Comprhensive 20 Plants

COMPREHENSIVE INDUSTRY DOCUMENT SERIES:
COIN DS/6412006-2007
COMPREHENSIVE INDUSTRY
DOCUMENT ON VERTICAL
SHAFT KILN BASED MINI
CEMENT PLANTS
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CENTRAL POLLUTION CONTROL BOARD

(MINISTRY OF ENVIRONMENT & FORESTS)
Website: www.cpcb.nic.in e-mail: cpcb@nic.in
February 2007
COMPREHENSIVE INDUSTRY DOCUMENT
SERIES: COINDS/64/2006-07
COMPRHENSIVE INDUSTRY
DOCUMENT ON VERTICAL
SHAFT KILN BASED MINI
CEMENT PLANTS
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CENTRAL POLLUTION CONTROL BOARD

(Ministry of Environment & Forests, Govt. of India)
Parivesh Bhawan, East Arjun Nagar
Delhi-110032
Website : www.cpcb.nic.in e-mail : cpcb@nic.in
CPCB 200 Copies, 2007
Published By: Dr. B. Sengupta, Member Secretary, Central Pollution Control Board, Delhi - 32
Printing Supervision & Layout: P.K. Mahendru and Mrs. Anamika Sagar
Composing & Laser Typesetting : Mohd. Javed
Printed at: DSIIDC Ltd.
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Central Pollution Control Board
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3T1 Ministry of Environment & Forests
Phone : 22304948 / 22307233
J. M. MAUSKAR, IAS
Chairman
FOREWORD
The Central Pollution Control Board has published several industry specific documents,
called Comprehensive Industry Documents (COINDS), envisaging the environmental
issues and preventive measures. The present document on vertical shaft kiln based mini
cement plants is in continuation of the series of COINDS. A Study was undertaken by
Central Pollution Control Board through National Council for Cement and Building
Materials, in which depth examination of selected vertical shaft kiln based mini cement
plants was conducted.
This Report provides detailed information on number of units in the country, their
locations, capacities, manufacturing process, emissions generated, present status of
pollution control measures and also the recommendations for abatement and control of
pollution. This will enable the vertical shaft kiln based mini cement plants need to install
proper pollution control devices and to operate them to achieve the intended objective of
pollution control.
I would like to express my sincere appreciation for the work done by the team of NCBM,
headed by Dr. L.K. Janakiraman. I also appreciate the efforts made by my colleagues Sh.
P.K. Gupta, Environmental Engineer and Sh. J.S. Kamyotra, Additional Director for
coordinating and finalizing the Study under the guidance of Dr. B. Sengupta, Member
Secretary, CPCB.
We in CPCB hope the Study will be useful to the vertical shaft kiln based mini cement
plants, regulatory agencies, research organizations and to all interested in pollution
control.
8` h February, 2007 (J. M. Mauskar)
'Parivesh Bhawan C.B.D.-cum-Office Complex, East Arjun Nagar, Delhi-110 032

Fax': 22304948 / 22307078 email : cpcb@alpha.nic.in
Website : http://www.cpcb.nic.in
CONTENTS
Page No.
EXECTIVE SUMMARY i — iii
1.0 INTRODUCTION
2.0 OBJECTIVES OF THE STUDY
3.0 GROWTH OF MINI CEMENT PLANTS
4.0 WORLD SCENARIO OF MINI CEMENT 2
5.0 COMPARISION OF LARGE AND MINI CEMENT PLANTS 3
6.0 CEMENT MANUFACTURING TECHNOLOGIES 5
TO TYPES OF MINI CEMENT PLANTS IN INDIA 16
s.0 TYPES OF MINI CEMENT PLANTS IN CHINA 27
9.0 TYPES OF MINI CEMENT PLANTS IN COUNTRIES
OTHER THAN CHINA AMD INDIA 2.7
10.0 OPERATION OF A CRI -MODERN VERTICAL SHAFT KILN 29

11.0 RAW MATERIALS AND THEIR CONSUMPTION FACTOR 34
12.0 ELECTRICAL ENERGY AND THERMAL ENERGY 34
13.0 FIELD STUDIES 35
14.0 EMISSION STANDARDS FOR CEMENT SECTOR 66
15.0 DUST COLLECTION SYSTEMS 67
16.0 SOURCES OF AIR POLLUTION 77
17.0 GUIDELINES TO CONTROL THE DUST EMISSION 79
LIST OF FIGURES
Page No.
Fig 1: Fluid Bed Process 7
Fig 2 (a): Material flow in Reba Process 10
Fig 2 (b): Gas Flow in Reba Process 10
Fig 3: Lurgi Sinter Grate II
Fig 4: Flow Sheet of Dry Process Rotary Kiln Cement Plant 13
Fig 5: Flow Sheet of Black Meal Vertical Shaft Kiln Cement Plant 15
Fig 6: General Arrangement - CRI Modem Vertical Kiln 17
Fig 7: Flow Sheet of CRI - MVSK Cement Plant 19
Fig 7A; Flow Sheet of 200 TPD Vertical Shaft Kiln of M/s Dalmia Cement
(Bharat) Ltd. 23
Fig 7B: Process Flow Sheet of M/S Saboo Tiny Cement Plant 25
Fig 7C Flow Sheet of Dry Process Rotary Kiln Cement Plant 28
Fig 8: Schematic of Gravity Settling Chambers 69
Fig 9: Design Proportions of A Cyclone Dust Separator 70
Fig 10: Longitudinal Section of Multicyclone 72
Fig 1 l : Typical Bag House 74

Fig 12: Wet Scrubber 76
LIST OF TABLES
Page No.
Table 1: Status of Mini Cement Plants at a Glance as on March 31, 2001 2

Table 2: Status of Mini Cement Plants at a Glance as on March 31, 2006 2
Table 3: Global Survey of Vertical Shaft Kilns in Operation 4
Table 4: Operation Data on Vertical Shaft Kiln based on CRI -MVSK
Technology 33
Table 5: Raw Materials Consumption Factor 34
Table 6: Electrical Energy Requirement 35
Table 7: Sections Causing Air Pollution for Plant 1 37
Table 8: Stacks Emission Monitoring Results at outlet of APCD 37
Table 9: Other Stacks Emission Monitoring Results 38
Table 10: Ambient Air Quality Monitoring Results 38
Table 11: Chemical Composition of Raw Materials & Raw Meal 39
Table 12: Design Parameters of Air Pollution Control Devices Installed at
Various Sections 41
Table 13: Capital and Operation & Maintenance Cost of Air Pollution Control
Devices 41
Table 14: Noise Level 42
Table 15: Water Quality 42
Table 17: Stacks Emission Monitoring Results at outlet of APCD 44
Table 18: Other Stack Emission Monitoring Results 44
Table 19: Ambient Air Quality 45
Table 20: Chemical Composition of Raw Materials & Raw Meal 45
Table 21: Design Parameters of Existing Air Pollution Control Devices 47
Table 22: Noise Level 47
Table 24: Raw Materials Consumption Factor for Plant 3 50
Table 26: Raw Materials Consumption Factor for Plant4 53
"Table 29: Sections Causing Air Pollution for Plant 6 58
Table 31: Sections Causing_ Air Pollution for Plant 7 61
Table 35: Particulate Matter Emission Standards in India 67
Table 36: Section wise Suggested Dust Collectors 79
ANNEXURES
Page No.
Annexure- 1 List of VSK Mini Cement Plants 81

Annexure- 2 Emission Data of Plant No. 3 137
EXHIBITS
Page No.
Exhibit-- I Distribution of Mini Cement Plants in India 149

Exhibit 2
— Flow sheet of Plant- 1 150
Exhibit 3
— Location of Noise measurement Plant- 1
— 151
Exhibit —4 Flow sheet of Plant-2 152
Exhibit 5
—
153
Exhibit 6
— Flow sheet of Plant-3 154
Exhibit 7
— 155
Exhibit 8
— Flow sheet of Plant- 4 156
Exhibit 9
—
157
Exhibit 10 Flow sheet of Plant- 5
—
158
Exhibit 11 Location of Noise measurement Plant- 5
— —
159
—
160
— —
161
Exhibit 14 Flow sheet of Plant-7
—
162
—
—
163
—
164
—
—
165
EXECUTIVE SUMMARY
Presently in India there are 333 vertical shaft kiln (VSK) based mini cement
plants of various capacities ranging from 20 to 300 tonnes per day (TPD) of
various technologies set up in different parts of the country. The distribution is in
the form of clusters.
2 Out of 333, only 193 VSK based mini cement plants are in operation having
operating capacity of 3.47 million tones per annum.
3 Mini cement plant is basically air polluting industry. The air pollution is mainly in
the form of particulate matter emission.
4 To assess the present environmental scenario of Indian Vertical Shaft Kiln (VSK)
based Mini Cement Plants, a questionnaire was prepared and sent to 279 VSK
Mini Cement Plants.
The Mini Cement Plant clusters were divided into two regions namely southern
region and northern region. Two plants from southern region and six plants from
northern region were selected for the study. The two plants in A.P are based on
CRI -MVSK technology having the installed capacity of 200 TPD with two VSKs of
100 TPD each. Six plants selected in Behror, Rajasthan are based on Saboo
VSK Technology having the installed capacity ranging from 20 to 50 TPD.
5 In-depth study was pursued in eight plants. The data in these plants were
collected with respect to history of the plant, manufacturing process and flow-
sheet, sources of air pollution, stack emission monitoring, analysis of particulate
mater for particle size distribution, raw materials quality and its effect on air
pollution, pollution control devices adopted and their design, economics, noise
pollution etc.
6 The methodology adopted for collection of data and information includes:
a) Visit to VSK mini cement plants

b) Discussion of various environmental related issues with the management.
c) Environmental monitoring was carried out for the following:
i) Ambient Air Quality in downwind and upwind directions
ii) Fugitive dust at various working areas.
iii) Stack emission: Stacks of VSK: Particulate matter, SO2
Stacks of Other Sections : Particulate matter
iv) VSK flue gas analysis: Monitoring of 0 2 , CO 2 , CO and N 2
v) Particle size distribution of particles emanated from VSK.
vi) Noise monitoring near various processing equipment.
7. In plant no. 1 all the sections were provided with necessary pollution control
devices. The particulate matter emission from raw mill, cement mill and VSK is
69, 86 and 348 mg/Nm 3 respectively. It was observed that by changing the raw
mix design, the particulate matter emission from VSK can be brought down to 95
mg/Nm 3.
Ambient air quality monitoring was conducted for RSPM, SPM, 50 2 and NO X in
up wind and down wind direction. The value of RSPM, SPM, SO2 and NO X in the
up wind direction is 280, 641, 12 and 7 µg/m 3 respectively. The value of RSPM,
SPM, SO2 and NO X in the Down wind direction is 310, 899, 14 and 8 µg/m 3
respectively.
8 In plant no.2, Air Pollution Control Devices were provided only in raw mill and
cement mill sections. The particulate matter emission from raw mill, cement mill,
VSK no. 1 and VSK no. 3 is 153 mg/Nm 3 , 67 mg/Nm 3 , 167 mg/Nm 3 and 73
mg/Nm 3 respectively.
Ambient air quality monitoring was conducted for RSPM, SPM, 50 2 and NO in
up wind and down wind direction. The value of RSPM, SPM, SO2 and NO in the
up wind direction is 142, 910, 7 and 6 µg/m 3 respectively. The value of RSPM,
SPM, SO2 and NO in the Down wind direction is 275, 1205, 9 and 7 µg/m 3
respectively.
9. In plant no. 3, the average value of particulate matted emission from VSK is
119 mg/Nm 3 . Ambient air quality monitoring was conducted for RSPM, SPM,
SO2 and NO in up wind and down wind direction. The value of RSPM, SPM,
SO2 and NO in the up wind direction is 151, 170, BDL and 34 µg /m 3
respectively. The value of RSPM, SPM, SO2 and NO in the Down wind
direction is 194, 205, BDL and 65 µg/m 3 respectively.
10 In plant no. 4, the average value of particulate matter emission from VSK is 226
mg/Nm 3 . Ambient air quality monitoring was conducted for RSPM, SPM, SO2 and
NO, in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO x
in the up wind direction is 144, 507, 17, and 52 µg/m 3 respectively. The value of
RSPM, SPM, SO2 and NO in the Down wind direction is 158, 674, 27 and 66
µg/m 3 respectively.
NO in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO X
in the up wind direction is 258, 454, 9, and 33 µg/m 3 respectively. The value of
RSPM, SPM, SO2 and NO X in the Down wind direction is 415, 900, 12 and 61
NO X in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO
in the up wind direction is 121, 238, 15 and 116 µg/m 3 respectively. The value of
mg/Nm 3 . Ambient air quality monitoring was conducted for RSPM, SPM, SO 2 and
NO in up wind and down wind direction. The value of RSPM, SPM, SO2 and NO,,
in the up wind direction is 137, 410, 10 and 128 µg/m 3 respectively. The value of
14 In plant no. 8, the particulate matter concentration at inlet and out let of dust
settling chamber of VSK is 584 and 104 mg/Nm 3 respectively. Ambient air quality
monitoring was conducted for RSPM, SPM, 502 and NO in up wind and down
wind direction. The value of RSPM, SPM, SO2 and NO in the up wind direction is
177, 967, BDL and 155 µg/m 3 respectively. The value of RSPM, SPM, SO 2 and
NO in the Down wind direction is 289, 1313, BDL and 164 µg/m 3 respectively.
15 Few CRI -MVSK (Cement Research Institute of India - Modern Vertical Shaft Kiln)
cement plants are having pollution control devices in all the sections while other
technology based VSK plants are not having pollution control devices in all the
sections. These plants are having only open type bags as pollution control
devices in all the sections, which needs to be modified.
16 As a guideline following pollution control devices are suggested for various
sections of VSK based mini cement plants subject to compliance of emission
standards:
a) Crushing and raw materials proportioning section - Bag Filter.
b) Raw mill section - Twin cyclone and Bag Filter
c) Homogenising Silo - Bag Filter
d) Nodulizer - Bag Filter
e) VSK stack - Cyclone
O Clinker crusher and discharge section - Bag Filter

