Largest Cement Producer Research Articles

Using the Best Available Technologies in the Production of Cement to Reduce Greenhouse Gas Emissions

The article analyzes approaches to reducing greenhouse gas emissions using the best available technologies (BAT) to achieve the strategic goal of low-carbon economic development in Russia. The study focuses on the development of a strategy to reduce greenhouse gas emissions at the regional level, taking into account the contribution of each sector to the total greenhouse gas emissions in the Novosibirsk Region’s carbon balance. Particular attention is paid to the Industrial Processes sector and its impact on climate change, in particular within cement production. Using the example of JSC Iskitimcement, the largest cement producer in the Novosibirsk Region (NSO), direct and indirect greenhouse gas emissions are calculated, and the specific indicators per unit of production for the period 2018–2021 are analyzed. The article presents various BAT, applied in cement production, including the use of non-traditional raw material components, alternative fuels, utilization of waste heat for power generation, and reduction of clinker share in cement, among others. The climate effect of these technologies has been assessed. These studies make it possible to develop strategies to reduce greenhouse gas emissions in the region and contribute to sustainable environmental development.

Experimental Study on Properties of High volume GGBFS and High Volume Flyash Concrete

Abstract: Construction industry consumes a huge volume of concrete every year and the demand for concrete as a construction material is on the increase. The main ingredient of concrete is cement and India is the second largest producer of cement in the world. The attention to environmental impacts of cement production has grown faster in recent decades. The cement industry is a significant greenhouse gases emitter mainly due to the calcinations of raw materials and the combustions of fuels. Portland cement production is increasing globally and contributes to greenhouse gas emissions. The current contribution of greenhouse gas emission from Portland cement production is about 1.5 billion tons annually or about 7% of the total greenhouse gas emissions[11].This leads to the utilization of wastes and industrial by-products in order to minimize the Portland cement consumption and also focuses on using eco-friendly concrete. In this experimental study There are 13 trials have been conducted on M40 Concrete in this study. out of 13trials , one trial is with control mix, 6 trials with Flyash at 60,70&75% of OPC replacement and the remaining 6 trials with GGBS at 60,70&75% OPC replacement. The investigations are being conducted for the fresh concrete properties like Workability of concrete, Temperature of concrete, Yield of concrete and Air percentage in concrete.

Comparative Analysis & Design of RCC & Steel Preheater Tower Structure by Using STAAD. Pro

A liquid material after water concrete is the most consuming material in the world, concrete is the most important construction material used extensively to construct buildings, dams, roads, etc. As we know that concrete is a composite material with cement, coarse & fine aggregates bonding together with water that gives hardness with time. As per the 2018 year statistics, India is the second largest producer of cement in the world with 460 million tonnes per year which is over 8% of the global installed capacity. Cement is the most important material in concrete, In India, at present, there are 120 major cement plants and nearly 300 mini cement plants are manufacturing the cement. In Cement plants ‘Preheater tower’ is used, these preheater tower consists of several cyclones, these raw materials are fed at the top of the preheater tower through cyclones it travels to the bottom of the preheater tower, each cyclone in the preheater serves as a heat exchanger and a separate. In this project, a comparative analysis & design will be done between both the RCC structure & Steel structure Preheater tower as per Indian design standards by using Staad Pro software. In this design process, the loads which are affecting the structure will be taken and designed. And also the pros & cons will be discussed between the RCC & Steel structure Preheater tower. Here the height of the RCC and steel Preheater tower taking as 110 meters. It is observed that Maximum displacements at a height of 110 mts in RCC preheater tower are 130.59 mm and Steel preheater tower is 102.238 mm. The Maximum Moment at critical load combination is more in RCC preheater tower (i.e 205.6 kN.m) than Steel preheater tower (i.e 190.1 kN.m).The Maximum shear at critical load combination is more in Steel preheater tower 62.0 kN is more than RCC preheater tower 28.7 kN.

