Effective Environment Regulatory Compliance in Cement...
Transcript of Effective Environment Regulatory Compliance in Cement...
Effective Environment Regulatory Compliance in Cement industry
Acts, Rules & Regulations – Cement Plants
Dr.S.Suresh KumarChief Technical Director
Knowledge Lens India Pvt Ltd
CONCENTRATION IN AMBIENT AIR
Pollutant
Time-
weighted
average
Industrial,Residential
, Rural and Other
Area
Ecologically Sensitive
Area (notified by
Central Government)
SulphurDioxide (SO2),
(µg/m3)
Annual * 50 20 - Improved West and Geake Method
24 hours** 80 80 - Ultraviolet Fluorescence
Oxides of Nitrogen as
(NO2) , (µg/m3)
Annual * 40 30 - Modified Jacob & Hochheiser Modified (Na
Arsenite)
24 hours** 80 80 - Chemiluminescence
Particulate Matter (size
less than 10 um) PM10
(µg/m3)
Annual* 60 60 - Gravimetric
- TOEM
24 hours** 100 100 - Beta attenuation
Particulate Matter (size
less than 2.5 um) or
PM2.5 (µg/m3)
Annual* 40 40 - Gravimetric
- TOEM
24 hours** 60 60 - Beta attenuation
Ozone (O3) 8 hours* 100 100 - UV Photometric
- Chemiluminescence
1hour** 180 180 - Chemical method
Lead (Pb) (µg/m3) Annual* 0.50 0.50 - ASS/ICP Method after sampling using EPM
2000 or equivalent Filter paper
24 hours** 1.0 1.0 - ED-XRF using Teflon filter
Ammonia(NH3) (µg/m3) Annual* 100 100 - Chemiluminescence
24 hours** 400 400 - Indophenol blue method
CarbonMonoxide (CO) 8 hours** 02 02 - Non Dispersive Infra Red (NDIR)
1 hour 04 04 - Spectroscopy
NATIONAL AMBIENT AIR QUALITY STANDARDS
10/10/2018 2
CONCENTRATION IN AMBEINT AIR
Pollutant Time-weighted average
Industrial,
Residential, Rural
and Other Area
Ecologically
Sensitive Area
(notified by
Central
Government)
Method of Measurement
Benzene (C6H6)
µg/m3
Annual * 05 05
- Gas Chromatography based continuous
analyser
- adsorption and Desorption followed by
GC analysis
Benzo-a-pyrene (BaP)
– Particulate phase
only, ng/m3Annual* 01 01
- Solvent Extraction followed by HPLC/GC
-Analysis
Arsenic (As)
ng/m3 Annual* 06 06
- AAS/ICP method after sampling on EPM
2000 or equivalent filter paper
Nickel (Ni),
ng/m3Annual * 20 20
- AAS/ICP method after sampling on EPM
2000 or equivalent filter paper
*Annual arithmetic mean of minimum 104 measurements in a year at a particular site taken twice a week 24
hourly at uniform intervals.
** 24 hourly or 8 hourly or 1 hourly monitored values, as applicable, shall be compiled with 98% of the time in
a year. 2 % of the time, they may exceed the limits but not on two consecutive days of monitoring.
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S.N
oPollutant
Concn. in Ambient Air
Method of measurementDetection
LimitIndustrial,
Residentia
l & rural
Ecologically
sensitive
area
1 SO2 µg/m3 80 80IS 5182 Pt2 24 hrs monitoring
Flow rate : 0.5 ltr/min ; Abs Sol’n:50 ml8 µg/m3
2 NO2 µg/m3 80 80IS 5182 Pt 6 ; 24 hrs monitoring;
Flow Rate: 0.5 ltr/min ; Abs Sol’n: 30 ml5 µg/m3
3 PM10 µg/m3 100 100 IS 5182 Pt 23; 24 hrs monitoring 5 µg/m3
4 PM2.5 µg/m3 60 60 Gravimetric
5 Ozone µg/m3 100 100
Method of Air Sampling and Analysis (Ed III) ;
8 hrs sampling
Flow Rate: 2 ltr/min ; Abs Sol’n 30 ml
5 µg/m3
6 Lead µg/m3 1 1IS 5182 Pt 22; 16-24 hrs monitoring;
Flow Rate:1.1 m3/min2 ng/m3
7 CO mg/m3 2 2IS 5182 Pt 10, GC-FID (through methanizer)
Grab Sampling in tedler bag (NDIR under d’ment)2.5 mg/m3
8 Ammonia µg/m3 400 400
Method of Air Sampling and Analysis (Ed III)
Indophenol Method ; 24 hrs sampling ;
Flow Rate:2 Ltr/min ;Abs Sol’n 50 ml
9 µg/m3
9 Benzene µg/m3 5 5ASTM D 3686
24hrs monitoring ; Flow rate: 0.5 ltr/min3 µg/m3
10
Benzo(a)pyrine
(particulate phase)
ng/m3
1 1IS 5182 Pt 4(for sampling); USEPA 8270(for analy.)