g) Cement mill and packing house - Bag Filter
The above air pollution control devices are indicative in nature. Cement Plant
may explore the possibilities of other devices also. The important thing which is
to be kept in mind is that in all the cases the plant has to meet the prescribed
emission standards.
Clm
1.0 INTRODUCTION
The capacity of a mini cement plant based on Vertical Shaft Kiln (VSK)
technology is limited to 300 TPD or 99000 TPA and the capacity of a mini cement
plant based on Rotary Kiln (RK) technology is limited to 900 TPD or 2,97,000
TPA (For the plant based on RK technology, the capacity has been enhanced
from 600 TPD or 1,98,000 TPA to 900 TPD or 2,97,000 TPA vide notification no.
20/99 — Central Excise dated 7 May 1999). These plants are mainly based on
vertical shaft kiln technology (VSK). At present there are 333 VSK mini cement
plants of capacities ranging from 20 - 300 TPD of various technologies located in
different parts of the country. During the various operation of cement
manufacturing, dust is emitted which poses problem of air pollution. Majority of
these plants are located in clusters in Andhra Pradesh, Karnataka, Madhya
Pradesh and Rajasthan. Rests of the plants are distributed in the other parts of
the country as shown in Exhibit — 1.
2.0 OBJECTIVES OF THE STUDY
In the absence of definite techno-economic control devices, air pollution control

in VSK mini cement plants could not be achieved at the desired level. The
present technologies adopted by most of the plants are not adequate.
Considering the above, it was decided to develop .a comprehensive industry
document (COINDS) on VSK mini cement plants.
The present study of VSK mini cement plant deals with manufacturing process,
identification of sources of dust emission, stack emission monitoring, analysis of
particulate matter for particle size distribution, air pollution control devices
adopted, ambient air quality monitoring and section wise suggestions for dust
control system.
3.0 GROWTH OF MINI CEMENT PLANT
The prevailing scenario of acute cement scarcity in mid seventies with

inadequate investment in this core sector, led to the Government policy for
promotion of mini cement plants which could fulfill many objectives in addition to
producing cement to meet the local needs. Taking into account various factors
which were prevailing then, the Government of India came out with the policy for
promotion / establishment of mini cement plants in early 1979. In addition to the
several incentives and concessions offered by the Government for establishing
mini cement plants, the policy also had laid stress on certain socio-economic
objectives to be fulfilled in setting up the mini cement plants.
As a result of the Government's encouragement backed by the technological

support extended by the National R&D laboratories in the country, a number of
mini cement plants came up in different parts of the country, mostly on
conventional dry process rotary kiln and vertical shaft kiln technologies of CRI,
Saboo & RRL, Jorhat. The first VSK based (30 tpd CRI -MVSK) mini cement
1
plant became operational in early 1981, whereas the first (200 tpd) mini cement
plant based on rotary kiln technology went on stream in 1982. In addition, some
VSK plants mostly in small-scale sector came up, whose plant and machinery
were supplied by M/s. Shree Engineers, Jodhpur.
Status of mini cement plants at a glance as on 31 March 2001 and 31 March

2006 is given in Table 1 and Table 2 respectively. Thus, it could be seen that
during the Xth Five Year Plan, there has been an addition of 8 plants based on
Rotary Kiln Technology, increasing the operating capacity from 5.96 MTPA to 6.4
MTPA. Number of mini cement plants in the country, installed capacity, location,
year of commissioning of various technologies is listed at Annexure 1.
Table 1: Status of Mini Cement Plants at a Glance as on March 31, 2001
Cement Plants
Originally Set up In operation
SI. Technology Nos. Installed Nos. Installed Production
No. Capacity Capacity (MTPA)
MTPA (MTPA)
1 Rotary Kiln 31 4.003 24 3.411 2.388
2 CRI -MVSK 101 3.354 30 1.179 0.825
3 RRL-VSK 31 0.286 - - -
4 Saboo-VSK 202 3.449 78 1.378 0.689

Total 365 11.092 132 5.968 3.902
Table 2: Status of Mini Cement Plants at a Glance as on March 31, 2006
Originally Set Up No. of Cement Plants Operating

Closed In operation Capacity
(MTPA)
Rotary kiln: 39 26 13 2.93
Verticlal Shaft Kiln: 333 140 193 3.47
Total 37 2 1 66 20 6 6.40
4.0 WORLD SCENARIO OF MINI CEMENT PLANT
The Chinese cement industry has seen a rapid growth over the last five decades.
The production of cement was less than 3 Million tonnes in 1952, but in 1999 the
total production of cement reached 573 Million tonnes. Thus, China, accounting
for about one third of the global cement production ranks first in the world today
in terms of cement output.
The total installed capacity of the Chinese cement industry is estimated at 700
Million tonnes from over 7000 cement plants, which means that the average
capacity of each cement plant is about 1,00,000 tonnes per annum. In China,
K
the cement industry has a multiple ownership structure and a major part of the
industry belongs to the Ministry of Agriculture under its Administration of Town
and Village Industrial Enterprises (TVIE). The cement plants belonging to this
sector are small and based on Vertical Shaft Kilns (VSK), which traditionally have
consumed high levels of raw materials, fuel and power and therefore cause
serious environmental pollution.
During the last five years, there have been planned efforts to look at the energy
and environmental issues of these plants with the help of international
organizations like UNIDO, IVAM Environmental Research and University of
Amsterdam. These international bodies have undertaken the study for cleaner
production technology and energy conservation measures in these cement
plants.
As previously mentioned, the Chinese cement industry still uses the VSK process
as its principal technology. However, in the last two decades, there has been the
introduction of modern preheater and precalciner kiln systems at medium and
large sized plants. The sum total effect has been the existence of a mix of
technologies and there are now over 13,000 VSK plants in China.
Currently, the modern large cement plants with precalciner technology cover less
than 10 percent of the total cement output of the country. About 12 percent of
the output comes from a plethora of small and medium size rotary kiln plants.
The total output from the VSK plants constitutes about 78 percent. According to
a regulation issued in 1997, the VSKs with a capacity of 44,000 tonnes per
annum or less were to be discontinued by the end of 2000, barring only a few
regions where the deadline is 2005. By the end of 1999, it had been officially
reported that the VSK plants with an aggregate production capacity of about 20
Million tones per annum had been closed down. The production and distribution
of Vertical Shaft Kiln (VSK) mini cement plants worldwide are given in Table 3.
5.0 COMPARISON OF LARGE AND MINI CEMENT PLANTS
Cement is one of the most important building materials. The total cement
production in the world reached 1950 million tonnes in 2003. A major percentage
of this total production is from large-scale plants with capacities ranging from
2000 to 20,000 tpd and transported to the place of use in bulk or bags.
Large capacity plants are appropriate for deriving the benefits from economies of
scale in locations where:
- Large enough deposits of the basic raw material i.e. limestonne is

available.
- Infrastructural needs such as power and transportation system are
sufficient.
- Cement consumption is substantially concentrated.
- Transportation costs are low
3
Capital-intensive technology is preferable from socio-economic
considerations.
Table 3: Global Survey of Vertical Shaft Kilns in Operation
SI Country No. of VSK No. of Active Production

No Cement Plants Kiln X103 TPA)
9 Kenya 1 2 100
2 Brazil - - -
3 Iraq 1 2 292
4 Bhutan 3 4 74
5 Indonesia 1 2 110
6 Lao Peoples Dem
1 1 65
- Rep.
7 Nepal 4 5 150
8 Germany 2 15 1200
9 Italy 1 1 60
10 Slovak Republic 1 4 150
11 France 5 20 1500
12 Russia 1 6 310
13 China 107 221 25202
14 USA - - -
15 Australia - - -
16 Madagaskar 1 2 200
17 European Union - - 400
18 CEMBUREAU - - 400
19 Central America - -
20 South America - - -
Mini cement plants are appropriate for other areas particularly in cases like :
- Small countries, which intend to develop their own cement industry to

cater to their limited needs, thus becoming independent of imports.
- Large countries with low population density and/or low per capita cement
consumption.
- Only scattered limestonne deposits, which cannot sustain large-scale
cement plants, are available.
- Large cement plants cannot be set-up due to infrastructural constraints —
specially hilly and remote regions.
4
Areas where local and regional market will absorb the production of a mini
cement plant only and that industrial size plants could not operate at
economic production rates.
Socio -economic consideration justifies a Labour intensive technology
rather than a capital intensive one.
Mini cement plants have following advantages.
- Lowers capital investment per unit production without sacrificing quality of

either the plant or the product.
- Helps realise quicker returns on capital invested because of lower
gestation periods.
- Brings cement industry within the financial access of smaller entrepreneur
and thus enlarge entrepreneurship in the country.
- Contributes to uplifting local economy and development as well as to
formation of rural cooperatives as owners of cement plant.
- Creates employment opportunities in rural areas on a well dispersed basis
- Enables development of cement industry in terrains where movement of
heavy machinery and cement are difficult.
- Makes it possible to exploit small deposits of limestonne as well as limited
quantities of calcareous industrial wastes.
- Avoids wasteful movement and thus helps to bring down the average unit
cost of transportation of cement in the country as well as strain on Nation's
transportation system.
- Eliminates packing charges where the utilisation point is localised by
resorting to bulk supply.
6.0 CEMENT MANUFACTURING TECHNOLOGIES
The various technologies, which have been tried for adoption in mini cement
plant, are:
i) Fluidized Bed Process (Fuller Pyzel)

ii) Reba Process
iii) Travelling Grate (Lurgi sinter grate)
iv) Rotary kiln and
v) Vertical Shaft Kiln
In a nutshell, in all these five alternative schemes of technological lines, there is

an upper and lower threshold of size beyond which either it is technologically not
feasible or economically not viable. Down scaling of plants under any particular
technology even within these threshold results in
Increase in investment per annual tonne of installed capacity

Increase in the cost of production per tonne.
5
So when the technical and economical threshold is reached for any given
technology line, other technology lines may still give technically feasible and
economically viable results.
The conventional rotary kiln is normally uneconomical below 300 to 600 tpd and
so the technology lines like Sintergrate and Reba evolved, but they could not
succeed due to inherent defects.
A brief process description for all these technological lines which were tried or
adopted for manufacture of cement in small scale are given in the following
sections:
6.1 Fluidised Bed Process
Of these the fluidised bed or Pyzel process is the least popular because the
number of plants working on this process are extremely few even on global basis
and not much is known except for some broad principles of working. This
process, invented by Robert Pyzel, has been developed in USA by Fuller. A 100
tpd pilot plant based on this technology is reported to be in operation on
experimental basis for the last six years with M/s. Scientific Design Company,
New York, USA. (Fig. 1)
6.1.1 Process Details
The plant consists of a fluidised bed reactor; raw meal consisting of finely ground
feed mixture is pneumatically conveyed to the fluidised bed alongwith fuel and
preheated air. The temperature of the fluidised bed is maintained at
approximately 1315°C by introducing the fuel directly into the fluidised bed.
Cement clinker being almost refractory, coarse clinker particles of 0.8 to 8 mm

can be maintained in granular form in suspension, when finely ground raw mix is
pneumatically blown in, raw cement phases are formed on the hot surface of
characteristically round clinker particles, so that they grow in size continuously.
The Specific heat consumption reported without any heat recovery system is
2600 Kcal/kg of clinker and with heat recovery system 1046 Kcal/kg of clinker.
Energy requirement for production of clinker alone by the fluidised bed reactor is
55 Kwh/t as against 20-25 Kwh/t of clinker in case of rotary or shaft kilns.
Fuels like gas, oil, coal, anthracite and coke could be used in this process.
This process stands a good chance for a promising market in USA as there are
very strict environmental protection specifications regarding oxides of sulphur
and nitrogen. At the same time special `low alkali' cement specifications
0
-•- HOT KILN GAS
SIZE RECYCLE
CLINKER
REFRACTORY
LINING
CLINKER OVERFLOW
CARBON STEEL
SHELL
CAST REFRACTORY
PRE HEATED