The nexus of disaggregated energy sources and cement production carbon emission in China

Cement production reportedly accounts for the largest global materials flow, thus achieving global environmental sustainability through responsible consumption and production is central to the sustainable development scenario. But even that China, the world's largest carbon emitter and largest cement producer, is under-studied. Thus, the current study employed the nonlinear ARDL and frequency domain causality methods to unearth the contributory or mitigating role of energy sources and economic progress in China's cement carbon emission (CCE) over the period 1971-2020. Overall, the study establishes long-run equilibrium relationship between the study variables of interest Subsequently, the baseline regression suggests that a positive shift in economic growth, energy from fossil fuel and primary energy consumption all increase emissions while a negative shift does not have a significant effect on emissions. Moreover, a positive (negative) shift in renewable energy decreases (increases) emissions in both the short and long-run. The result of the Frequency Domain causality analysis resonates with the results of NARDL regression. As a policy, this study infers energy development and economic-related measures are strategically important in achieving sustainable cement production and consumption.

Performance and life-cycle assessment of high-volume fly ash concrete mixes containing steel slag sand

The present study discusses the performance of high-volume fly ash concrete (HVFAC) mixes containing slag sand which is a solid waste obtained from basic oxygen steel making industry. The design of such mixes was optimized to attain sufficient strength for structural purposes and then cement and natural sand in them were replaced with fly ash and slag sand up to 50%. Other than temperature developments, their fresh and hardened properties like slump, air content, compressive and tensile strengths, elastic modulus, strain softening response under uniaxial compression, shrinkage, water permeation, sorption and absorption, chloride ions diffusion and migration, and bulk electrical resistance at different ages were also studied in detail. The impact of fly ash and slag sand on the sustainability of such mixes were assessed and their co-effects on concrete microstructure were discussed with the results of scanning electron microscopy and Mercury intrusion porosimetry. The HVFAC mixes displayed a slower strength increase at early ages, but they were found to be highly workable, durable, and temperature rise in them was comparatively lower. The strength and durability of these mixes at early ages were found to enhance in the presence of slag sand which is generally capable of strengthening the aggregate-paste interface. India is the second largest producer of cement in the world. Both the fly ash and slag sand possess a lower energy requirement and their inclusions led to the production of eco-friendly concrete which is highly desirable for Indian conditions.

A systematic review on the impact of cement industries on the natural environment.

The negative health effects of cement plant exposure are well-known in industrial settings, but they are less well-known among the general public who live near plants. The broad objective of the review was to provide a detailed systematic analysis of the global situation of the cement industry, including generation, pollution, impact on the natural ecosystem, technological and process improvements, sustainable models, the latest laws, challenges, needs, and ways forward. As an initial evaluation, a list of critical keywords was compiled, and a search of all accessible databases was conducted (i.e., Scopus, Web of Knowledge, Google Scholar). The manuscripts published in the journal between 2011 and 2021 were included. According to the findings, India is the second largest cement producer after China, with an installed capacity of 537 million tonnes and around 7.1 percent of the world's production, up from 337.32 million tonnes in 2019. NOx, SOx, CO, CO2, H2S, VOCs, dioxins, furans, and particulate matter are all common air pollutants from cement manufacturing. Other sources of dust particles include quarrying, blasting, drilling, trucking, cement plants, fuel production, packaging, path cleaning, and slabs. Other methods of reduction play an important part in decreasing industrial emissions, resulting in lower carbon and more sustainable products. The decision-making trial, in conjunction with the DEMATEL evaluation laboratory and the analytical hierarchy process (AHP) technique, will aid in determining the priority of climate alteration and mitigation options. Furthermore, employing sustainable techniques and technology, switching to alternative fuels will save 12% of total CO2 emissions by 2050.

Carbon and air pollutant emissions from China's cement industry 1990–2015: trends, evolution of technologies, and drivers

