials and from the combustion of fuels. At present norms exist for dust, TOC, HCl, HF, SOx, NOx Hg, Heavy Metals and Dioxin in India, which are comparable or better as compared to China, Indonesia and Philippines. Ref. Table-2, shows the comparison; Emission Standards at different countries. In India the CEMS system started approximately 5-7 years ago for monitoring particulate emissions and subsequently NOx. Policy guidelines were also formulated and released on 10th May 2016 for emission control by the Ministry of Environment. A brief status as compared to China, Indonesia and Philippines is given in table in next page; As mentioned above the Indian Government (Ministry of environment, forest and climate change) released a new notification on 10th May 2016 for control of emissions released from cement industry.
The Ministry of Environment addressed Emission Limits for old plants as mentioned in table above. Ref. Table1,3
Status of Alternate Fuels and Thermal Substitution Rate
KHD Humboldt Wedag has expertise in using alternative fuels either in the calciner or in the kiln. KHD supply award wining Combustion chamber for dry municipal waste and other difficult fuels In fact Humboldt Wedag India supplied Vikram Cement a handling and firing system in order to use of Jaipur City Waste. We also delivered a similar system to Jaypee Cement to use Chandigarh City Waste.
With the unlimited growth potential in India, Technological innovations leading to low thermal and electrical energy consumption become the center point of focus. In parallel there is need of environmental friendly technologies for sustainability. Of course everything comes with a price but advancement and success lies in the technological innovations which are effective and cost competitive also. Continual development based on the need from the industry are the foray in which we as cement technology suppliers have to think ahead.
About the authors:
Ashok Dembla, Managing Director, Humboldt Wedag India.
Balesh Singh, Process Head, Humboldt Wedag India.