About the Book:
This
Book is about Designing new large cement plants that would promote Sustainable
Growth, preserve natural resources to the maximum possible extent and make
least possible additions to the Greenhouse Gases that cause global warming.
These are the Green Cement Plants.
Process of making cement involves
'calcination' of limestone- that is release of Carbon Dioxide the principal
greenhouse gas. In ordinary portland cement, OPC, ratio of cement to clinker is
1.05. Every ton of cement produced releases 0.8 ton of Co2. By increasing the
cement/clinker ratio that is by making 'blended cements' this emission can be
reduced to 0.53 to 0.30 tons per ton of
cement depending on the type of blended cements viz. PPC, BFSC or composite
cements made.
Combustion of fuel - needed to make
clinker also releases CO2 ( quantum included in values mentioned above )Reduced
sp. fuel consumption thus reduces
ghg emissions. Substitution of fossil fuels by waste -alternate fuels some of
which are 'carbon neutral' thus saves exhaustible fossil fuels and also lowers
ghg emissions.
Presently a lot of heat is wasted
thru kiln and cooler exhaust gases even after they are used to dry raw
materials and coal. If the heat therein is recovered to generate power, a dual
advantage accrues in that fossil fuel is saved and ghg emissions are lowered.
World is paying urgent attention to
harnessing inexhaustible and renewable sources of energy like wind and sun.
Both Solar and wind power are renewable and ghg emissions are practically nil.
New cement plants should therefore be designed to use renewable energy to the
extent possible depending on the present day status of cost and production
factors.
There are other ways of reducing CO2
emissions like capturing the emitted gas and either storing it for other uses
or for making new cements like Calera. New green cement plants should also
examine possibilities of developing cement substitutes like Calera, Caliix,
Novacem, Aether and Geopolymer cements etc. that are 'green cements'.
The concept of saving energy and
saving materials by recycling are also applied to construction of cement plants
by constructing green buildings, to mining operations and so on.
All these aspects and activities add
up to making 'Green Cement'. They have been dealt with in the book. Large new
cement plants should be designed to incorporate all these aspects. Cement
making machinery to be selected and cement plant layouts to be developed should
also contribute to this concept of
'green cement'.
This book like its predecessor
'Handbook for Designing Cement Plants would be a useful tool in the hands of
Cement Engineers, Cement Technologists and Cement Consultants to achieve the
objective of the day viz sustainable
growth thru Green Cement
Distinctive
Features of the Book
•
Clear definition of Green Cement
•
Factors contributing to generation and emission
of Greenhouse Gases and steps that can be taken to reduce it.
•
Steps that can be taken to
•
Make blended cements
• To
use alternate fuels
• To
install waste heat recovery systems Impact of these steps on reduction in green
house gases and savings of natural resources
•
Impact of these steps on reduction in green house gases and savings of natural
resources
•
Prospects and feasibility of using renewable energy - wind and solar power
•
Look at the future - carbon capture and storage
and substitute cements like
Novacem, Calix, Calera and Geopolymer
and Aether cements for example.
•
Design of new large plants of 5000 to 10000 tpd ( single kiln clinkering
capacity) incorporating above features of green cement plants Development of
plant general layouts
•
Essential data for quantities, storages, capacities of major machinery units
for large new green cement plants in
active excel spreadsheets
• Indication of
Capital Costs and Costs of Production, Impact and benefits |
