Sustainable Production in the cement manufacturing industry

1. Assignment - 1
Submitted to: Ms. Aarti Solanki Submitted by: Ajay Gayakwar
Radhe Kumar
Bittu Singh
Shubham Singh

2. Manufacturing Process of Cement Industry
• Basic ingredient of construction and the most widely used construction
material.
• Very critical ingredient, because only cement has the ability of enhancing
viscosity of concrete which in returns provides the better locking of sand
and gravels together in a concrete mix.
• Production of cement completes after passing of raw materials from the
following six phases.

3. • These are:

4. PHASE – 1 (Raw material extraction)
• Cement uses raw materials (limestone, clay and
sand) that cover calcium, silicon, iron and
aluminum.
• Limestone - Calcium. (Combines with much
smaller proportions of sand and clay.)
• Sand & clay fulfill the need of silicon, iron and
aluminum.
• Generally cement plants are fixed where the
quarry of limestone is near bye.
• Saves the extra fuel cost and makes cement
somehow economical.
• Raw materials are extracted from the quarry and
by means of conveyor belt material is transported
to the cement plant.
Fig: Extraction of raw material and crushing of
material

5. PHASE – II (Grinding, Proportioning and Blending)
• The raw materials from quarry are now routed in plant laboratory
where, they are analyzed and proper proportioning of limestone and
clay are making possible before the beginning of grinding.
• Generally, limestone is 80% and remaining 20% is the clay.
• Now cement plant grind the raw mix with the help of heavy wheel
type rollers and rotating table.
• Rotating table rotates continuously under the roller and brought the
raw mix in contact with the roller.
• Roller crushes the material to a fine powder and finishes the job

6. PHASE – III (Pre-Heater Phase)
• After final grinding, the material is ready to
face the pre-heating chamber.
• Pre-heater chamber consists of series of
vertical cyclone from where the raw material
passes before facing the kiln.
• Pre-heating chamber utilizes the emitting
hot gases from kiln. Pre-heating of the
material saves the energy and make plant
environmental friendly.
Fig: Preheating of raw material
Vertical Cyclone

7. PHASE – IV (Kiln Phase)
• Kiln is a huge rotating furnace also called as the
heart of cement making process.
• Here, raw material is heated up to 1450 ⁰C.
• This temperature begins a chemical reaction so
called de-carbonation.
• In this reaction material (like limestone)
releases the carbon dioxide. High temperature
of kiln makes slurry of the material.
• The series of chemical reactions between
calcium and silicon dioxide compounds form
the primary constituents of cement i.e.,
calcium silicate.
• Kiln is heating up from the exit side by the use
of natural gas and coal.
• When material reaches the lower part of the
kiln, it forms the shape of clinker. Fig: Rotary Klin

8. • After passing out from the kiln, clinkers are cooled by
mean of forced air.
• Clinker released the absorb heat and cool down to
lower temperature.
• Released heat by clinker is reused by re circulating it
back to the kiln. This too saves energy.
• Final process of 5th phase is the final grinding.
• There is a horizontal filled with steel balls. Clinker reach
in this rotating drum after cooling. Here, steel balls
tumble and crush the clinker into a very fine powder.
• This fine powder is considered as Cement. During
grinding gypsum is also added to the mix in small
percentage that controls the setting of cement.
PHASE – V (Cooling and Final Grinding)
Fig: Clinker cooling
Fig: Rotating ball mill

9. PHASE – VI (Packing and Shipping)
• Material is directly conveyed to the silos
(silos are the large storage tanks of
cement) from the grinding mills. Further,
it is packed to about 20-40 kg bags.
• Only a small percent of cement is packed
in the bags only for those customers
whom need is very small.
• The remaining cement is shipped in bulk
quantities by mean of trucks, rails or
ships.
Fig: Transportation of cement