AIR AIR PLENUM
RAW FEED
FUEL
FIG. 1 FLUID BED PROCESS
7
necessitate the rejection of large quantity of dust in rotary kiln burning operation.
This dust with high alkali content can be used as a cement raw mix in the Pyzel
reactor.
The specific advantages of Pyzel process have been claimed where there is (a)
high alkali problem; (b) strict environmental protection regulations regarding
oxides of sulphur and nitrogen from exit gases; (c) disposal problem of kiln dust
with high alkali content; and (d) using different fuels like gas, oil, coal, anthracite
and coke.
The high investment cost for the heat recovery systems and stringent controls
through an elaborate instrumentation and automation and non-availability of
highly skilled personnel for the operation of the reactor, go against the very
philosophy of mini cement plant. Due to the inherent technological problems in
stabilising the operation of plants based on the above process and also due to
the reported high investment cost per annual tonne of installed capacity, mini
cement plants based on the above technology have not been reported to be a
commercial success anywhere in the world.
6.2 Reba Process
In this process, the feed operation requires crushing of limestonne to — 15 mm

size, storing in bays/bins, proportioning of raw materials and final grinding in a
roller/ball mill, homogenisation of raw meal and storage.
The fuel used is oil or gas. The homogenised raw meal is fed to a noduliser
where nodules are formed with addition of water and are then fed to a
combustion chamber. The nodules are dried in the preheating zone and heated
in the calcining zone to about 1100°C. The granulated material is then sintered
at about 1450°C and cooled in the shaft cooler. The flow of gases is in opposite
direction to flow of material and thus air used to cool the clinker heats up and is
used as secondary air together with primary air when burning the fuel.
Reba process has not so far been operated on solid fuel, i.e. coal and as such no
operational data are available on such applications.
It was claimed by the firm M/s. Ready Mix Cement Engineering of FRG that the
Reba Kiln installations for production of cement in the range of 50-200 tpd still
have low investment costs and less energy consumption. The heat consumption
is estimated to be approximately 730 Kcal/kg of clinker. Furthermore, the
electrical energy consumption should correspond to that of rotary kilns. The
energy consumption for burning of materials alone is claimed to be 14 Kwh/t.
It is understood that the Reba process has been tried successfully only for
burning of lime and the firm is yet to establish the technology for burning of
cement clinker on a commercial basis. Further, the quality of limestonne and fuel
tried are of very rich quality, i.e., very high percentage of lime in limestonne of the
order of above 52% and coal with every low ash content (10%) and high calorific
value and till date the technology has not been proved using cement grade
8
limestonne and coals with high ash content. No commercial plants are known to
be in operation in the world on this technology. (Fig. 2)
,
6.3 Travelling Grate (Lurgi Sinter Grate)
In this process, the feed operation requires crushing of limestonne to — 15mm

size in a crusher/mill, storing the materials of —15 mm size in gantry/storage bins,
proportioning of raw materials and final grinding in closed circuit ball mill/roller
mill, homogenisation of raw meal and storage, crushing and screening of coal to
—5 mm size in closed circuit operation and storing of crushed coal in bin.
The raw meal and crushed coal are then extracted from respective bins
according to requirement and conveyed to a drum type nodulizer. In addition, the
noduliser is also fed with 15% of —5mm size burnt clinker to form core of nodules
and 15% water spray. The nodules are conveyed by a belt conveyor to moving
sinter bed made of cast iron grate base. A 75 mm thick layer of + 5 mm and —10
mm burnt clinker is first spread over this bed and then the fresh nodules fall over
this. The sinter bed passes through various zones over some distance where
suction is maintained through ID fan. Light diesel oil is fired over the bed in hood
fixed about 200 mm above the bed height and the resulting clinker is discharged
through a rotating arm type breaker in red hot condition over an open pan type
horizontal conveyor where it undergoes cooling. (Fig. 3)
6.4 Small Rotary Kiln
Here the kiln feed and fuel preparation requires crushing and grinding operations,
like:
- Crushing of limestone and additives in a hammer mill or 2-stage, viz., jaw
crusher and hammer mill to —15 mm size.
- Storing the crushed raw materials in storage yard/bins.
- Proportioning and grinding the raw materials in a roller/ball mill.
- Homogenising and storage of raw meal in blending and storage sections.
- Fuel, viz, coal (VM 25-30%) is pulverised in a separate section (combined
coal drying-cum-grinding section).
Blended and homogenised raw meal is then fed to the suspension preheater of
counter current type, where it is preheated and partially calcined by the kiln hot
gases passing in counter current. Raw meal enters the kiln at a temperature of
700°C - 800°C. The exit gases from the preheater are then passed through the
dust collection system and discharged to atmosphere. Dust collected is recycled.
Pulverised coal mixed with primary air is fired from the lower end of the rotary kiln
through coal burners. Secondary air is supplied through clinker cooler to make
up for the combustion air. A flame at around 1660°C is maintained. This heat
er

GRANULATING TABLE
CHAMBER-2
PREHEATING SHAFT
GRATE
GRATE
CALCINATION ZONE
GRATE
UPPER PUSH CAR
SINTERING ZONE
GRATE
LOWER PUSH CAR
CLINKER COUNTER CURREN
SHAFT COOLER
COOLER DISCHARGE
HG. 2(a) MATERIAL FLOW IN REBA PROCESS
EXHAUST GAS
EXHAUST
rfI
GAS FAN o
-s py A
6 - FAN -CALCINATING ZONE
° 2
FAN SINTREING ZONE
--^ FRESH AIR
^^ COOLER FAN
° FRESH AIR
FIG. 2(b) GAS FLOW IN REBA PROCESS

10
t W
tJ
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J ^
um
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F-
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W W
Y W cx
Z ^ l_7
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ia O
<U-
11
the material as the kiln rotates at 1 to 2 rpm. Various chemical reactions
(Calcination, sintering, cooling) takes place as the material temperature goes
upto 1440°C. Hot gases having transferred the heat to material escape in
counter flow i.e. from lower- end to upper end through suspension preheater and
dust collectors to atmosphere. Clinker is discharged into clinker cooler, which
may be rotary, planetary or moving grate type. Clinker is then transported to
storage yard and finally ground with gypsum. Control is maintained through
various control instruments and inspection of burning conditions. (Fig. 4)
6.5 Vertical Shaft Kiln
The use of vertical shaft kiln process for cement manufacturing dates back to the
year 1824 when Portland cement was invented. However, because of its non-
continuous operation, this process was found uneconomical and produced
clinker of non-uniform quality.
Later after the development of continuous pan type noduliser, a significant

advance was achieved and the shaft kiln performance improved considerably
thus permitting its adoption and production of uniform quality of clinker on a
continuous basis. Cement manufacture by using Modern Vertical Shaft kiln is
reportedly being carried out in different countries like China, India, West
Germany, Australia, Italy, Indonesia, Nepal, Bhutan etc. In fact, a wide variety of
processes have been adopted for the manufacture of cement through Vertical
Shaft Kiln and it would be desirable to mention some of these in the following
sections.
6.5.1 Black Meal Process
This is the most popular type of process used for manufacture of cement through
Modern Vertical Shaft Kiln in which the fuel (usually low volatile coal or coke
breeze) is interground with the raw mix for efficient and uniform burning. Most of
the cement plants using Vertical Shaft Kiln like CRI — Modern Vertical Shaft Kiln,
Vertical Shaft Kiln supplied by M/s. Loesche of West Germany etc are mainly
based on the black meal process.
In this process, the vertical shaft kilns are fed with raw mix of appropriate
composition in the form of nodules. The feed operation usually requires crushing
of limestonne to about -15 mm size in storage bins, proportioning of raw
materials and grinding in a roller or ball mill, homogenizing and nodulizing in pan
type nodulizer. The successful operation of shaft kiln, to a great extent, depends
upon the size of nodules, their uniformity, porosity and thermal stability. The
noduliser consists of an inclined disc or pan rotating about its axis. Raw meal is
charged into noduliser by means of screw conveyor and water is sprayed, while
all the parameters are maintained at optimum conditions. A specially designed
rotating scraper continuously cleans the bottom and the collar of the drum of the
raw meal deposited. The nodules slide down the chute and are •charged in the
12
AIR LACK
FEEDER
SECONDARY AIR
BLOWER
CEMENT CYCLaN
MILL
BUCKET
ELEVATOR
LOADING
1
BAGGING R
BRANDING
FIG. 4 FLOW SHEET OF DRY PROCESS RBTARY KILN CEMENT PLANT

13
vertical shaft kiln evenly all around the periphery continuously with the help of a
rotary feeder situated on the top of the kiln.
The vertical shaft kiln in which the nodules are converted into clinker consists of
a cylindrical shell with conical portion at the top and lined with refractory bricks.
The sintering is normally complete within the conical portion, which is specially
designed to accommodate for shrinkage of nodules. The various zones of
reaction starting from the top of the kiln are; the drying zone, the calcining zone,
the sintering zone and the cooling zone. The combustion air supplied by Roots
blower ascending from below in the cooling zone absorbs heat from the
descending clinker. The whole kiln charge composed of unburnt nodules and
clinker rests on a flat grate rotating slowly at the bottom of the kiln and mounted
over the kiln shaft. The grate is driven with the help of variable speed motor in
order to control the discharge rate of clinker. The clinker is finally taken out of
kiln bottom with the help of a triple air lock mechanically (or hydraulically)
operated discharge gates or Gamma Ray controlled Material Block Tube System
used in Modern Vertical Shaft Kilns. (Fig. 5)
6.5.2 Coal Slurry Process
A variation of the Black Meal process as proposed by Dr. Steven Gottlieb is `Coal
Slurry Process' the main difference being in the method of feed preparation. The
method requires the raw meal to be ground `white', i.e. without fuel. The fuel
(coal with volatile matter upto 16-18%) is ground separately in a wet ball mill to
make slurry with about 50% moisture. The 'white meal' and the `coal slurry' are
separately stored in hoppers over the noduliser platform and are pumped at
controlled rates (through flow meters) into a double paddle mixer to mix the feed
continuously and discharge into the standard noduliser where practically no or
very little water is added to give final shape to the nodules. These nodules are
charged and burnt in the vertical shaft kiln in the same manner as in the case of
"Black Meal' process.
The main advantage claimed by this process is that by wetting of the coal
particles before nodulising, the retention time for the volatile component of the
fuel is increased, thereby allowing this to travel to a zone where adequate
oxygen is available to complete the combustion of the volatile matter within the
bed — thereby permitting a higher volatile content in the coal when compared to
that used in the 'Black Meal' process.
6.5.3 Differential Heat Burning Process
This process, which is a slight variation of the black meal process, has been
reportedly tried out in a number of cement plants in China. In this process about
50% of the total fuel required is interground with the raw meal and the balance is
added later prior to nodulisation. This has been based on the assumption that
the heat requirement at the periphery of the bed in a VSK is usually more by
14
WEIGH BRIDGE
LIMESTONE ADDITIVE
STORAG E
HOPPER
HOPPER HOPPER HOPPER HOPPER
TABLE ^ TABLE TABLE TABLE TABLE
FEEDER FEEDER FEEDER FEEDER FEEDER
BELT CONVEYOR
BUCKET ELEVATOR
7 RAW MIX HOPPER

TABLE FEEDER
FAN
kW MILL
SCREW
CONVEYOR BUCKET ELEVATOR
L P BLOWER
BLENDING SILO
H P BLOWER
RAW MEAL STORAGE
SC 1jJ
CONVEYOR 1
BUCKET ELEVATOR
RAW MEAL HOPPER
SCREW CONVEYOR
NODULISER 4--WATER
EXHAUST VERTICAL SHAFT
KILN
ROOTS
BLOWER
CLINKEI
TABLE I HOPPER
FEEDER
CEMENT Q CEMENT
SILO
LOADING BUCKET
ELEVATOR
WARE PACKING &
HOUSE BRANDING
IG. 5 FLOW SHEET OF BLACK MEAL VERTICAL SHAFT KILN

CEMENT PLANT
15
about 150 kcal/kg of clinker than that in the middle and in this process some
additional fuel is added at the periphery of the bed as compared to that in the
middle to balance the heat distribution.
7.0 TYPES OF MINI CEMENT PLANTS IN INDIA
7.1 CRI — Modern Vertical Shaft Kiln Technology
CRI — Modern VSK technology was pioneered in India by Cement Research

