Handbook for Designing Green Cement Plants (2nd edition) by SP Deolakar
The First edition of this book was first published in 2008 (reprint, 2009) under the name: “Handbook for Designing Cement Plants” by the same author.
Over the last decade, since the publication of first the edition, Indian cement industry has seen major shifts such as “Installing higher capacity (~10000 tpd) plants increased usage of pet coke as main fuel (instead of coal) with or without alternate fuels (industrial and bio wastes), technology innovations in areas of compact plant layouts, pyro-processing, cement grinding, waste heat recovery power generation, clinker coolers, blended cements, renewal energy (solar energy) utilisation compact and green building design concepts for plant/non-plant buildings”.
It has necessitated the designers of cement plants to develop the plant designs to these new trends in Industry. Taking into this account, the author thought it is the right time to update the earlier edition (which was a comprehensive guide/source covering, process, technologies, concepts of plant design and projects planning, design/norms/standards etc.,) taking into account the major changes taken in the industry for the reference and use by plant designers and also operating teams.
The second edition, which aptly titled as “Handbook for Designing Green Cements Plants”, addresses the challenges a cement designer faces for developing technical concepts/designs by providing relevant guidelines focussing on installing Higher capacity cement plant up to 12,000 TPD kin systems, 100 per cent pet coke utilisation and the sustained development initiatives taken by industry.
This book can be looked as a major source for guidelines for the basic design, Selection criteria for various options available for cement plant designers to conceptualise and finalise a most suitable technology and optimal engineering solution for setting up modern cement, large capacity (~12000 t) with various sustainable development technologies in place.
The author has also incorporated few webpages developed by him, which can be referred/used for any preliminary calculations for design AF firing systems, to arrive at potential waste heat available for power generation at different preheater/cooler exit gas temperatures. The web pages also cover table for typical storages in a plant for 10,000 plant, which can serve as basis for preparation of basic design package and conceptual plant layouts. Nomo graphs are also added in the web pages along with calculation sheets and tables for quick reference and use.
The basic design safety norms/standards, which are included in this edition provides as ready reckoner for reference to plant engineers (maintenance/process/safety) for assessing the design adequacy of existing equipment/plant areas for implementing immediate remedial measures (e.g. Augmenting or replacement of structural supports, working platforms, walkways, ladders etc.) to prevent accidents.
All the new sections covering various developments taken place over last decade are well integrated and fully compliments the other design criteria and guidelines of the first edition. Retention of the chapters of old process technologies such as eet process and semi dry process, planetary and rotary coolers, makes this edition as a comprehensive cement design encyclopaedia, which covers the entire gamut of technology and design development aspects of the cement manufacture over a period of more than 100 years.
As in the case of the first edition, all the plant design guidelines have been developed by author based on his extensive, long proven experience of cement Plant designs for various capacities from concept to commissioning and in depth know of equipment
designs of original equipment machinery suppliers, such as FL Smidth,, KHD, thyssenkrupp, Fives, IKN, Loesche, Pfieffer, Claudius Peters, Siemens, Hazemag etc. The author has also taken into consideration proven standards/norms/practices followed by the cement industry and engineering consultants (Holtec) of cement plants.
In the section, “Sources”, the author has listed details of sources, from where the specific inputs for preparing the tables and figures are sources. This will enable the reader to get further detailed information, while referring any table or figure, as required from the referred company/company.
To summarise, this book is a compendium of cement technology development and plant designs till year2020, which takes into account all concepts for pl ants designs, including the trends observed in the cement manufacturing in decade 2010-20. The book can be considered as a source of guidelines/data for entry level/experienced technical teams of cement plant and designers for basic sizing of all equipment, storages, section wise selection of suitable technologies, preparation of flowsheets, conceptual layout and land/utility requirements.
The book also provides guidelines lines to arrive at the expects levels usage of energy, raw materials, fuels, additives, correctives and all utilities to enable for preparing the initial production cost and capital investment to arrive at pre-investment feasibility of a greenfield/brownfield expansion and also for plant upgradation for modernisation/capacity balancing.
The basic sizing concepts of all main and auxiliary’s/utility equipment and basic calculation worksheets (editable) given in webpages makes this editions as quick reference book for revalidation of plant/equipment designs of any operate plants for implementation of immediate/short term improvement through modifications for safe and sustained operations. To conclude, this book is recommended as must buy for:
All cement manufacturing units for as reference book for in-house cement plant designers and operation and maintenance teams
Engineering consulting companies
Libraries of engineering colleges/institutes, offering courses in cement technology/plant designs/chemical and mechanical engineering.
ABOUT THE REVIEWER:
Satyamurthy V Yenamandra holds a masters degree in chemical engineering from Indian Institute of Science, Bengaluru. His area of specialisation is process and project engineering. He is consultant for cement and mineral industries with over 35 years with working experience in ACC and Reliance Cement in functional areas of Process & Production, Project Engineering.