10. Cement Industry : Environmental Problems
 Building industry is one of the leaders in deterioration of environment by depleting resources and
consuming energy or creation of waste.
 A considerable amount of emissions of greenhouse and acidifying gasses has the origin in building
industry.
 The cement industry is an energy enormous intensive and products many emissions, odors and noise.
 The emissions from cement plants which cause greatest concern and which need to be dealt with are
dust, carbon dioxide CO2, nitrogen oxides (NOx) and sulphur dioxide (SO2).
 Cement production also results in the release of a significant amount of solid waste materials and
gaseous emissions.
 The manufacturing process is very complex, involving a large number of materials (with varying
material properties), pyro-processing techniques (e.g., wet and dry kiln, preheating, re-circulation) and
fuel sources (e.g., coal, fuel oil, natural gas, tires, hazardous wastes, petroleum coke)
 The cement manufacturing industry has always been under close scrutiny because of the large
volumes of CO2 emitted. Actually this industrial sector is thought to represent 5–7% of the total CO2
anthropogenic emissions.

11. Cement Industry : Environmental Impacts
 The main environmental issues associated with cement production are consumption of raw
materials and energy use as well as emissions to air.
 Waste water discharge is usually limited to surface run off and cooling water only and causes
no substantial contribution to water pollution.
 The storage and handling of fuels is a potential source of contamination of soil and
groundwater. Additionally, the environment can be affected by noise and odors.
 The key polluting substances emitted to air are dust, carbon oxides nitrogen oxides (NOx) and
sulphur dioxide (SO2).
 Carbon oxides, polychlorinated di-benzo-p-dioxins and dibenzofurans, total organic carbon,
metals, hydrogen chloride and hydrogen fluoride are emitted as well.
 The type and quantity of air pollution depend on different parameters, e.g. inputs (the raw
materials and fuels used) and the type of process applied.

12. Cement Industry : Energy Consumption
 The cement production needs the very high amount of energy.
 Energy cost represents 40% of total production costs involved in
producing of 1 ton of cement.
 Thermal energy demand (fuel) and electrical energy demand are the most
important.
 Specific energy consumption depends on size and plant design, raw
materials properties and its moisture, specific caloric values of fuel,
throughput of kiln, type of clinker and many other factors.
 Thermal energy demand is in range of 3000 - 6500 MJ per 1 tone of
clinker, the electricity demand range from 90 to 150 kWh per 1 ton of
cement

13. Cement Industry : Water Consumption
 Water is used at a number of stages during the production process.
 Water is used for the preparation of raw material, in clinker burning and cooling processes,
such as the cooling of gases, as well as in the technological process for slurry production.
 In the semi-dry process, water is used for pelletizing the dry raw meal.
 Plants using the wet process use more water (per ton of cement produced) in preparing the
kiln feed slurry and a typical water consumption of 100 – 600 liters water per ton clinker is
reported.
 Furthermore, for special applications, water is used for clinker cooling and a water usage of
around 5 m3/hour has been reported.
 In most cases, the water consumed is not potable water.

14. Cement Industry : Air Emissions
 Emissions to air and noise emissions arise during the manufacture of cement.
 With regard to the use of waste, odors can arise, e.g. from the storage and handling of waste.
 In this section, ranges of air pollutant emissions are presented for the process of cement
production, including other process steps, such as the storage and handling of, e.g. raw materials,
additives and fuels including waste fuels.
 The Integrated Pollution Prevention & Control (IPPC) Directive includes a general indicative list of
the main air-polluting substances to be taken into account, if they are relevant for fixing emission
limit values. Relevant to cement manufacture including the use of waste are:
• oxides of nitrogen (NOx) and other nitrogen compounds,
• sulphur dioxide (SO2) and other sulphur compounds dust,
• total organic compounds (TOC) including volatile organic compounds (VOC),
• polychlorinated di-benzo-p-dioxins and dibenzofurans (PCDDs and PCDFs),
• metals and their compounds,
• hydrogen fluoride (HF),
• hydrogen chloride (HCl),
• Carbon monoxide (CO).