16-24 hrs monitoring; Flow Rate 1.1 m3/min0.47 ng/m3
11 Arsenic ng/m3 6 6IS 5182 Pt 22 ; 16-24 hrs monitoring;
Flow rate: 1.1 m3/min2 ng/m3
12 Nickel ng/m3 20 20IS 5182 Pt 22
16-24 hrs Monitoring; Flow Rate : 1.1 m3/min2 ng/m3
EMISSION STANDARDS FOR DIESEL ENGINES FOR GENERATOR SETS
Engine Power (P) Date
CO HC NOx PM Smoke
g/kWh 1/m
P ≤ 19 kW
2003.7 5.0 1.3 9.2 0.6 0.7
2004.7 3.5 1.3 9.2 0.3 0.7
19 kW < P ≤ 50 kW
2003.7 5.0 1.3 9.2 0.5 0.7
2004.7 3.5 1.3 9.2 0.3 0.7
50 kW < P ≤ 260 kW 2003.7 3.5 1.3 9.2 0.3 0.7
260 kW < P ≤ 800 kW 2004.7 3.5 1.3 9.2 0.3 0.7
Emissions from new diesel engines up to 800 kW used in generator sets have been
regulated by the Ministry of Environment and Forests, Government of India [G.S.R.
371 (E), 17 May 2002]. The emission standards are listed below.
Parameter Area Category Total engine rating of the
plant (includes existing as
well as new generator sets)
Gerator sets commissioning date
Before 1/7/2003 Between 1/7/2003
and 1/7/2005
On or after
1/7/2005
Nox (as NO2) (AT 15% O2), dry basis, in ppmv A Upto 75MW
1100 970 710B Upto 150MW
A More than 75MW
1100 710 360B More than 150MW
NMHC (as C) (at 15% O2), mg/Nm3 Both A and B 150 100
PM (at 15% O2), mg/Nm3 Diesel Fuels - HSD
& LDO
Both A and B75 75
Furnace Oils - LSHS
& FO
Both A and B150 100
CO (at 15% O2), mg/Nm3 Both A and B 150 150
Sulphur content in fuel A <2%
B <4%
Fuel specification For A only Up to 5MW Only Diesel Fuels (HSD, LDO) shall be used.
Stack height (for generator sets commissioned after
1/7/2003)
Stack height shall be maximum of the following, in meter:
i.14 Q 0.3, Q = Total SO2 emission from the plant in kg/hr
ii.Minimum 6 m above the building where generator set is installed.
(iii) 30 m.
EMISSION STANDARDS FOR DIESEL ENGINES (ENGINE RATING MORE
THAN 0.8 MW (800 KW) FOR POWER PLANT, GENERATOR SET
APPLICATIONS AND OTHER REQUIREMENTS
CEMENT PLANT WITHOUT COPROCESSING
PARAMETER STANDARDS
Rotary Kiln - Without Co processing
Date of Commissioning Concentration not to Exceed in mg/Nm3
SO2 in mg/Nm3 Irrespective of date of commissioning100, 700 and 1000 when pyritic sulphur in thelimestone is less than 0.25%, 0.25 to 0.5% andmore than 0.5% respectively.
Oxides of Nitrogen (NO2) in mg/Nm3
After the date of Notification (25.8.14) (1) 600
Before the date of Notification (25.8.14)
(2) 800 for rotary kiln with In Line Calciner (ILC)technology.
(3) 1000 for rotary kiln using mixed stream ofILC, Separate Line Calciner (SLC) and suspensionpreheater technology or SLC technology aloneor without calciner.