Abstract. China is the largest cement producer and consumer in the world. Cement manufacturing is highly energy-intensive and is one of the major contributors to carbon dioxide (CO2) and air pollutant emissions, which threatens climate mitigation and air quality improvement. In this study, we investigated the decadal changes in carbon dioxide and air pollutant emissions for the period of 1990–2015 based on intensive unit-based information on activity rates, production capacity, operation status, and control technologies which improved the accuracy of the cement emissions in China. We found that, from 1990 to 2015, accompanied by a 10.3-fold increase in cement production, CO2, SO2, and NOx emissions from China's cement industry increased by 627 %, 56 %, and 659 %, whereas CO, PM2.5, and PM10 emissions decreased by 9 %, 63 %, and 59 %, respectively. In the 1990s, driven by the rapid growth of cement production, CO2 and air pollutant emissions increased constantly. Then, the technological innovation in production of replacing traditional shaft kilns with the new precalciner kilns equipped with high-efficiency control facilities in the 2000s markedly reduced SO2, CO, and PM emissions in the cement industry. In 2010, nationwide, 39 % and 31 % of the nationwide PM2.5 and NOx emission were produced by 3 % and 15 % of the total capacity of the production lines, indicating the disproportionately high emissions from a small number of the super-polluting units. Since 2010, the growing trend of emissions has been further curbed by a combination of measures, including promoting large-scale precalciner production lines and phasing out small ones, upgrading emission standards, installing low NOx burners (LNB), and selective non-catalytic reduction (SNCR) to reduce NOx emissions, as well as adopting more advanced particulate matter control technologies. Our study highlights the effectiveness of advanced technologies on air pollutant emission control; however, CO2 emissions from China's cement industry kept growing throughout the period, posing challenges to future carbon emission mitigation in China.

Sustainability performance of the Indian cement industry

The cement industry in India has witnessed a remarkable growth making India presently the second largest producer of cement in the world. However, the production of cement involves emission of pollutants that are considered to be a severe threat to the environment. The objective of this paper is to identify the environment management practices (EMP) adopted by this industry to reduce the impact of its operations on the environment and then assign sustainability scores to the firms according to the extent of EMP adopted by them. Sustainability scores have been assigned to the firms by undertaking content analysis of the annual reports/sustainability reports and environmental clearance reports. The results suggest that there has been considerable improvement in adoption of EMP in most of the cement firms throughout the time period 2010–2017 and that the cement industry is indeed approaching a path of sustainability.

Review on vertical roller mill in cement industry & its performance parameters

India is the world's second largest producer of cement and produces more than 8 per cent of global capacity. Due to the rapidly growing demand in various sectors such as defense, housing, commercial and industrial construction, government initiative such as smart cities & PMAY, cement production in India is expected to touch 550–600 million tones per annum (MTPA) by the end of year 2025. With recent growth and success journey there is also a threat approaching to cement industry that its input cost is increasing. Power cost, fuel cost, raw material cost have doubled up in recent years whereas cement price has not hiked in that fashion. Also 40% of the cement production costs are energy costs out of which more than 60% of the total electricity is used in grinding circuits. In order to survive and sustain in the market they need to increase their profitability which can only be achieved by increasing productivity and reducing power consumption. High productivity and low power costs can be achieved by increasing output, lowering breakdowns and optimizing the energy consuming grinding process. The objective of the study, is to draw attention to the need of Cement grinding process optimization to minimize power consumption and achieve higher productivity. In the study the advantages of vertical roller mill are discussed over ball mills. VRM construction, its process and parameters which affects the performance and productivity of vertical roller mill are discussed. Also the consequences of variations in parameter explained. With proper optimization of these parameters, the productivity of vertical roller mill can be improved and performance stability can be achieved by addressing root causes.. This study can benefit the organizations using VRM and are not able to utilize its full productivity due to some bottlenecks or constraints.

Plant Maintenance Modelling Through Availability Analysis In Raw Mill of Cement Production

Maintenance activities are a particular concerned at PT XYZ, which is the largest cement producer in Eastern Indonesia. PT XYZ has five main factories located in Pangkep, South Sulawesi, units 1,2,3,4, and 5. In 2019, PT XYZ’s five clinker production only reached 2,445,515 tons or 93, 64% of the target. The details, raw meal production was not achieved, namely 4,041,377 tons or 96.54% of the target set by the company due to the unplanned shutdowns. This research tries to control the breakdowns of raw mill machine by evaluating the availability and day of operation (calendar day). The availability analysis method used is the discrete system simulation approach because the discrete system simulation can accommodate random behavior and dependence between variables. In the existing condition, system availability is 72.83% and calendar day is 239 days. These two parameters are still less than the target. To overcome this problem, experimentation was carried out with 3 scenarios. The best simulation results shows that the preventive maintenance activities changes the value of TTF (Time to Failure), TTR (Time to Repair), and reduces the duration of overhaul activities. This can increase the availability to 83.04% and calendar day to 255 days.