15. Cement Industry : Noise Pollution
 Noise emissions occur throughout the whole cement manufacturing process from
preparing and processing raw materials, from the clinker burning and cement
production process, from material storage as well as from the dispatch and shipping of
the final products.
 The heavy machinery and large fans used in various parts of the cement manufacturing
process can give rise to noise and/or vibration emissions, particularly from:
• chutes and hoppers;
• any operations involving fracture, crushing, milling and screening of raw material, fuels,
clinker and cement;
• exhaust fans;
• blowers;
• duct vibration.

16. Sustainability a way of life
Ambuja cement continues to set industry benchmarks in tackling carbon emissions and
creating sustainable solutions.
Ambuja Cement is committed to group-level targets to mitigate the effects of climate
change.
The company has also taken the lead in encouraging the construction sector to formulate
sustainable development strategies in India.
Sustainability our mission
• Adopt eco-friendly technology in plant and mining operations
• Ensure zero harm to employee visitors and contractors
• Minimise green house emissions
• Use resources judiciously and substitute them with Eco-friendly alternatively
• Enhance quality of life of local communities

17. Numbers speak
• CO2 levels in 2016 further reduced by 29.7% from 1990, as compared to 28.3% for
2014
• In 2016, the specific net CO2 per tone of cementitious products reduced to 543kg
• Direct Absolute Gross CO2 emissions (including CO2 from onsite power generation)
reduced by 3.2% from 2014 levels
• Over five times water positive in 2016
• Plastic positive
• 6.5 % of energy produced through renewable energy sources

18. Stakeholder engagement
The company has engaged with varied groups of stakeholders at different levels to understand their
expectations and to make them partners
Stakeholder Modes of Engagement Frequency
Shareholders and investors Annual General Meeting
Investor Grievance Cell
Board meetings/ communications
Annual report
Annual
Dealers and suppliers Annual Channel satisfaction
survey general meeting
Grihalakshmi conference
Annual meet
Marketing meets
Biannual
Annual
Continuous
Customers Technical services team
Camps, workshops, seminars, site visits, etc.
Across the year
Employees Employee engagement survey
Department specific meets and newsletters
Magazines – I CAN, I SIGHT
Town hall, functions and programmes
Biannual
Continuous
Quarterly/monthly
Continuous
Community and NGOs Ambuja Cement Foundation
Community advisory panel
Site-specific impact assessment
Continuous
Government and regulatory authorities Compliance to laws
Representations to proposed legislations
Continuous
Media Press briefing and invitation to events On an as-needed basis
Construction professionals Foundations: Ambuja Knowledge Initiative
Ambuja Technical Literature Series
Continuous
Industry associations Committee meetings, policy papers, telecons,
delegation, etc.
On an as-needed basis

19. Environment and energy
It’s stands way ahead of its peers for its
• Management of natural resources
• Energy management
• Carbon emissions reduction
• Conservation of water resources and biodiversity
• And management of waste
It is provides sustainable waste management solutions to industries, municipalities
and the agriculture sector under the brand name, Geocycle India.
Ambuja cement Co-processed about 2.6 lakh tones of alternative fuels in 2016,
achieving a thermal substitute rate of 5.14% compared to 3.95% in 2014.

20. Reducing carbon emission
• Co-processing of industrial and other wastes at the company’s kilns as alternative
fuels has reduced emission of greenhouse gases in recent years. For captive
power plants, the company focuses on fuel mix optimization with alternative/low
cost fuels, thermal efficiency and station heat rate (SHR) improvement, reduction
in auxiliary electrical energy consumption and capacity utilization to reduce its
carbon footprint.
• The company’s waste heat recovery project, which started operation in 2015 at
Rabriyawas, is registered under the Clean Development Mechanism of United
Nations Framework Convention on Climate Change to accrue 35,000 Certified
Emissions Reductions (CERs) per year for the next 10 years.

21. Corporate social responsibility
• ACF aims to ‘Energies, Involve and Enable Communities to Realise their Potential’
through its initiatives.
• The foundation undertakes projects and schemes to promote the social and
economic development of communities
• These people by working with the beneficiaries, NGOs and the government.
• ACF is functional across 12 states covering 22 locations in India and has succeeded in
bringing about change in the lives of 1.5 million people.
• ACF’s focus areas include water resource management, agro-based livelihood, health
care, education, women's empowerment, infrastructure, disaster relief, energy
conservation and wildlife protection.