The timeline for implementation of emission standards for all the parameters i.e.Sulphur Dioxide (SO2), Oxides of Nitrogen (NOx) and Particulate Matter (PM), withrespect to Rotary Kiln without co processing shall be up to the 31st March, 2017.
CEMENT PLANT WITH COPROCESSINGPARAMETER STANDARDS
Rotary Kiln - With Co processing of Wastes
Date of Commissioning Concentration not to Exceed in mg/Nm3
PM in mg/Nm3
on or after the date of notification(25.8.2014)
30
before the date of notification (25.8.2014) 30
Oxides of Nitrogen (NO2) in mg/Nm3
After the date of Notification (25.8.14) (1) 600
Before the date of Notification (25.8.14)
(2) 800 for rotary kiln with In Line Calciner (ILC)technology.
(3) 1000 for rotary kiln using mixed stream ofILC, Separate Line Calciner (SLC) and suspensionpreheater technology or SLC technology aloneor without calciner.
SO2 in mg/Nm3 irrespective of date of commissioning100, 700 and 1000 when pyritic sulphur in thelimestone is less than 0.25%, 0.25 to 0.5% andmore than 0.5% respectively.
HCl in mg/Nm3 -- 10
HF in mg/Nm3 1
TOC in mg/Nm3 10 Permitting authority may prescribe separate standards on case to case basis, if TOC does not result from the co-processing of waste.
PARAMETER STANDARDS
Rotary Kiln - With Co processing
Date of Commissioning Concentration not to Exceed in mg/Nm3
SO2 in mg/Nm3
Irrespective of date of commissioning100, 700 and 1000 when pyritic sulphur in thelimestone is less than 0.25%, 0.25 to 0.5% and morethan 0.5% respectively.
Irrespective of date of commissioning100
[when pyritic sulphur in the limestone is less than 0.25%]
Irrespective of date of commissioning
700[when pyritic sulphur in the limestone is
less than 0.25 to 0.5%]
Irrespective of date of commissioning1000
[when pyritic sulphur in the limestone is more than 0.5%]
PARAMETER STANDARDS
Rotary Kiln - With Co processing
Date of Commissioning Concentration not to Exceed in mg/Nm3
Oxides of Nitrogen (NO2) in mg/Nm3
After the date of Notification (25.8.14) 600
Before the date of Notification (25.8.14)800
for rotary kiln with In Line Calciner (ILC) technology.
Before the date of Notification (25.8.14)
1000 for rotary kiln using mixed stream of ILC, Separate
Line Calciner (SLC) and suspension preheater technology or SLC technology alone or without
calciner.
CEMENT PLANT WITH COPROCESSING
PARAMETER STANDARDS
Rotary Kiln - With Co processing of Wastes
Date of Commissioning Concentration not to Exceed in mg/Nm3
Hg and its compounds in mg/Nm3 irrespective of date ofcommissioning
0.05 mg/Nm3
Cd +Tl and their compoundsirrespective of date ofcommissioning
0.05 mg/Nm3
Sb+As+Pb+Co+Cr+Cu+Mn+Ni+V andtheir compounds
irrespective of date ofcommissioning
0.5 mg/Nm3
Dioxins and Furansirrespective of date ofcommissioning
0.1 ngTEQ/ Nm3
CPCB General Emission Standards –Cement Plants
▪ Cement Plants (with co-processing)
▪ Rotary kiln based plants (Particulate Matter from raw mill,kiln and pre-calciner system put together)
▪ 0.125 kg/ tonne of clinker.
PREVENTION AND CONTROL OF FUGITIVE EMISSIONS FROM CEMENT PLANTS
Unloading Section (Limestone, Coal & other Relevant Material)
▪ Control Measures to be Provided : Enclosureshould be provided for all unloadingoperations, except wet materials likegypsum.
▪ Guideline: The enclosures for the unloadingsides could be flexible curtain type materialcovering up to height of dumpers dischargefrom the roof.
▪ Control Measures to be Provided : Watershall be sprayed on the material prior andduring unloading.
▪ Guideline: A dust suppression system shouldbe provided to spray water.
Material Handling Section (Including Transfer Points)
▪ Control Measures to be Provided : All transferpoint locations should be fully enclosed.
▪ Guideline: The enclosures from all sides with theprovision for access doors, which shall be kept, closedduring operation. Spillages should be periodicallyremoved.