Effects of Corn Cob Ash as Mineral Admixture on Mechanical and Durability Properties of Concrete – A Review

Concrete is the second most consumed product next to water on earth. Cement is the key ingredient for making concrete. India is the second largest cement producer in the world. The production of cement is emitting an equal amount of CO2 in to the atmosphere and is accounted as about 8% of the world’s total emissions. The addition of mineral additives as supplementary cementitious materials in concrete is one of the solution to avoid such environmental pollution. The natural mineral admixture obtained from the novel agricultural by-product, namely corn cob ash (CCA), is being utilized in cement manufacturing and concrete construction. The similarities in both physical and chemical properties of CCA were established when compared to the decade old agro-based mineral admixtures like rice husk ash (RHA) and sugar cane bagasse ash (BA) through research findings. The results are mentioned that the CCA can be used as chemically active mineral admixture and micro-filler in concrete. With this background, the paper presents a review on the effect of substituting CCA in fresh, mechanical and durability properties of concrete.

Study on the spatial spillover effects of cement production on air pollution in China

Since 1985, China has become the largest cement producer and consumer in the world. The pollutants emitted from cement production and processing have aggravated China's pressure to conserve energy and reduce emissions. Considering the fact of cross regional transfer and capacity replacement of cement industry, this paper explores the influence of cement production on air pollution by using spatial econometric models. The results illustrate that the concentration of PM2.5 is obviously spatially dependent and presents high-east and low-west agglomeration characteristic on a national scale. Moreover, the positive correlation between cement production and air pollution is quite obvious, the spatial spillover effects of cement production on air pollution increase progressively, and the indirect spillover effects are seven times greater than the direct spillover effects. The results also show that the phenomenon of cement industries obtaining benefits at the cost of hurting air quality in surrounding areas is the most severe in eastern China. Thus, rules should be based on local conditions when making policies in cement industries and the strong correlation between the pollution of adjacent areas should be fully considered.

A STUDY ON FINANCIAL PERFORMANCE ANALYSIS OF ULTRA TECH CEMENT LTD - AN ANNUAL GROWTH ANALYSIS

The global cyclical upswing since mid - 2016 strengthened during the year. Among the advanced economies, notably Germany, Japan, Korea and the United States, growth in the third quarter of 2017 was higher than projected. Key emerging markets and developing economies like Brazil, China and South Africa also posted impressive growth. Global trade was significantly higher, supported by a good flow of financial, particularly among advanced economies and increased Asian manufacturing output. The stronger momentum experienced in 2017 is expected to carry into 2018 and 2019, with global growth rising to 3.9% for both years. The International Monetary Fund (IMF) remained optimistic of India’s potential and retained GDP growth forecast for the country at 6.7% in 2017 and 7.4% in 2018. In its World Economic Outlook Update, it also estimated that the Indian economy could grow 7.8% in 2019, making it the world’s fastest-growing economy in 2018 and 2019, a ranking that it briefly lost to China in 2017. The economy’s growth trajectory was sustained on the back of a series of reforms undertaken over the past year. India is the world’s second largest cement producer. In anticipation of demand, ~ 90 million tonnes of capacity was added during the past five years. During the year, the industry reported a rise in cement demand and after seven years’ the industry is likely to report historical demand growth multiple against GDP. The Government’s thrust on infrastructure development remained the key growth driver. Besides, revival in rural housing demand and accelerated execution under the low cost housing program, bolstered volume off-take. This article financial performance analyses of actual and trend performance of Ultra Tech Cement Ltd (ULC). KEYWORDS- Million tones, Financial, Ultra Tech, Profitability.

Mechanical and Durability Properties of Concrete Incorporating Flyash

India is a second largest producer of cement in the world. about 300 million tones of cement had produced in 2012. Day to day life we using large amount of cement it causes to reduction of natural resources. By using coal 60% of electricity was produced per annum. fly ash are produced as by product in coal about 175 million tones. so as we trying to replace cement by using admixture fly ash. As per indian government norms that at least 10% of fly ash should be used during cement production.fly ash has zero percentage of binding property so we replacing the cement by fly ash up to 70% only and our motive are how the mechanical and durability properties perform in the concrete due to the replacing large amount of fly ash. we find that fly ash reduced chloride attacking in concrete, reducing the pores size, improved workability. Hence, higher volumes of fly ash can be used to replacecement in concrete mixes and care should be taken during the design mix to obtain the similar compressive strengths as that of the control mix. this can be achieved by reducing the water cement ratios of concrete mixes incorporated with higher volumes of fly ash.