22. Health and Safety
Ambuja Cement is committed to achieving Zero Harm at its workplace. Strong
emphasis on improving health and safety (H&S) parameters has helped the company
substantially reduce the number of onsite injuries
Four pronged strategy for health and safety
• Reduce risks through people engagement
• Capability building
• Advanced engineering solutions for key risk areas
• Strengthening H&S management systems and processes

23. Sustainable Development Ambition 2030
The Sustainable Development Ambition 2030 provides a broad framework for the company’s
strategies to meet the challenges in four broad thematic areas:
• Climate: Reduce net specific CO₂ emission by
• Circular Economy:
Vs 2020 2030
1990 33% 40%
2015 5% 12%
2020 2030
Tonnes of waste resource/year Use: 9 Million Use: 13 Million

24. • Water & Nature:
• People & Communities:
2020 2030
Reduce fresh water withdrawal in cement
operation by 10%
Reduce fresh water withdrawal in cement
operation by 15%
Improve water balance index to 5 Improve water balance index to 6
Implement biodiversity indicator and reporting
system at all queries
Show positive change for biodiversity
2020 2030
Have zero onsite fatality Have zero onsite fatality
Reduce LTI FR < 0.70 Reduce LTI FR < 0.20
Reduce TIFR by 30% Reduce TIFR by 50%
Implement India road safety vision 2020
Develop social programs to benefits 1.8 Million
people
Assess 100% high risk active suppliers and
implement consequence management
Complete human right assessment

25. Sustainability policies
Ambuja Cements Ltd. recognizes the significant global threat caused by high concentration of Green
House Gases (GHG) in the atmosphere.
Reduce our carbon footprint by:
• Inventorization of carbon emissions throughout our processes
• Integrating energy efficient considerations into all aspects of our business including
manufacturing, transportation and investments
• Exploring/implementing alternative sources of energy
• Increasing production of blended cement
• Retrofitting energy efficient technology including installation of CFLs in our buildings, lighting
controls and metering systems
• Reducing our travel emissions wherever possible
• Offsetting our carbon emissions through plantation

26. SUSTAINABLE INITIATIVE
TAKEN BY LAFARGE

27. Improving their employee health and safety
• Health and safety is the overarching company value of LafargeHolcim
• Our 2016 health and safety roadmap has five priority areas:
Leadership and accountability, Health and safety management
systems, People capability, Effective execution, Road safety
• Improve transport saety
• Reach zero fatalities and virtually eliminate lost time incidents for our
employees and contractors.

28. Promoting diversity and inclusion
• Values and promote diversity
• promote equal opportunities in recruitment, employment,
promotion, development, compensation, and retention
• treat employees at all times with dignity and respect
• Skill development
• Access for women to senior management.

29. Preserving the environment and tackling
global warming
• LafargeHolcim: second lowest CO2 emissions per ton of cement.
• Become an active member in sustainable building certification
organization in 35 countries.
• Contribute to 500 energy efficient construction projects using atleast
one of the lafarge efficient building systems.
• How they plan to do it
• Minimize our impact
• Harness inovation’s power
• Reduce co2 emmission from supply chain and buildings
• Use more renewable energy

30. Acting locally to promote social and economic
progress
• aims to enhance local economies and wealth for people
• By 2030, LafargeHolcim aims to reach 75 million people through its
affordable housing projects, its social investments, and inclusive
business models.
• Contribute 1 million volunteer hour per year to locally selected
projests in the realm of job creation, biodiversity, water conservation,
skills training, affordabe housing or health.
• Be a driver of local socio-economic development

31. Preserve water and nature
• LafargeHolcim is committed to reducing freshwater withdrawal in its
cement segment by 30 percent by 2030.
• Working closely with nature conservation NGOs, at local and global
levels
• To design and implement sustainable biodervisity management
practices.

34. Reused and recycled materials: Ensure 20% of our
concrete contains reused or recycled materials