Institute of National Council for Cement and Building Materials as early as 1972
and was first tried out in 1974. General arrangement of CRI- Modern Vertical
Shaft Kiln is shown in Fig. 6. The CRI — Modern VSK cement plant as a compact
unit incorporates the following salient features:
a) A hopper with ramp and reciprocating/laminated feeder has been provided

to ensure continuous feed of uncrushed limestonne to primary crusher.
b) Crushing section usually consists of two stage crushing, Jaw Crusher as
primary and Hammer Mill as secondary one. This will ensure better mill
performance due to uniform feed to the raw mill.
c) Continuous, automatic and accurate raw materials extraction for
proportioning by rotary table feeder/vibratory feeder, with electronic weigh
feeder as an optional feature.
d) Conventional closed circuit air swept ball mill system with trunion and girth
gear arrangement with grit separator, cyclone and bag filters for grinding
of raw materials to ensure the desired granulometry of raw meal resulting
in proper burning.
e) Differential (HP & LP) pneumatic blending with quadrant system reduces
the variation to 1:10 within the smallest possible time.
f) Specially designed Double Collar Noduliser with automatic closed loop
control results in nodules of higher green strength due to extra rolling
action and desired size, porosity and moisture content.
g) Continuously operated rotary feeder drive with adjustable tilt angle and
adjustable height in order to achieve the desired bed profile in the MVSK.
h) Material Block Tube along with `Gamma ray level control device' for clinker
extraction from the MVSK has the advantages of less air leakage, less
dust and noise, lower maintenance and more efficient burning process
due to reduced fluctuations in the combustion air supply.
i) Improved instrumentation system has been provided to monitor all
important process parameters on a continuous basis. All major system
parameters are indicated and recorded.
j) Fully equipped laboratory for physical testing and chemical analysis as per
requirements of BIS. Provision for optimum raw mix design also exists
through CRI -MVSK raw mix design software.
k) In order to improve the burning process inside the VSK and to achieve
higher output and better quality of product, automatic closed loop process
control has been incorporated in the noduliser and VSK section.
16
SP
MATERIA
WITH GAMMA
=R
UrU v ilw
ARRANGEMENT
GENERAL ARRANGEMENT
CRI MODERN VERTICAL SHAFT KILN
FIG. L
17
I) Safety measures including carbon-monoxide alarm system and electrical
interlocking of drives have been provided in order to protect the manpower
and equipment which include a special alarm for combustion air failure to
prevent any flame shoot out due to carbon-monoxide formation.
m) Dust collection system with stacks is incorporated in all the sections like
crushing, raw mill, blending, cement mill and cement packing which will
ensure a very clean and dust free environment in the CRI -MVSK cement
plant. In addition, modern and proper dust collection arrangements at all
transfer points including proper ventilation of tunnels and a specially
designed low cost dust limitator in the MVSK chimney have been provided.
A typical flow sheet for mini cement plant based on CRI- Modern Vertical Shaft
Kiln is shown in Figure 7. The process is explained below:
CRI -MVSK technology is based on the black meal process in which all the raw
materials, viz, limestonne, clay fuel (coke breeze, pet coke, Jhama coal or any
suitable low volatile coal) and other corrective materials are ground together to a
fineness of 10% retained on 170 mesh as in dry process and intimately blended
to satisfy the chemical requirements for the raw meal. The homogeneous raw
meal is formed into nodules of the desired size by adding water in a pan
nodulizer and fed into the vertical shaft kiln through a revolving feed hopper. As
the material passes down the kiln, it is dried heated and then burnt into clinker.
The clinker is then cooled and discharged from the kiln by a rotary grate at the
bottom of the kiln through a triple air lock discharge device or gamma ray
}
controlled Material Block Tube (MBT). The combustion air to the kiln, which is
provided by a Roots blower, also serves the purpose of cooling the clinker and
thus avoids wastage of heat. The clinker then passes to a cement mill where it is
ground with about 5% gypsum to produce cement of standard quality.
7.2 RRL Technology
Regional Research Laboratories (RRL), Jorhat constituent laboratories of Council

of Scientific and Industrial Research (CSIR), has also done considerable work on the
development of Vertical Shaft Kiln Technology under Indian conditions. About 5
plants based on RRL technology are operating in India and about 10 plants are
under various stages of erection and commissioning. Out of these plants only
one is of 100 tpd capacity and the remaining are of 40 tpd and smaller sizes.
This technology could not become very popular as RRL, unlike NCB, does not
directly associate with the project right from the inception to the commissioning
stage and the licenced fabricators/consultants could not effectively manage the
turn-key supply, erection and commissioning of such plants.
The details of RRL Technology are not available since even a single plant is not
in operation.
18
THIS DRAWING IS PROPERT OF NATIONAL COUNCIL FOR CELTENT -'
A4O BUILDING MATERIALS. AND ITS COPY RIGHTS SOLELY WITH
NCB.. IT SHOULD NOT BE COPIED. REPRODUCED. LOANED OR DISPOSED ..
OF WITHOUT WRITTEN PERMISSION OF N C B.
7.3 M/S Dalmia Cement (Bharat) Ltd.
A mini cement plant of 170 tpd based on the Gottlieb Coal Slurry Process is
presently under operation in India at M/s. Dalmia Cement (Bharat) Ltd. at
Dalmiapuram. Although the production of cement from the plant is reported to be
satisfactory, the plant has not been able to achieve the advantage of using the
high volatile Indian coal used by other rotary kiln cement plants and is reported to
be using low volatile coal/coke breeze as being used by other VSK plants in India
based on the black meal process. Thus the additional investment incurred by the
plant due to separate coal slurry grinding and handling system has not given the
expected returns.
7.3.1 Process
A 200 tpd vertical shaft kiln was installed at M/s Dalmia Cement (Bharat) Ltd,
Dalmiapuram during 1982 and it is now working satisfactorily. This VSK is
operating on 'coal-slurry' process. It is an imported technology supplied by Dr.
S Gottlieb of Australia. A detailed study of this VSK starting from quarry to
cement stage is explained below.
7.3.1.1 Quarrying and Crushing
The limestone is being brought from open cast mines — Kallakudi, Vadugarpet,
Kovandakurichi and Perianagalur by means of locos and lorries. The limestone
will be dropped into the hopper by means of winches or electrical hoist depending
upon the case. The uncrushed limestone will be fed into Double Swing Hammer
Mill, supplied by. FLS., Copenhagen, through a laminated conveyor. This mill is
being driven by 2 HT motors (3.3 KV). The crushed limestone will be carried by
means of inclined belt conveyor to the limestone storage yard.
7.3.1.2 Raw Mill
The crushed limestone, clay and additives if required will be fed into the
respective hoppers by means of EOT crane. These raw materials through the
weigh feeder dropped into `Loesche' mill which is supplied by West Germany.
The capacity of the mill is 52 tonnes per hour. This mill is consisting of 2 rollers
kept over a moving thick metallic pad. The raw materials come in between the
moving pad and the rollers will be ground to the required fineness. These rollers
can be moved up and down by means of hydraulic pressure. The white meal
thus produced in this `Loesche' mill will pass through ESP and this will be fed into
the top of the blending silo of the double decker silo by means of flexo pump.
The corrected white meal will be dropped into the storage silo.
The white meal from the storage SP 10 will be pumped into VSK hopper through
Flexo pump. The capacity of this hopper is 400 tonnes. The white meal will be
fed into the boot of an elevator by means of double screw conveyor. The output
of the elevator is fed into the sieve screw conveyor. The capacity of elevator is
17 tonnes per hour and the capacity of sieve screw conveyor is 15 tph. The
foreign bodies will be removed in the sieve screw conveyor. The output of the
sieve screw conveyor will be fed into the weigh feeder where the quantity of white
meal will be weighed and fed into double shaft paddle conveyor. The rate of
white meal feeding is 11 tph. A special provision is provided underneath the
weigh feeder so that 95% of white meal will go to double shaft paddle conveyor
and the remaining 5% of white will be used for surface conditioning in the
noduliser.
7.3.1.3 Coal Mill
Single chamber tubular mill is used in M/s DCB Ltd, Dalmiapuram for coal
grinding. The capacity of this mill is 8 TPH. 50% coal or coke breeze and 50%
water will be fed into this mill. The output of this coal mill is called 'coal slurry'
which will be fed into the storage tank 'T 1 '. This coal slurry will be transferred
from tank 'T 1 ' into tank `T 2 ' by means of pump. The capacity of tank 'T2' is 60 to
80 tonnes. From the tank `T 2 ' the coal slurry is fed into the tank `T 2 A', situated at
a height of 8.6 m from the ground, by means of an elevator. From the tank `T 2A',
this coal slurry is pumped into tank 'T 3 ' ( called constant level tank) situated at a
height of 23.7 m from the ground by means of pump. From tank `T 3 ' the coal
slurry will be fed into double shaft peddle conveyor.
The white meal and the coal slurry will be thoroughly blended by means- of the
paddles of the double shaft paddle conveyor. This slurry will be fed into the
noduliser drum.
7.3.1.4 Noduliser
Controlled amount of water will be added and the pellets will be formed in the
drum. The size of the pellets is 10 to 16 mm. There is a provision provided for
the white meal coating — surface conditioning — over the pellets.
7.3.1.5 Rotary Feeders
Thus the pellets formed in the noduliser drum will be fed into the kiln through
rotary feeder. This is imported equipment. This rotary feeder can be moved up
and down and also left and right side by operating the controller. The nodules
will be distributed uniformly in the kiln.
7.3.1.6 Vertical Shaft Kiln
These nodules are thus distributed uniformly in the kiln and the kiln is kept
changed to a constant level and operates continuously. The material is first dried
in the enlarged upper portion and then falls slowly to the narrow portion.
Decarbonisation takes place at about 950 ° C and the final burning of the clinker
21
takes place at 1450 ° C. The clinker thus formed will be cooled in the lower part of
the kiln before it reaches the discharge gate.
The clinker is discharged through a rotary grate and a discharge gate.
7.3.1.7 Rotary Grate
By adjusting the speed of rotation of the grate, the amount of clinker discharged
and thus the rate of burning can be controlled. The type of grate is flat grate.
This grate consists of 6 segments of opening size 95 x 95 mm,
7.3.1.8 Discharge Gate
The discharge gate is provided with a triple gate air lock mechanism to prevent
loss of drought and production of dust. The discharge is automatic and the parts
of which are actuated hydraulically. The rotary feeder, discharge gate
mechanism and the king shaft assembly are all imported equipment and their
total cost is approximately one crore.
7.3.1.9 Blower
The air required for combustion is supplied by means of 2 blowers driven by 75

kw motors. One blower will be always running at constant speed and delivering
air at the rate of 125 Nm 3 /min constantly. The other blower is driven by a viable
speed motor, whose quantity of air can be varied from 26 Nm 3 /min to 100
Nm 3 /min. The air requirement for this VSK (at DCB) is 187 Nm 3 /min.
7.3.1.10 Cement Mill
Thus the clinker formed in VSK will be fed into the vibrating screen I. From there
this will go to clinker yard through vibrating screen II. This clinker will be fed in to
the cement mill hopper by means of EOT crane. Clinker and gypsum will be fed
into the 3 compartment tubular mill where these materials will be ground and the
output of this mill be fed into the cement silos through flexo pump. Earlier Dalmia
Cement (Bharat) Ltd, provided a clinker crusher underneath the discharge gate
and now they removed it since there is not much of lumps.
The flow sheet of 200 tpd VSK of M/s Dalmia Cement (B) Ltd is shown at Fig.
7A.
7.4 Tiny Cement plants
In India, any industry for which the cost of plant and machinery does not exceed
Rs 1,46,00,000 comes under the definition of `Small Scale Industry (SSI)' and is
offered certain concessions. Keeping this primarily in view, certain individuals /
small organisations have downscaled the VSK technology so as to offer such
plants under the SSI. Such plants are in the size range of 5 to 20 tpd and are
22
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23
popularly known as Tiny Cement Plants. In this direction, an individual called Mr.
D.P. Saboo of Jodhpur in Rajasthan has put in considerable efforts, and has put
up about 25 nos. of such tiny plants; most of these being based on high grade
limestonne deposits in the state of Rajasthan. The investment cost in such
plants have been brought down by resorting to in-house fabrication of machinery
as well as by elimination of certain equipment from the process line and resorting
to manual operation.
However, unfortunately, the tiny cement plant concept in India has taken a
dangerous turn with a large number of other individuals/spurious organisations
having entered the field of fabricating and supplying these plants, which are in
fact poorly copied version of certain proven technologies without the provision of
requisite technical back-up. This has already resulted in setting up of a few such
tiny cement plants, which have since become sick and have discontinued
production.
Brief Process of Manufacture of Portland Cement from Saboo VSK Tiny Cement
Plant is given below.
Limestone, Breeze Coke, Clay (Red-burning clay of Village Potters) and other
additives, as required, are crushed and stored automatically in different silos,
wherefrom they are again taken out in the desired proportions by a weigh-
batcher. They are further conveyed to a pre-blender and the blended materials
are thoroughly ground in an open-circuit Ball Mill to form homogenized Raw
Meal, from where it is conveyed through an elevator to blending silos and later to
a storage silo. This raw meal is subsequently lifted to the hopper of a noduliser,
where nodules are formed.
These nodules travel downwards into the kiln through a Rotary Chute and find an
access to the pre-heating zone followed by calcinations and clinkering zones,
wherein drying, pre-heating, calcining and sintering take place, leading to
conversion of nodules into clinker. This clinker, as received from the kiln through
the cooling zone, is subsequently mixed with gypsum in suitable proportion for
further grinding in the cement mill to produce the finished product, i.e pure
Portland Cement.
The flow sheet of Saboo VSK Tiny Cement Plant is shown at Fig. 7B.
7.5 J & K Cements, Wuyan
This 60-tpd plant is based on Lurgi Sinter Grate Process. This requires use of
light diesel oil as a fuel in addition to the low volatile coal already contained in the
nodules. The cement production at the plant has never exceeded 55% of the
installed capacity. The cost of fuel is as high as Rs 700 per tonne of clinker.
Apart from the high cost of production, the plant also finds it difficult to cope with
frequent breakdowns and quite involved maintenance is required due to
complicated machinery. The electrical energy consumption per tonne of cement
24
DAw kirAl VAfn
MILL
BUCKET
ELEVATOR
STORAGE
SILOS
WEIGH
BATCHER
BUCKET
ELEVATOR
RAW MILL
(OPEN CIRCUIT BALL MILL)
BUCKET
ELEVATOR
BLENDING
SILOS
BLOWER
BUCKET
RAW MEAL SECTION ELEVATOR