A study on initial setting time and the mechanical properties of AASC using the PS ball as fine aggregate

India is the second largest producer of cement in the world with an annual production of 455 Million Tonnes (MT) which is expected to reach up to 550MT by 2020. In India, the increased demand for cement in the construction industry is required to meet the needs of infrastructure development. However, the production of Portland cement releases significant amounts of CO2 to the atmosphere. Therefore, it is necessary to look for sustainable solutions for concrete production by the use of supplementary cementitious materials. The alternative replacement for Ordinary Portland Cement (OPC) can be Ground Granulated Blast Furnace Slag (GGBS), Fly-ash, Silica fume, Rice-husk ash, which is the various industrial by-products. In this present work, an attempt was made to develop Alkali Activated Slag Concrete (AASC) using Precious Slag (PS) ball as fine aggregate. The development of AASC was made with GGBS as the principal binder. Mixes were developed with binder content 443 kg/m3, Sodium Silicate (SS)/Sodium Hydroxide (SH) ratio of 1 and their performance when exposed to ambient temperature were studied. Alkali binder ratio (0.3) with 8, 10, 12 and 14M NaOH was selected for all the AASC mixes. The test results showed that the slump values for the different mixes satisfying the MoRTH guidelines for concrete pavements. The AASC mixes have higher compressive strength ranging between 41–64 MPa. The fatigue life of the AASC mix was has improved by the addition of PS ball, at the higher concentration of NaOH.

Carbon Emissions of China’s Cement Packaging: Life Cycle Assessment

China is the largest producer of cement in the world. With this tremendous production of cement, the extensively used cement packaging embodies significant carbon dioxide emissions. However, this has scarcely been investigated. This paper presents the first investigation into three types of cement packaging in China using the life cycle assessment methodology. The carbon dioxide emissions in each production phase of cement packaging were calculated and compared to the emissions in the western, middle, and eastern regions in China. The results show that in the production phase, the consumption of electricity accounted for the highest proportion of total carbon dioxide emissions (23.39–35.14%), followed by the consumption of polypropylene-based material (23.39%). From a packaging perspective, laminated plastic woven bags emitted the most carbon dioxide (0.637 kg/bag), followed by paper–plastic composite bags (0.536 kg/bag) and paper bags (0.022 kg/bag). In regional terms, the western region emitted the most carbon dioxide (3.06 million tons) compared with the eastern (2.01 million tons) and middle (1.81 million tons) regions due to the low bulk rate. Our findings indicate that using paper–plastic composite bags instead of laminated plastic woven bags and using recycled materials instead of new materials in certain production phases can considerably reduce the environmental impacts of cement packaging. The government should encourage the use of non-coal energy power generation for the production phase. Further improvements could focus on the use of bulk cement instead of packaged cement.

Partial Replacement of Biomedical Waste ASH in Concrete

Cement is a binder, a substance used for construction that sets, hardens and adhering to other materials, binding them together. Cement is seldom used on its own, but rather to bind sand and gravel together. Cement is used with fine aggregates to produce mortar for masonry, or with sand and gravel aggregates to produce concrete. Concrete is a composite material composed of fine and coarse aggregate bonded together with a fluid cement that hardens over time. Annual production of cement is nearly 425 million tonnes, India is the second largest cement producer in the world and accounts for 6.9 percent of worlds cement output. Biomedical waste, generated from medical sources and activities is a cause of concern for environmentalist. These wastes are generated in the process of diagnosis treatment and similar activities pertaining to human and animals. Also in the production or testing of biological instruments/components. Biological waste is broadly classified as biological and nonbiological wastes that may or may not be infectious.

China's cement demand and CO2 emissions toward 2030: from the perspective of socioeconomic, technology and population.

