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Cement Plant
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Second Edition

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Contents

Introduction 6
1. Environmental context and sustainability challenges 8
n The way forward: extended co-processing to produce alternative binders with a zero environmental footprint........... 10
Jean-Pierre Degré, Cementis, Switzerland
n Sustainability and cement – addressing evolving challenges.............................................................................................................. 16
Philippe Fonta, Cement Sustainability Initiative (CSI), Switzerland
n CO2 reduction: principles of the EU Emissions Trading System........................................................................................................... 20
Tino Villano, Lafarge Zement Wössingen GmbH,Germany
n Sustainability in the cement sector............................................................................................................................................................... 22
Marco Goisis, Italcementi, Italy
n Proposed industrial coal reduction regulation for Ontario, Canada ................................................................................................. 25
Kåre Helge Karstensen, Foundation for Scientific and Industrial Research (SINTEF), Norway
n Our contribution to the societal challenges of the future...................................................................................................................... 27
Cembureau,Europe
n Tighter regulations for emissions................................................................................................................................................................... 29
Phil Kerton, CPK Consultancy, UK

2. Quarry operations and ecosystems 32

n The Quarry Life Award: research and dialogue to promote biodiversity conservation.............................................................. 34
HeidelbergCement AG, Germany
n Quarry restoration leader in Medley, Florida............................................................................................................................................. 38
Audrey Becnel and Muhammad Khan, Titan Florida LLC, USA
n Spain: water network improvements at Toral Los Vados...................................................................................................................... 40
Ana Gonzalez de Aledo and Maria Luisa Bueno, Cementos Cosmos (Votorantim Group), Spain
n Conserving nature’s foundations: biodiversity management plan guidance................................................................................ 42
Philippe Fonta, Cement Sustainability Initiative, Switzerland

3. CO2 emissions and energy efficiency 44

n Achieving the best energy consumption: the key drivers and some practical case studies...................................................... 46
Lawrie Evans, EmCem Ltd, UK
n ACK’s waste heat recovery power generation system for cement plants........................................................................................ 50
Chongren Zhong, Anhui Conch Kawasaki Engineering Co Ltd (ACK), China
n Waste heat recovery in India’s cement industry....................................................................................................................................... 54
R Nand Kumar, ACC Ltd,India
n Energy conservation in the cement plants of Japan............................................................................................................................... 60
Japan Cement Association, Japan
n Maintaining the EU ETS in practice................................................................................................................................................................ 62
Arthur Harrisson, Arthur M Harrisson Ltd,UK
n Reduction of CO2 emissions: a winning strategy....................................................................................................................................... 65
Cementos Argos SA, Colombia
n CO2 mitigation from the use of alternative fuels....................................................................................................................................... 68
Enrique De Hoyos Guajardo, Cemex,Mexico
n The potential for energy savings from electrical power audits........................................................................................................... 71
Lawrie Evans, EmCem Ltd, UK
n Energy conservation: E=MC2 -.......................................................................................................................................................................... 75
St Marys Cement Inc, Canada

4. Strategies and systems for using AFRs 78

n Developing an AF road map.............................................................................................................................................................................. 80
Brian McGrath, ResourceCo,Australia
n The creation and use of alternative fuels around the world................................................................................................................. 82
David Hooper, Global AFR Ltd, Hong Kong
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n Success in growing a waste fuel business.................................................................................................................................................... 85

Geocycle, France and Belgium
n Alternative fuels and raw materials: a win-win solution for the Indian cement industry.......................................................... 88
Somnath Bhattacharjee and Ritu Bharadwaj, Institute for Industrial Productivity, India
n Key considerations in the introduction of alternative fuels and raw materials............................................................................. 90
Pavel Cech, Lafarge Asia Sdn Bhd, Malyasia
n Permitting requirements for co-processing of wastes in China and India....................................................................................... 92
Kåre Helge Karstensen, Foundation for Scientific and Industrial Research (SINTEF), Norway
and Yan Da-Hai , Chinese Research Academy of Environmental Sciences, China
n Secondary fuel preparation............................................................................................................................................................................. 97
Boris Sassenrath and Tim Hamer, VecoPlan AG,Germany

5. Alternative fuels case studies 100

n Making a green commitment......................................................................................................................................................................... 102
Lucky Cement Ltd, Pakistan
n Experiences with wastes as alternative fuels and materials.............................................................................................................. 104
Tino Villano, Lafarge Zement GmbH, Germany
n Using FIRSU as an alternative fuel................................................................................................................................................................ 107
Enrique De Hoyos Guajardo, Cemex México,Mexico
n Environmental implications of introducing solid fuels into the energy mix of the Egyptian cement industry................ 110
Fernas El-Hakim, Arabian Cement Company, Egypt
n The use of biomass at Votorantim Cimentos’ Nobres plant, Brazil.................................................................................................. 112
Lívia Ballot de Miranda and Naiara Meireles de Souza, Votorantim Cimentos,Brazil
n Hon Chong cement plant in Vietnam – The “Best Sustainable Performers 2009-2013”........................................................... 114
Luong Thi Phuong Lan, Holcim Vietnam, Vietnam

6. Emission monitoring and abatement 116

n Using advanced modelling tools to reduce NOx and CO emissions from cement kilns............................................................. 118
Tahir Abbas and Michalis Akritopoulos, Cinar Ltd, UK
n The filter bag as a key component for reducing emissions and costs.............................................................................................. 122
Dr Georg Rathwallner, Evonik Fibres GmbH, Austria
n Mercury: addressing ever-tightening regulations.................................................................................................................................. 127
John Kline and Charles Kline, Kline Consulting LLC, USA
n NOx reduction – when SNCR is not enough............................................................................................................................................... 131
John Kline, Kline Consulting LLC, USA
n Experiences with the new regenerative thermal oxidation (RTO) system at the Wopfing cement plant, Austria........... 134
Gerhard Philipp, Wopfinger Baustoffindustrie GmbH, Austria
n NOx emission reduction in Vidal Ramos Plant.......................................................................................................................................... 137
Mario Henrique Interlenghi and Carlos Roberto Moreira da Cunha, Votorantim Cimentos,Brazil
n Using high-sulphur raw materials and fuels in a cement plant – a case study............................................................................. 140
Prakash Singh, P Chandrasekhar and L Rajasekar, UltraTech Cement Ltd, India
n Formation and control of dioxins in modern preheater/precalciner dry -process kilns........................................................... 143
Kåre Helge Karstensen, Foundation for Scientific and Industrial Research (SINTEF), Norway
n More than meets the eye: emissions (bio-)monitoring, dispersion and risk analysis as innovative tools.......................... 146
Maria João Botelho, Secil and José Manuel Palma-Oliveira, University of Lisbon/Secil, Portugal

7. Cement milling and products 150

n Reducing CO2 emissions through cement grinding optimisation.................................................................................................... 152
Mike Sumner, Keith Marsay, Ricardo Stoppa and Josephine Cheung, Grace Construction Products, UK
n Production and use of cements with artificial pozzolan...................................................................................................................... 156
Silvia Regina Soares S Vieira and José Eustáquio Machado, Votorantim Cimentos, Brazil
n LC3 – Limestone calcined clay cement....................................................................................................................................................... 159
Karen L Scrivener, Jérôme D Laffely and Aurélie Favier, Ecole Polytechnique Fédérale de Lausanne, Switzerland
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