SURGE SILO SCREW CONVEYOR
WATER SURLY
SCREW CONVEYOR

Cat? NODUUZER
SABOO V S K
GYPSUM
KILN SECTION
BLOWER
CLINKER YARD
CEMENT MILL SECTION CEMENT MILL(OPEN CIRCUIT BALL MIIL)

LrING
L
0 0
I
• WEIGHING
• NOT SUPPLIED
FIG.7B PROCESS FLOW SHEET M/s SABOO TINY CEMENT PLANT
25
produced is as high as 208 Kwh. The heat consumption per kg of clinker
production is also as high as 2404 Kcals.
Although the quality of the cement produced by this process is 'reported to be

meeting all the specifications well, the working of the plant and its profitability has
all along been headache for the plant management. Due to the above
constraints, the plant management has ultimately decided to discard the
complete sinter grate system and have placed an order for CRI — Modern Vertical
Shaft Kiln along with the necessary balancing equipment to replace the existing
system. This clearly shows that the sinter grate technology has failed to be a
techno-economically viable solution for the manufacture of cement in small scale.
Since the above plant is not in operation for the last 1 1/2 decades and also the
equipment are obsolete in nature, plant is not able to provide data in this regard.
7.6 Small Rotary Kilns
Use of small rotary kilns has been adopted by many countries for cement
manufacture in small scale by downscaling the conventional rotary kilns. In
India, there are about 31 nos. of rotary kiln based mini cement plants under
operation and about another 5 nos. under implementation; most of these being
designated as 200 tpd in order to derive incentives offered by the Government of
India in terms of rebate in excise duty (which has since been discontinued) and a
free market. However, most of these plants are using kilns of 3 m dia and 40 or
45 m length — which under Indian conditions are rated as 300 tpd. One of the
major reasons for this has been the fact that the machinery
fabricators/consultants did not find it technically appropriate to further reduce the
kiln dimensions in view of anticipated problems relating to higher refractory
failure.
Thus, although a few mini cement plant based on the rotary kiln technology have
been set up in India as well as other countries of the world, mainly because of
the reason that this technology is a direct down-scaling of the conventional rotary
kilns which are technically well established, the cost of production and the
investment cost per annual tonne of installed capacity in such plants are found to
be exceptionally high due to the scale effects. Moreover, if one attempts to make
these small rotary kiln plants economically viable, then certain process and
operations have to be eliminated and the degree of sophistication of
instrumentation and process control systems would have to be lower which
would amount to sacrificing some of the modern features which are essential for
satisfactory performance and economic operation. Due to the inherent techno-
economic disadvantages of mini cement plants based on rotary kiln as compared
to those based on Modern Vertical Shaft Kiln — like higher investment cost,
higher operating cost, higher energy consumption, higher pollution etc; the
Government of India, as a matter of policy, is not encouraging any further setting
up of mini cement plants based on rotary kiln technology.
26
The process flow sheet of Small Rotary Kiln is shown in Fig. 7C.
8.0 TYPES OF MINI CEMENT PLANTS IN CHINA
China uses minor variations in the process with the vertical shaft kiln technology.
There are some plants which use black meal process as in India, there are
others which use semi-black meal process in which only a part of the total coal
required is interground with the raw meal and the balance is added in coarse
fraction later prior to nodulisation. Some plants use compound mineralizers also
for lowering the firing temperature. Different types of discharge grates have been
used in the vertical shaft kiln, like roller grate, flat grate, conical grate,
reciprocating grate etc. Non-mechanised kilns use stationary grate. Since the
Chinese plants, because of this design and operational features, emit sizeable
amounts of dust, dust collection equipment like electrostatic precipitators, bag
filters, etc. is being installed. The smallest and the largest sizes of mechanized
vertical shaft kilns in China have diameters of 1.7 metres and 3.6 metres
producing about 35 tonnes per day and 300 tonnes per day against design
capacities of 45 tonnes per day and 380 tonnes per day respectively.
A number of mini cement plants in China have been facing problems of non-
uniform cement quality, poor management and operational skills, higher cost of
production, high heat consumption, environmental pollution, etc. The
Government of China has therefore decided to slowly disband the old non-
mechanised plants numbering about 2000 and take up modernization of those
plants which can produce cement of good quality through mechanization (at the
rate of about 300 plants a year).
9.0 TYPES OF MINI CEMENT PLANTS IN COUNTRIES OTHER THAN INDIA

AND CHINA
Although the latest information regarding the exact number of mini cement plants
operating in different parts of the world are not available. Table 3 shows a global
survey of vertical shaft kilns under operation in different countries.
So far as mini cement plants based on CRI -MVSK technology are concerned,
M/s. Penden Cement Authority of Bhutan, have installed a 50 tpd CRI -MVSK
plant at Gomtu and later expanded it to 100 tpd by installation of another 50 tpd
CRI -MVSK line. One more cement plant of M/s. Lakhi Cements Pvt. Ltd. 100
TPD CRI -MVSK cement plant installed at Gomtu, Bhutan. One mini cement
plant of 160 TPD capacity based on Vertical Shaft Kiln of size 2.4 metre dia and
8-metre height supplied by M/s. Loesche, West Germany is already under
operation at the works of M/s. Himal Cement Company, Nepal. Another mini
cement plant of 30-tpd capacity based on CRI -MVSK is presently in operation at
Anboo-Khaireni in Nepal. This plant purchased 100 TPD (2x50 TPD) CRI -MVSK
cement plant of Penden Cement Authority and expanded upto 200 TPD.
27
WE HOUSE BAGGING &
BRANDING
FIG. 7C FLOW SHEET OF DRY PROCESS ROTARY KILN CEMENT PLANT
28
M/s. Loesche of West Germany have supplied more than 14 mini cement plants
based on black meal VSK process in more than nine countries. The first multiple
VSK plant supplied by M/s. Loesche had gone into operation in 1955 at the
cement plant of M/s. Portlandzemtnfabrik Blaubeuren Gebr. Spohn Ag at
Blaubeuren, Germany. Later on M/s Loesche have supplied plants based on
VSK to various countries like Japan, New Zealand, Austria, Spain, Italy, Nepal,
Brazil, Madagascar and Indonesia. In the latest design of 400 tpd (2x200 tpd)
plant at Kupang in Indonesia, pre-blending techniques for controlling of the
variation in quality of limestonne and clay were employed. Different fuels of
various mixtures have been used at Paggau ranging from anthracite dust to coke
breeze and petrol coke, the application of which in all the cases have been
reported to be a success.
In addition to above, M/s Maerz Ofenbau of Zurich also supplied mini cement
plants based on VSK technology on turnkey basis. M/s. Maerz are the exclusive
licencee for the manufacture of Prerov machinery designed mini cement plants
with as many as 16 cement shaft kilns operating in different parts of the world.
The heat consumption in these plants is claimed to be about 900-Kcal/Kg clinker.
10.0 OPERATION OF A CRI -MODERN VERTICAL SHAFT KILN
As already explained, in the black meal process, the cement raw materials are
interground with the fuel and the resultant raw meal is blended and then
converted into nodules of sufficient uniformity, strength and porosity in an
inclined disc type noduliser by the addition of required quantity of water. The
nodules are fed to vertical shaft kiln where the pyroprocessing takes place.
10.1 Before Lighting up
The kiln should be checked for

a) Rotary Grate: The grate segments and crown with cutter teeth should be
intact and in position. A full revolution should be given to the grate to
ensure it does not touch lining plates anywhere.
b) Lining plates should not be loose.
c) Refractory Lining: The lining must be checked and repaired wherever
necessary. If the thickness of lining in burning zone gets reduced below
80mm, it must be replaced.
d) All starters/main switches of the electrical installation should be checked
whether they are all in working condition.
e) Roots Blower. In accordance with the manufacturer's recommendations,
oil must be checked. Filters must be cleaned. The weights in the safety
valve are to be adjusted to suit to the anticipated kiln bed resistance.
f) Chimney's dampers, rotary feeder, kiln hood doors, discharge gates must
be checked for their mechanical operation and lubrication.
29
g) All the flanges of the kiln, bottom hood cup, chutes, discharge gates etc.
should be properly sealed so that the combustion air does not leak
through the gaps between the joints.
10.2 Lighting up of the Kiln
The kiln should be filled with either the clinker already manufactured, or
limestonne chips or brickbats upto a level of 1-1.5 metres from the conical
portion. Care should be taken that the material is dust free and while filling the
refractory lining is not damaged. In order to remove the dust, the roots blower
has to be run for about 15 minutes after every 1-metre depth of new material is
loaded or better if the blower is run continuously while the kiln is loaded with the
chips or clinker. After-every 2 metres depth of new material has been loaded, the
grate is set in motion, to ensure that the material is moving down the shaft
evenly. Above this material, about 100 kg of dry firewood is now stacked
uniformly over this bed in two or three layers. The chimney damper has to be
opened partly and the air by-pass valves/ball valves are to be kept open in the
kiln air duct. The firewood so spread would be lighted up using torches and after
an incandescent bed is formed, steam coal is charged into the kiln. There will be
an uniform incandescent bed of fire after few minutes. Now charging of the
nodules can commence. One should refrain from adding a new charge of
nodules until the edges of the fire can be just seen. When the bed level reaches
to about 50 cm. below the conical portion, the discharge gate is to be operated
slowly.
10.3 Normal Kiln Operation
Stabilised kiln operation as obtained after the initial lighting up may now be
continued under the following instructions:
1. Uniform discharge rate should be maintained as far as possible by

adjusting the grate speed whenever necessary.
2. The nodule size, feed rate and bed level must be maintained.
3. The bed should always be covered with the nodules by continuously
feeding them on a circle some distance away from the refractory lining so
that the nodules themselves distribute both over the periphery and in the
centre. A glowing ring on the periphery and continuous steam emerging
from the centre of bed indicates good fire and good combustion
conditions. The temperatures of various zones should be periodically
recorded.
4. It is necessary to ascertain frequently that the entire bed is descending
uniformly. This is ensured by cleaning the sides frequently with the help of
a rod with flattened tip. While cleaning the sides, care must be taken not
to damage the refractory of kilns.
5. Once the kiln is stablised neither the process parameters nor the raw mix
composition should be changed frequently.
M
10.4 Kiln Controls
10.4.1 Feed
Strict controls should be observed on the preparation of feed right from the raw
material stage. The table feeders/weigh feeders should be monitored
periodically so that the component ratios conform to the values for raw mix
design. Blending operation is carried out till a uniform blending with the desired
T C content is obtained. The T C in raw mix should not vary beyond ± 0.20% of
the desired value.
The nodules should be checked for appropriate size, porosity, moisture and
strength on hourly basis. The feed rate and discharge rate should be
synchronised to maintain constant bed level.
10.4.2 Combustion Air
The combustion air can be regulated by adjusting the valve on by-pass pipe.
The measurement is done with the help of two instruments provided on the
burner's platform; one from the orifice plate to give combustion air flow and the
other connected at the bottom for measuring the pressure at the inlet to the kiln
which gives an idea of the bed resistance. If during a normal operation both the
instrument readings are constant, the burner should understand that the kiln is
filled with properly burnt clinker. In case the inlet pressure varies the burner gets
indication that the bed resistance is varying and necessary corrective action
should be applied.
10.4.3 Discharge Rate
Under stabilized operating conditions, the discharge and feed rates should be
synchronised to maintain constant bed level. If there are too big lumps or too
loose a clinker near the grate, the discharge rate will fall or increase. Depending
on the case, immediately the grate speed is to be changed; otherwise the bed
level would rise or burning zone would collapse destroying the entire kiln
operation in next few hours. Intermittent discharge is not desirable. The rotary
grate speed should not be abruptly changed and it should be done gradually step
by step.
10.4.4 Temperature
A normal kiln operation is also judged from, in addition to the above, the
temperatures of flue gases, clinker, burning zone, cooling zone and also of the
kiln shell from outside. The temperature of the kiln is judged from the
thermocouple based temperature indicators and also crosschecked by touching
the kiln shell around periphery at various heights to feel the uniform temperature
gradient. The desired temperature profile for a VSK is shown in Fig. 8.
31
10.5 Kiln Disorders
10.5.1 Bridging
When the clinker produced is so lumpy that it does not contain any loose
material, there are chances that the lumps form a bridge and rest over the sides
of the conical portion of kiln resulting in rise in fire bed. In such a case the feed
should either be slowed down or stopped and air reduced. The bed should be
given some disturbance in clearing the sides and poking from burner's platform.
If necessary the roots blower should be stopped and then the feed. The bed
should be able to descend with some effects. The cause should be investigated
and the process parameters immediately rectified in order to avoid repetition of
this.
10.5.2 Side Discharge
Sometimes if the clinker produced is suddenly too loose it would pass through
the bigger lumps and get discharged quickly. Even red-hot yellow nodules
(clinker) may discharge representing that at a certain position there is no bed to
support the burning zone. The burning zone seems to collapse and loose fire. In
such a condition, the grate speed should be reduced or it should be stopped, to
reduce discharge for some time and the burning zone built up slowly even though
the level may rise. The discharge may be reduced till the trouble is overcome.
The underburnt clinker may be separately stocked and appropriately blended
with the good clinker at the time of grinding after ascertaining a suitable
proportion. The kiln process parameters should be immediately attended to.
This may be a result of maintaining the bed level too low inside the cone.
10.5.3 Lump Formation
Sometimes a big lump may be noticed in the burning zone, which is very strong
and as big as kiln internal diameter. This may not descend. This generally
occurs due to melting on account of a very high temperature there. The raw mix
composition should be immediately examined and feed should be accordingly
corrected. The fuel with low ash fusion or too much of fuel will cause this. The
lump so formed should be broken with poking rods and grate speed should be
adjusted to ensure its descent. At the same time too much poking should be
avoided. The lumps that descend though big, give no trouble as they would get
crushed and discharged as soon as they reach the rotary grate.
10.6 Operational Optimisation and Training with Simulator
Achieving the rated output at high and consistent quality clinker is the real task
for the burners. For this all the input parameters are to be maintained at an
optimum level and the kiln operations should be monitored continuously. Even a
32
slight disturbance to any of the input parameters for a short duration will
destabilize the steady state and disturb the entire process.
In this connection, understanding the interdependency of the input parameters to