▪ Control Measures to be Provided : Airborne dustat all transfer operations / points should becontrolled either by spraying water or byextracting to bag filter
▪ Guideline: Either water spray system should be providedfor suppressing the air borne dust or dry extraction cumbag filter with adequate extraction volume.
▪ Control Measures to be Provided : Beltconveyors should preferably be closed.
▪ Guideline: This will avoid wind blowing offines.
Coal Storage Section▪ Coal yard / storage area should be clearly earmarked.
▪ The pathways in coal yard for vehicle movement should be paved.
▪ Accumulated dust shall be removed / swept regularly and water the areaafter sweeping.
▪ Coal other than coal stock pile should preferably be stored under coveredshed.
▪ Instead of dust extraction cum bag filter system, If dust suppressionmeasure is used, following additional control measures should be provided.
▪ Wetting before unloading
▪ Spray water at crusher discharge and transfer point
Clinker Cooler Section▪ Air borne fines extracted from clinker cooler shall be separated and
sent to last possible destination directly, if possible.
▪ The unit may need to install necessary provisions for separating fineparticulates from the clinker cooler ESP collection.
▪ Fines separation may be achieved by passing collected dust throughcyclone.
▪ The fines escaping cyclone to be separated,
▪ Cyclone collection (coarse particles) could be recycled.
▪ The fines shall be recycled to the last possible destination (like clinkerday silo) suitable or safely disposed.
Clinker Stock Piles Section
▪ In new cement plant, clinker should be stored preferably in silo.
▪ Clinker should be stored in closed enclosure covered from all sidesand should have a venting arrangement along with a bag filter.
▪ The dust extracted and captured in bag filter should be avoided tofeed back / recycled to the clinker stockpile, if possible
▪ The storage should be done under covered shed
▪ Dry fly ash shall be transported by closed tankers. In case of wet flyash trucks may be used for transportation
▪ Dry Fly ash shall be stored in silos only.
▪ Flyash in the dry form should be encouraged and in wet form shouldbe discouraged.
Storage of Limestone, Gypsum, Flyash and other Additives
▪ All roads on which vehiclemovement of raw materials orproducts take place should bepaved.
▪ Limit the speed of vehicles
▪ Employ preventive measures tominimize dust build up on roads.
▪ Carry out regular sweeping ofroads to minimize emissions.
Roads
Co-Processing refers to the use of waste materials such ascement, lime, steel, glasses, power generation etc….Instead of fossil fuels & natural resources
Cement Kiln Co-processing
Co-processing
▪ Upgrades waste management within the waste hierarchy
▪ Reduces global environmental impacts
▪ Maintains and improves the industrial sector'scompetitiveness
▪ Decreases (largely) the costs of waste management
▪ Improves all technical-economical factors
Co-processing in the Waste Hierarchy
The co-processing of waste has been recognized as a recovery operation under EU legislation.
100% Material Recovery
100% Energy Recovery
Five Main Types of Waste Used as Alternative Fuels
Co-processing in CementWaste materials to be used as alternative fuels :
▪ Used tires,
▪ Meat and bone meal, animal fat,
▪ Plastics,
▪ Packaging waste,
▪ Waste wood, impregnated saw dust,
▪ Paper, cardboard,
▪ Sludge (paper fiber, sewage)
▪ Agricultural and organic waste,
▪ Shale, oil shales,
▪ Coal slurries, distillation residues,
▪ Fine/ anodes / chemical cokes,
▪ Waste oils, oiled water,
▪ Spent solvents.
Waste co-processing Principles
Refuse the listed "banned wastes"
Anatomical Hospital Wastes
Asbestos-containing Wastes
Bio-hazardous Wastes
Electronic Scrap
Entire Batteries
Explosives
High-concentrationCyanide Wastes
Mineral Acids
Radioactive Wastes
Unsorted Municipal Garbage
Pre and Co-Processing: Liquid WastesStandard Installation
Receiving Station (covered) Storage, dosing, pumping the kiln
All on hard, impermeable surface, roof covered.
Fire fighting equipment and water management system.
AFR Pre-Processing
Select the Correct Fuel Feed Points
The Cement Industry and the Preservation of Natural Resources
THANK YOU
Contact usDr.S.Suresh Kumar, Chief Technical Director
Knowledge Lens India Pvt LtdEmail: [email protected]
Mobile: 9884836199; 9940157123