China is the largest cement producer and carbon dioxide (CO2) emitter in the world. The country has attracted too much attention in calculating and comparing its CO2 emissions. However, as the second largest CO2 emitter after the fire power industry, China's long-term cement demand and cement-related CO2 emission projections were not fully studied. The Chinese government, however, committed that by 2020 and 2030, China's per capita GDP of CO2 emissions would be lower than that in 2005 by 40-45% and 60-65%, respectively. In this paper, China's cement demand in 2030 was projected based on the population size, urbanization rate, fixed assets investment, and per capita GDP. Furthermore, decoupling study in China's cement industry was also involved based on the GDP and CO2 emissions during 2001-2015. We also used the diffusion rate of 12 types of CO2 reduction measures and two changed scenarios of clinker-to-cement ratio, to project the cement CO2 emission factors toward 2030 after determining the accounting scope. Meanwhile, the CO2 emissions of China's cement industry through 2030 were projected naturally. The results showed that China's cement output in 2030 will be approximately 2000, 1650, and 937 Mt. based on the fixed assets investment, urbanization rate, and per capita GDP respectively. The projected two scenarios cement CO2 emission factors were resp. 407.83 and 390.02kg CO2/t of cement which were 42.6 and 45.1% lower than that in 2005. The cement CO2 emissions were projected to be in the range of 366 to 818 Mt. in 2030. Additionally, China's total cement output value has been decoupling from cement CO2 emissions from 2012, which is mainly attributed to eliminating backward capacity, reducing excess capacity or the declining cement output. And decoupling economic from China's cement CO2 emissions may change to be strong or weak decoupling in the near future. As cement production is one of the factors effecting cement CO2 emissions, the most important measure for controlling cement CO2 emissions is a reasonable capacity utilization rate. It is therefore important to control the growth of cement CO2 emissions by regulating the capacity utilization rate within a reasonable range. Eliminating backward capacity, removing excess capacity, controlling new capacity, staggered production, and the "going global" of cement equipment can have great impacts in controlling the total amount of cement output and CO2 emissions.

Assessing air pollution abatement co-benefits of energy efficiency improvement in cement industry: A city level analysis

Abstract China is the world's largest cement producer, contributing to 60% of the global total. Jiangsu province takes the lead of cement production among China's provinces, contributing to 8.4% of the national total cement output. In this study, a geo-graphical information system-based energy model is developed to assess the potential of energy savings and associated mitigation of CO2 and air pollutant emissions in Jiangsu's cement industry during 2015–2030. Results show that 1) compared to 2015, energy consumption in the baseline scenario will decrease by 54% at the provincial level. Economical energy saving potential for 2030 is around 50 PJ, which equals to 35% of energy use in the baseline in 2030. 2) At the city level, Changzhou, Wuxi, and Xuzhou are top three cities in terms of energy saving potential. 3) The economical CO2 emission reductions will decrease by 4.4 Mt in 2030, while the emissions of PM and NOx would decline by 30% and 56%, respectively. This study will help policy makers develop integrated policies to support the coordinated development of Jiangsu and can also enhance the effectiveness of the implementation of joint prevention and control of atmospheric pollution to improve regional air quality.

Effect of Work Attitude and Total Productive Maintenance on the Overall Equipment Effectiveness and Production Continuity

<div><p><em>This study aims to examine and analyze the impact of work attitude, Total Productive Maintenance (TPM) on the Overall Equipment Effectiveness (OEE) and production continuity and the other effect of Work Attitude and Total Productive Maintenance (TPM) on production continuity: The mediating role of Overall Equipment Effectiveness (OEE). The research was conducted at PT. Semen Tonasa i.e. units II to V unit which is the largest cement producer in eastern Indonesia. Withdrawal of respondents did with the criteria that only respondents yang having their respective sectors and who have work experience of at least one year were used as samples. Results of analysis Partial Least Square (PLS) Version 2.0.M3 used in analyzing the contribution of exogenous variables on endogenous variables directly, Sobel Test was used for pushing analyze the contribution of the indirect effect (mediation) whereas importance- performance analysis (IPA) to analogous interpret the relationship loading factor value and the average value. The results of this study provide evidence of work attitude has a positive and significant effect on the overall equipment effectiveness (OEE), total productive maintenance (TPM) has a positive and significant effect on overall equipment effectiveness (OEE), work attitude, total productive maintenance (TPM) and overall equipment effectiveness (OEE) positive and significant impact on production continuity.</em></p></div>