the other operational and process parameters in a quantitative way is very much
essential for the process optimization of the kiln. CRI -MVSK simulator is an
extra-ordinary powerful tool for imparting training to the plant operating personnel
in the quickest way possible without causing any damage to the plant, machinery
or process and can also be utilized for optimization of CRI -MVSK plant operation,
including optimum Raw Mix Design and proportioning almost at the flick of a
button.
The CRI -MVSK Simulator is a device, which shows the working of complete
vertical shaft kiln section of a cement plant without any physical connections to
the plant, wherein all the inputs, the process as well as the output are
electronically generated within a computer. The simulator through a specially
developed software programme simulates the actual operating conditions of a
vertical shaft kiln cement plant on an ordinary desktop IBM-PC compatible
computer. A mimic diagram of the vertical shaft kiln section of a cement plant is
displayed on the computer screen with all values of process parameters, which
keep on changing with respect to time just as in an actual plant. The operator
can adjust or change any process parameter as per his wish and see the effect
of the same on the plant operation. All the disturbances normally encountered in
the kiln operation either due to changes in raw materials / fuel quality and / or
improper operation can be created on the simulator and the operator can be
trained to effectively deal with such situations. Working on CRI -MVSK simulator
does not require any knowledge of working on a computer terminal or computer
programming.
The simulator consists of a colour graphic monitor, which shows the live mimic of
the nodulizer — vertical shaft kiln section. The operation data on vertical shaft
kilns based on CRI -VSK Technology are given in Table 4.
Table 4: Operation Data on Vertical Shaft Kiln based on CRI -MVSK Technology
SI. No. Name of the item Units Value

1 Nodule Size mm 6 to 12
2 Moisture in nodules % 12 to 14
3 Raw meal fineness % 6 to 14
Retained on 170 mesh
4 Fuel in raw meal % 12 to 13
5 Bed level from the top of kiln mm 200 to 400
6 Temperature of
6.1 Chimney °C 80 to 200
6.2 Burning zone °C 1400 to 1450
6.3 Clinker discharged °C 30 to 100
7 Heat input Kcal/kg of clinker 950 to 1050
8 Bed Rasistance mm WG 150 to 600
33
9 Quality of air NM3/kg of fuel 10
10 Litre weight gm/cc 1080 to 1180
11 Resistance time hrs. 8 to 10
12 Rotary grade speed rph 0.2 to 5
13 Chimney draft mm WG 1 to 3
14 Maximum size of clinker lump mm 100
15 Energy consumption
15.1 Clinker (upto kiln section) Kwh per tonne of clinker 80 to 90
15.2 Cement grinding alone Kwh per tonne of cement 30 to 40
(Only cement mill section)
11.0 RAW MATERIALS AND THEIR CONSUMPTION FACTOR
Raw materials to be used in Vertical Shaft Kiln mini cement plants and their
consumption factors (material balance) per tonne of clinker and cement are given
below in Table 5.
Table 5: Raw Materials Consumption Factor
SI. No. Raw Materials Consum ption factor

Per tonne of Per tonne of
clinker cement
1 Limestonne 1.25 to 1.30 1.19 to 1.24

2 Clay 0.10 to 0.30 0.095 to 0.285
3 Additives like iron ore, Bauxite, 0.05 to 0.10 0.048 to 0.095
Laterite etc.
4 Low Volatile fuel like coke 0.13 to 0.22 0.124 to 0.209
breeze, saleable low volatile
coal, Pet Coke, Jhamma Coal
etc.
5 Gypsum — 0.03 to 0.05
12.0 ELECTRICAL ENERGY AND THERMAL ENERGY
The electrical energy consumption for various sections and thermal energy
consumption of Vertical Shaft Kiln mini cement plants are given below:
12.1 Electrical Energy
The electrical energy requirements for different sections are given below in Table
6.
34
Table 6: Electrical Energy Reuirement
SI. No. Section Electrical Energy in

Kwh/tonne of materials
1 Crushing 1 to 3
2 Raw mill 28 to 35
(including mill auxiliaries)
3 VSK 20 to 25
4 RK 12to15
5 Coal Mill 25 to 35
6 Cement Mill 35 to 40
(Including mill auxiliaries)
12.2 Thermal Energy
Thermal energy requirement varies from 850 — 950 K.cal/kg of clinker.
13.0 FIELD STUDIES
Indepth study was conducted at 8 VSK mini cement plants including identification
of sources of air pollution (stack & fugitive), stack emission monitoring,
constituent of flue gases in terms of 0 2 , CO2, CO and N2 etc, pollution control
technology adopted, annual operation and maintenance cost, water requirement
and ambient air quality monitoring.
Most of the VSK mini cement plants are not equipped with pollution control
devices in all the sections due to the involvement of capital cost especially in
Saboo and RRL VSK mini cement plants. A few CRI -MVSK cement plants of
higher capacity are only having pollution control devices in all the sections of unit.
Many VSK mini cement plants are closed except the plants located in Jammu &
Kashmir and North Eastern region.
The study was conducted at 2 VSK cement plants in Andhra Pradesh and 6 VSK
cement plants in Rajasthan. The indepth studies conducted in all the 8 VSK mini
cement plants are given in the subsequent paragraphs.
13.1 Plant - I
13.1.1 History
1 Name of the plant Plant—I

2 Location Tirupati, Andhra Pradesh
3 Installed Capacity (TPD) 200 (2 x 100 TPD)
4 Year of Commissioning April 1996
5 Technology adopted CRI — MVSK Technology
6 Machinery Supplier NCB's licensee
M/s Promac Engineering
Industries, Bangalore.
7 Actual Cement Production 57,083 Tonne/Annum
8 Future Expansion Yes
9 Types of Cement Manufactured Slag Cement
(BIS: 445 - 1989)
The above plant is put up in order to utilize the slag generated by their steel
plant, situated in the same premises. The quality of granulated slag generated by
their steel plant is as per Bureaau of Indian Standards. The slag consumption
was upto 50% depending upon the quality of clinker produced.
The specific thermal energy consumption is 900 K.Cal/ Kg of clinker and

specific electrical energy consumption is 110 Kwh / tonne of cement.
Actual production from VSK (average) on the day of monitoring was 85 TPD.
13.1.2 Manufacturing Process and Flow Sheet
CRI — MVSK technology is based on the black meal process in which all the raw
materials, viz, limestonne, clay, fuel (coke breeze, Jhama coal or any suitable
low volatile coal) and other corrective materials are ground together to a fineness
of 10% retained on 170 mesh as in dry process and intimately blended to satisfy
the chemical requirements for the raw meal. The homogeneous raw meal is
formed into nodules of the desired size by adding water in a pan nodulizer and
fed into the vertical shaft kiln through a revolving feed hopper. As the material
passes down the kiln, it is dried, heated and then burnt into clinker. The clinker is
then cooled and discharged from the kiln by a rotary grate at the bottom of the
kiln through a triple airlock discharge device or gamma ray controlled material
Block Tube (MBT). The combustion air to the kiln, which is provided by a Roots
blower, also serves the purpose of cooling the clinker and thus avoids wastage of
heat. The clinker then passes on to a cement mill where it is ground with about
5% gypsum to produce cement of standard quality.
Flow Sheet of Plant - I is shown in Exhibit — 2.
13.1.3 Sources of Air Pollution
Sources of air pollution are shown in Table 7.
0
Table 7: Sections Causing Air Pollution
Section 1 Type of Pollution Control Equipment

1. Crushing Bag Filter
2. Raw Materials Bag Filter
Proportioning
3. Raw Mill Bag Filter
4. Blending Bag Filter
5. Nodulisation Bag Filter
6. VSK Wet Scrubber
7. Clinker discharges Bag Filter
8. Clinker tunnel --
9. Cement Mill Bag Filter
10. Packing Bag Filter
(Note: Wet scrubber was not connected)
13.1.4 Stack Emission
The stack emission monitoring was conducted at all the important sections and
details are given in Table 8 and 9.
Table 8 : Stacks Emission Monitoring Results at outlet of APCD
S. Parameters Raw Cement Kiln (outlet)

No. Mill Mill
(outlet) (outlet) With After
intermittent stabilization
feeding with
continuous
feeding _
1. Stack dimension (m) 0.50 0.50 1.2 1.2
2. Stack cross sec (m 2 ) 0.196 0.196 1.131 1.131
3. Flue gas temp ( ° C) 42 48 85 85
4. Exit velocity of flue gas 8.76 7.66 3.31 3.31
(mps)
5. Flow rate (m 3 / hr) 6181 5405 13436 13436
6. PM (mg/Nm 3 ) 1) 45 1) 70 1) 580 1) 358
2) 66 2) 96 2) 559 2) 340
3) 96 3) 92 3) 550 3) 346.
Avg. 69 Avg. 86 Avg. 563 Avg. 348
7. Emission rate (kg / hr) 0.43 0.46 7.56 4.67
8. S0 2 (mg/Nm 3 ) - - 7 7
37
Table 9: Other Stacks Emission Monitoring Results
Particulate Particulate Particulate Particulate

Matter Matter Matter Matter
Section Conc. Conc. Conc. Conc.
(mg/Nm 3 ) (mg/Nm 3) (mg/Nm 3) (mg/Nm 3 )
Sample I Sample I Sample I Average

Raw mill (Bag Filter Inlet) 873 852 843 856
Cement mill (Bag Filter Inlet) 185 176 164 -175
Packing plant (loading

52 60 50 54
activities not continuous)
Raw mill tunnel exhaust 70 81 77 76
TALD gate (Bag Filter Inlet) 800 815 815 810
TALD gate (Bag Filter Outlet) 315 325 332 324
The efficiency of bag filters in raw mill and cement mill was found to be 92%
and 95% respectively.
13.1.5 Ambient Air Quality
The ambient air quality was monitored in respect of suspended particulate

matter, respirable particulate matter, SO 2 , NO X and CO The sampling was
done at two locations in upwind and downwind directions on 8-hourly
frequency and 24 hours average value is computed.
The ambient air quality monitoring results are given in Table 10.
Table 10: Ambient Air Quality Monitoring Results
SI. No. Parameters Down Wind Direction Up Wind Direction

/m 3 _ (gIm 3 )
1 RSPM 310 280

2 SPM 899 641
3 SO2 14 12
4 NO 8 7
5 CO Traces Traces
38
13.1.6 Analysis of Particle Size Distribution of Particulate Matter
The particle size analysis of the dust collected in thimbles at the VSK Kiln is as
given below:
µ Size 0-3 3-5 5-10 10-20 20-40 40-60 60-90 90-105

% 10.70 6.20 8.50 19.50 7.10 26.90 20.3 0.71
13.1.7 Raw Mix Design and its Effect on Emission
The plant is using 5 component mixes for clinker manufacture. The raw
materials used are two type of limestonne high & low grade, clay, Iron dust and
coke breeze. The chemical composition of the above materials and the raw meal
is given in Table 11. The raw materials consumption factor per tonne of cement
is given below:
Limestonne - I 0.50
Limestonne - II : 0.89
Clay : 0.07
Additive : 0.03
Coke breeze : 0.18
Table 11: Chemical Composition of Raw Materials & Raw Meal
Materials LOl% S102% Al203% Fe20 %o CaO% MgO%

Limestonne - I 39.40 6.71 2.07 0.93 48.45 1.30
Limestonne - II 35.07 13.60 3.10 1.40 44.40 0.70
Clay 10.00 55.0 17.00 8.00 5.00 2.00
Additive 4.00 3.00 3.00 85.00 -- --
Coke Breeze 82.00 7.35 2.60 5.10 1.25 0.15

Raw meal 40.00 12.23 3.30 3.60 38.40 0.85
The modulii values obtained of the raw meal is given below:

SM : 1.77
AM : 0.92
LSF : 0.92
%LC : 31.00
The Cement quality obtained is shown below:
Compressive strength
3 days : 340 - 380 Kg / cm 2

7 days :440-480 Kg / cm 2
28 days: 550-600 Kg / cm 2
39
Soundness
Le Chatlier expansion (mm): 2.7

Autoclave (%) : 0.3
To study the effect of different raw materials proportions on clinker quality and
particulate matter emissions, using the same quality raw materials and only
changing the raw mix design (RMD), stack emissions were measured.
The present RMD had been changed to new RMD having following Modulii
values and increased liquid content which is given below:
SM AM LSF %LC
1.55 0.66 0.88 36.88
When the material with new RMD was fed to the kiln, the quality of clinker was
improved, the stack emissions were observed as given below:
Stack Emission Data with New Raw Mix Design
a) Stack dimension (m) : 1.2

b) Stack cross section area (m 2 ) : 1.131
c) Flue gas temp. (°C) : 84
d) Flue gas velocity (m /sec) : 3.31
e) Flow rate (m 3/hr) : 13436
f) Particulate Matter Emission (mg/Nm 3 ) : 95
g) Emission rate (kg/hr) : 4.00
Thus, it is observed that if the kiln is fed with proper nodules of optimum RMD
and proper process parameters are strictly followed as per the norms, particulate
matter emission from VSK is well below the stipulated norms.
13.1.8 Process Parameters of VSK
The process parameters of Vertical Shaft Kiln are given below:

a) Nodule Size (mm) 6-10
:
b) Moisture (%) 13-14

:
c) Fuel in Kiln Feed (%) 11

:
d) Rotary Grate Speed 600-750

:
(Dyno drive rpm)

e) Clinker Temperature (°C) 60-80
:
f) Bed length from top (mm) 300-500

:
13.1.9 Air Pollution Control Devices adopted and Design Efficiency
The air pollution control devices installed in various sections are given in Table 7.
The design parameters like fan capacity, drive hp, no. of bags in various sections
alongwith the capacity of equipment are given in Table 12.
40
Table 12: Design Parameters of Air Pollution Control Devices installed at
Various Sections
S. Section Capacity Fan Drive No. of Efficiency

No. (tph) Capacity (HP) Bags
m 3/hr
1 Crushing 30 4000 10 32 70
2 Raw Materials - 6600 15 56 74
Proportioning
3 Raw Mill 11 18000 100 144 92
4 Blending 75 T. Cap. 4000 10 32 70
5 VSK - -------- Wet Scrubber ---------
6 Clinker Discharge - 4000 10 32 70
(TALD)
7 Cement Mill 12 13300 25 96 95
8 Packing 20 7000 15 60 73
13.1.10 Economics
The capital cost of air pollution control devices along with its maintenance cost
per annum for various sections are given in Table 13.
Table 13: Capital and Operation & Maintenance Cost of Air Pollution
Control Devices
S. No. Section Air Pollution Capital Cost Operation and

Control (Rs. Lakh) Maintenance
Devices Cost / Annum
(Rs.)
1 Crushing Ordinary Bag 1.50 25,000
Filter
2 Raw Materials Ordinary Bag 1.50 25,000
Proportioning Filter
3 Raw Mill Pnu-jet bag 3.50 1,00,000
filter
4 Raw Meal Blending Pnu-jet bag 3.50 1,00,000
filter
5 Raw Meal Storage Ordinary Bag 1.50 1,00,000
Filter
6 VSK Wet Scrubber 3.50 35,000
7 Clinker Discharge Ordinary Bag 1.50 25,000
(TALD) Filter
8 Cement Mill Pnu-jet bag 3.50 1,00,000
filter
9 Packing Ordinary Bag 1.50 25,000
Filter
41

13.1.11 Environmental Standards
The limit stipulated by Andhra Pradesh Pollution Control Board for particulate
matter emission is 115 mg/Nm 3 . Ambient air quality standard for SPM is 500
µg /M 3 .
13.1.12 Noise Pollution
Detrimental and unpleasant sound energy transmitted from one area to another
is classified as "Noise". The noise is generated in various sections has been
measured as shown in Table 14. The major sources of noise generation are raw
mill and cement mill. The distance between source of noise and point of
measurement is approximately 3 m. About 3 persons were working near each
mill. The location of noise measurement is indicated in the plant layout and
shown at Exhibit — 3.
Table 14: Noise Level
SI. No. Sections Noise Measurements (dBA)

Day Time Night Time
1 Near DG Set 59 55
2 Second Gate 43 41
3 Colony 42 36
4 Cement Mill 91.8 91.0
5 Near Kiln Shed 46 43
6 Near Laboratory 45 43
7 Crusher Control Rooms 57 45
8 Near Packing 47 43
9 Near Raw Mill 93.4 92.4
13.1.13 Water Requirement
Water required for a 200-tpd CRI -MVSK cement plant is 200 KUday for the
process and domestic purpose. The water quality of the plant is shown in
Table15.
Table 15: Water Quality
pH 5.5-9.0
Suspended Solids : 200 mg/I
Total dissolved solid 2100 mg/I
13.1.14 Solid Waste
There is practically no solid waste generation in the plant.
42
13.2 Plant - 2
13.2.1 History
1 Name of the plant Plant-2

2 Location Near Vijayawada, A.P.
3 Installed Capacity (TPD) 300 (3 x 100 TPD)
4 Year of Commissioning 2x100 = 200 TPD, 1991
1x100 = 100 TPD, 1997
5 Technology adopted CRI — MVSK Technology
6 Machinery Supplier NCB's licencee
Mis Promac Engineering
Industries, Bangalore &
M/s. Kay Iron Works Pvt. Ltd.,
Yamunanagar.
7 Actual Cement Production 69,000 Tonnes / Annum
8 Future Expansion No
The specific thermal energy consumption is 1050 Kcals / kg of clinker and

specific electrical energy consumption is 115 Kwh / tonne of cement.
The actual production for both the kilns (average) on the day of monitoring was
70 TPD.
Manufacturing process is same as explained earlier in Plant-1. The flow sheet of

Plant-2 is based on crane layout for handling raw materials, fuel, clinker &
gypsum which is shown in Exhibit-4.
Sources of Air pollution are shown in Table 16.

Section Type of Pollution Control Equipment
1. Crushing -
2. Raw Materials Proportioning -
3. Raw Mill Pnu — jet Bag Filter

4. Blending -
5. Nodulisation -
6. VSK -
7. Clinker discharges -
8. Clinker tunnel -
9. Cement Mill Pnu —jet Bag Filter

10. Packing -
43
The stack emission monitoring was conducted at all the important sections and
details are given in Table 17 and Table 18.
Table 17: Stacks Emission Monitoring Results at outlet of APCD
Parameters Raw Mill Cement Kiln (outlet)

(outlet) Mill
I* III
(outlet)
1. Stack dimension (m) 1.03 0.315 1.3 1.3
2. Stack cross sec (m 2 ) 0.834 0.078 1.328 1.328
3. °
Flue gas temp ( C) 48 42 105 62
4. Exit Velocity of flue gas (m/s) 8.85 8.76 3.4 4.5
5. Flow rate (m 3 / hr) 26571 2460 16255 21514
6. PM (mg/Nm 3 ) 1) 161 1) 82 1) 171 1) 75
2) 148 2) 69 2) 166 2) 82
3) 150 3) 50 3) 164 3) 62
Avg. 153 Avg. 67 Avg. 167 Avg. 73
7. Emission rate (kg / hr) 4.07 0.166 2.72 1.58
8. SO 2 (mg/Nm 3 ) - - 6 6.5
* many leakages in stack
Table 18: Other Stack Emission Monitoring Results
Section Particulate Matter Emission (mg/Nm )
Raw Mill (Bag Filter Inlet) 1. 1300

2. 1200
3. 1118
Avg. 1206
Bag Filter Efficiency
The dust concentration at raw mill bag filter inlet was measured to estimate
the efficiency of the dust collector which was found to be 87.3%.
The Ambient Air Quality was monitored in down wind and up wind directions. The
ambient air quality monitoring results are given in Table 19.
44
Table 19: Ambient Air Quality
SI. No. Parameters Down-wind Direction Up-wind Direction

/m 3 /m3
1 RSPM 275 142
2 SPM 1205 910
3 SO2 9 7
4 NO 7 6
5 CO Traces Traces
13.2.6 Analysis of Particle Size Distribution of Particulate Matter
The particle size analysis of the dust collected in thimbles at the VSK Kiln is as
given below:
Size 0-3 3-5 5-10 10-20 20-40 40-60 60-90 90-105

% 9.98 6.56 8.86 19.40 7.20 26.75 20.44 0.81
13.2.7 Raw Mix Design
materials used are two types of limestonnes, coke breeze, clay, iron ore and
bauxite. The chemical composition of the above materials and the raw meal is
given in Table 20.
Table 20: Chemical Composition of Raw Materials & Raw Meal
Materials LOI% Si02% Al203% Fe203% CaO% M O%

Limestone 38.88 8.61 1.12 1.74 48.05 1.06
Low Grade
Limestone 37.76 10.32 1.27 2.22 46.91 1.10
Coke Breeze 69.76 17.61 2.46 6.53 2.34 0.78
Clay 13.13 48.23 8.45 16.95 8.24 3.25
Iron Ore 1.73 1.28 89.25 6.28 0.99 0.25
Bauxite 10.41 28.58 33.52 27.73 0.89 0.16
Raw Meal 39.77 12.49 4.15 4.15 37.79 1.10
The raw materials consumption factor per tonne of cement is given below:
Limestone - 1.28
Coke Breeze - 0.21
Clay - 0.09
Iron Ore - 0.025
Bauxite - 0.058
45
The cement quality obtained is shown below:
Compressive Strength
3 days :270-330 Kg / cm2
7 days :340-360 Kg / cm 2
28 days: > 480 Kg / cm 2
The raw mix design adopted by the plant is properly implemented with
appropriate process parameters.
The process parameters of Vertical Shaft Kilns (Kiln 1 & Kiln 2) are given below:
Kiln 1 Kiln 2
a) Nodule Size (mm) : 8-12 8-12
b) Moisture (%) : 13-14 13-14
c) Fuel in Kiln Feed (%) : 13.0-13.50 13.0-13.50
d) Rotary Grate Speed : 600-800 600-800
(Dyno drive rpm)
e) Clinker Temperature (°C) : 65-85 65-85
f) Bed level from top (mm) : 300-500 300-500
13.2.9 Pollution Control Devices adopted and Design Efficiency
The pollution control devices installed in various sections are given in Table 16.
The design parameters like fan capacity, drive hp, no. of bags in various sections
alongwith the capacity of equipment are given in Table 21.
13.2.10 Economics
The capital cost of air pollution control devices along with its operation and
maintenance cost per annum for various sections were not made available. It
was informed that 32 & 22 Nos. of polyster needle woven bags per annum were
changed in Raw Mill & Cement Mill Pnu-jet bag filters respectively.
13.2.11 Environmental Standards
The environmental standards stipulated by AP Pollution Control Board are

already given in the details of Plant No. 1.
The noise measurements taken at various locations in the plant are shown in
Table 22. The major sources of noise generation are raw mill and cement mill.
The distance between source of noise and point of measurement is
approximately 3m. The numbers of persons working near the mills are 3 each.
46

The location of noise measurement is indicated in the plant layout and shown at
Exhibit-5.
Table 21: Design Parameters of Existing Air Pollution Control Devices
S. Section Capacity Fan Drive No. of I Efficiency

No. (tph) Capacity (HP) Bags (%)
m 3/hr
1 Crushing 35 - - - -
2 Raw Materials - - - - -
Pro ortionin
3 Raw Mill 22 Not - 325 90
working polyester
needle
bags
4 Blending 132t each - - - -
2 Nos.)
5 VSK 300 TPD - - - -
6 MBT 5 - - - -
7 Cement Mill 13 16000 25 92 85
8 Packing with 2 - - - - -
spouts
Table 22: Noise Level
SI. No. Sections Noise Measurements (dBA)

Day Time Night Time
1 Near DG Set 63 52
2 Colony 32 25
3 Raw Mill 93.5 92.5
4 Cement Mill 88.4 87
5 Near Laboratory 38 36
6 Crusher Control Rooms 48 43 _
7 Near Packing 45 43
Water required for the plant is 200 KUday mainly for the process purposes.
Water is used for nodulisation, raw mill trunion bearing cooling and cement mill
shell cooling.
13.2.14 Solid Waste
There is practically no solid waste generation in the plant.
47
13.3 Plant - 3
13.3.1 History
1. Name of Plant Plant-3

2. Location Behror, Rajasthan
3. Installed Capacity 50 TPD
Actual output obtained 40 TPD
(Average) on the days of
monitoring
4. Year of Commissioning 1993
5. Technology Adopted Semi Dry Process
Saboo VSK Technology
6. Actual Cement Production 2,880 Tonnes/ Annum
7. Future Expansion No
8. Types of cement Ordinary Portland Cement
Manufactured (OPC)
Saboo VSK Technology based on black meal process in which all Raw Materials
viz. Limestone, Clay, Coke Breeze, and Iron ore are ground together to a
fineness of 10% residue on 170 mesh (90µ) as in dry process and immediately
blended to satisfy the chemical quality requirement for the Raw Meal. The
homogenous Raw Meal is formed into nodules of desired size (6 to 12 mm
diameter) by adding water in a pan noduliser and fed into Vertical Shaft Kiln
through revolving feed hopper inside VSK arrangement. As the material passes
down the kiln, it is dried, calcined and burnt into clinker. The clinker is then
cooled and discharged by a rotary grate at the bottom of the kiln. through
discharge arrangement. The combustion air is supplied through Roots Blower,
also serves the purpose of cooling the clinker and thus avoids wastage of heat.
The cooled clinker then passes on to cement mill where it is ground with about
5% Gypsum to manufacture Cement of Standard Quality.
Flow sheet of Plant — 3 is shown in Exhibit — 6.
Sources of Air Pollution are shown in Table 23.
48
SI. Types of Pollution Control Equipment

No. Section
1. Crushing Bags
2. Raw Materials Proportioning Bags
3. Raw Mill Bags
4. Blending Bags
5. Nodulisation Bags
6. VSK Wet Scrubber
7. Clinker Discharge Bags
8. Clinker Tunnel -
9. Cement Mill Bags

10. Packing -
The stack emission monitoring carried out in important sections is given in

Annexure II. Three samples of particulate matter emissions were taken at VSK
stack and these values are varying from 96 to 140 mg/Nm 3 . Particulate matter
emissions rate varies from 1.69 to 2.47 Kg / hr. SO 2 concentration in the flue
gas vary from 6 to 7 mg/Nm 3 . The details of the stack (VSK chimney) are given
below:
• Stack dimension Dia (m) / height (m) : 0.9 /4.0

• Stack cross sectional area (m 2 ) : 0.6362
• Flue gas temp. (°C) : 60
• Exit gas velocity of flue gas (Average)(m/sec) : 8.60
• Flow rate (m 3/hr) : 17618
Flue gas analysis was carried out with "Flue Gas Analyser". The flue gas
analysis indicates presence of Carbon Monoxide to the extent of about 4091
ppm. The flue gas analysis for 02, CO2, CO and N 2 is given at Annexure II.
Fugitive dust emissions were measured near Raw Mill and are given in Annexure
II. Ambient air quality monitoring was carried out in upwind and downwind
directions and results are given in Annexure II.
13.3.6 Analysis of Particulate Matter for Particle Size Distribution
Particle size distribution of the collected dust in thimbles (VSK Flue Gas) was
carried out and the values are given in Annexure II.
49
13.3.7 Raw Materials
materials used are limestonne, clay, coke breeze and Iron ore. The raw mix
design followed by the plant is given below.
Limestonne = 73%
Clay = 12%
Coke breeze = 13%
Iron Ore = 2%
i3.3.8 Consumption Factor of Raw Materials
The raw materials consumption factor per tonne of clinker and cement are given
below in Table 24.
Consum tion Factor

SI. No. Raw Materials Per tonne of Per tonne of
clinker cement
1 Limestonne 1.219 1.158
2 Clay 0.200 0.190
3 Coke Breeze 0.217 0.206
4 Iron Ore 0.033 0.031
The specific thermal energy consumption is 1056 Kcals/Kg of clinker. Whenever

there is no power supply, the plant is being operated with Diesel Generator set.
a) Nodule Size (mm) - 6-12

b) Moisture (%) - 12-14
C) Fuel in Kiln Feed (%) - 13
d) Clinker Temperature (°C) - 50-80
e) Bed Length from top (mw) - 300-500
Noise levels were monitored at varius sources in the plant and are given in
Annexure II. The distance between source of noise and point of measurement is
approximately 3 m. The number of persons working near the sources is 3 each.
50

The average quantity of water required for this VSK cement plant is 10,000 litres
/ day as reported by the plant.
13.3.12 Solid Waste
Solid waste generation is practically nil.
13.3.13 Manpower
The total manpower deployed, as reported by plant authorities, is 21 staff and 30

contract labours.
13.4 Plant - 4
13.4.1 History
1. Name of Plant Plant —4

monitoring
6. Actual Cement Production 9907 Tonnes / Annum
8. Types of cement OPC
Manufactured
viz. Limestonne, Clay, Coke Breeze, and Iron ore are ground together to a
fineness of 10% residue on 170 mesh (90).L) as in dry process and immediately
blended to satisfy the chemical quality requirement for the Raw Meal is formed
into nodules of desired size (6 to 12 mm diameter) by adding water in a pan
noduliser and fed into Vertical Shaft Kiln through revolving feed hopper inside
VSK arrangement. As the material passes down the kiln, it is dried calcined and
burnt into clinker. The clinker is then cooled and discharged by a rotary grate at
the bottom of the kiln through discharge arrangement. The combustion air is
supplied through Roots Blower, also serves the purpose of cooling the clinker
and thus avoids wastage of heat. The cooled clinker then passes on to cement
51
mill where it is ground with about 5% Gypsum to manufacture Cement of
Standard Quality.
Flow sheet of Plant —4 is shown in Exhibit — 8.
Sources of air pollution for this plant are shown in Table 25

No. Section
1. Crushing -
2. Raw Materials Proportioning -
3. Raw Mill 3 Bags

4. Blending 2 Bags
6. VSK Wet Scrubber
7. Clinker Discharge -
8. Clinker Tunnel -
9. Cement Mill 6 Air Filter Bags

10. Packing 2 Bags

Annexure Ill. Three samples of particulate matter emissions were taken at VSK
stack and values observed are 430, 119 and 129 mg/Nm 3 with average of 226
mg/Nm 3 . Particulate matter emissions rate in kg/hr are 4.33, 1.20 and 1.30
respectively. SO 2 concentration in the flue gas varies from 1.5 to 2 mg/Nm 3 . The
details of the stack (VSK chimney) are given below:
• Stack dimension Dia (m) / height (m) = 0.6096/3.5

• Stack cross sectional area (m 2 ) = 0.3
• Flue gas temp. (°C) = 32
• Exit gas velocity of flue gas (m/sec) = 9.77
• Flow rate (Average - m 3/hr) = 10,070
Flue gas analysis was carried out with "Flue Gas Analyser". The flue gas analysis
indicates presence of Carbon Monoxide in traces. The flue gas analysis for 02,
CO2, CO and N2 is given at Annexure Ill.
52
Fugitive dust emissions were measured at Jaw Crusher and are given in
Annexure III. Ambient air quality monitoring was carried out in upwind and
downwind directions and results are given in Annexure Ill.
carried out and the values are given in Annexure lil.
The plant is using 4 component mixes for clinker manufacture. The raw materials
used are limestonne, clay, coke breeze and Iron ore. The raw mix design
followed by the plant is given below.
Limestonne = 75%
Clay = 8.75%
Coke breeze = 12%
Iron Ore = 3.75%
13.4.8 Consumption Factor of Raw Materials
belowin Table 26.
Consumption Factor
clinker cement
2 Clay 0.150 0.143
4 Iron Ore 0.063 0.060


b) Moisture (%) - 12-14
c) Fuel in Kiln Feed (%) - 12
53
Noise levels were monitored at various sources in the plant and are given in
Annexure III. The distance between source of noise and point of measurement is
The average quantity of water required for this VSK cement plant is 15,000 Ilitres
13.4.12 Solid Waste
13.4.13 Manpower
The total manpower deployed , as reported by them, is 6 staff and 32 contract

labours.
13.5 Plant - 5
13.5.1 History

monitoring
6. Actual Cement Production 10,372 Tonnes / Annum
7. Future Expansion Yes
Manufactured
viz. Limestonne, Clay, Coke Breeze, and iron ore are ground together to a
fineness of 10% residue on 170 mesh (90.t) as in dry process and immediately
54
cooled and discharged from the kiln through discharge arrangement. The
combustion air is supplied through Roots Blower, also serves the purpose of
cooling the clinker and thus avoids wastage of heat. The cooled clinker then
passes on to cement mill where it is ground with about 5% Gypsum to
manufacture Cement of Standard Quality.
Flow sheet of Plant — 5 is shown in Exhibit — 10.
13.5.3 Sources of Air Pollution (Stack & Fugitive)

No. Section
1. Crushing Bag Filter
2. Raw Materials Proportioning Bag Filter
3. Raw Mill Bag Filter
4. Blending Bag Filter
5. Nodulisation Hood
6. VSK Dust Setting Chamber
7. Clinker Discharge Hood
8. Clinker Tunnel -
9. Cement Mill Bag Filter

10 Packi g Bag Filter

Annexure IV. Three samples of particulate matter emisions were taken at VSK
stack and the values observed are 400, 359 and 351 mg/Nm 3 and its average is
370 mg/Nm 3 . Particulate matter emission rate in kg/hr are 7.2, 6.46 and 6.32
respectively. SO2 concentration in the flue gas analysis varies from 5 to 5.5
mg/Nm 3 . The details of the stack (VSK chimney) are given below:

• Stack cross sectional area (m 2) = 0.632
• Exit gas velocity of flue gas (Average)(m/sec) = 8.9206
• Flow rate (m 3/hr) = 18,011
55
analysis indicates presence of carbon monoxide in traces. The flue gas analysis
for 02, CO2, CO and N 2 is given at Annexure IV.
Fugitive dust emissions were measured near raw mill section and the values are
given in Annexure IV. Ambient air quality monitoring was carried out in upwind
and downwind directions and results are given in Annexure IV.
carried out and the values are given in Annexure IV.
design following by the plant is given below.
Limestonne = 72.40%
Coke Breeze = 12.00%
Clay = 12.30%
Laterite = 3.30%
below in Table 28.
Consumption Factor
clinker cement
2 Clay 0.202 0.192
4 Iron Ore 0.055 0.052
The specific thermal energy consumption is 1008 K.cals/Kg of clinker. Whenever

56

b) Moisture (%) - 12-14
C) Fuel in Kiln Feed (%) - 12
Annexure IV. The distance between source of noise and point of measurement is
The average quantity of water required for this VSK cement plant is 15,000 litres/
day as reported by the plant.
13.5.12 Solid Waste
13.5.13 Manpower
The total manpower deployed at this plant, as reported by them, is 12 staff and
18 contract labours.
13.6 Plant - 6
13.6.1 History

monitoring
Manufactured (OPC)
viz. Limestonne, Clay, Coke Breeze, and laterite are ground together to a
cooled and discharged by a rotary grate at the bottom of the kiln through
Flow sheet of Plant —6 is shown in Exhibit — 12

No. Section
1 Crushing 3 Bag
2. Raw Materials Proportioning 2 Bag
3. Raw Mill 3 Bag
4. Blending 2 Bag
5. Nodulisation 1 Bag
6. VSK Cyclone system
7. Clinker Discharge -
8. Clinker Tunnel -
9. Cement Mill 3 Bag—-- —^
10 Packing 4 Ba g
The stack emission monitoriong carried out in important sections is given in

Annexure V. Three measurements of particulate matter emisions were taken at
VSK stack and these values vary from 455 to 504 mg/Nm 3 _ Particulate matter
emission rate vary from 0.67 to 0.75 Kg/hr. SO2 concentration in the flue gas vary
from 5 to 6 mg/Nm 3 . The details of the stack (VSK chimney) are given below:


• Flow rate (Average - m 3/hr) = 1,480
for 02, CO2, CO and N2 is given at Annexure V.
Fugitive dust emissions were measured near Jaw Crusher and are given in
Annexure V. Ambient air quality monitoring was carried out in upwind and
downwind directions and results are given in Annexure V.
carried out and the values are given in Annexure V.
3.6.7 Raw Materials
Limestonne = 72%
Coke Breeze = 11%
Clay = 13%
Laterite = 4%
belowin Table 30.
Consumption Factor
clinker cement
2 Clay 0.185 0.178
4 Iron Ore 0.065 0.062

59

b) Moisture (%) - 12-14
c) Fuel in Kiln Feed (%) - 11
Annexure V. The distance between source at noise and point of measurement is
approximately 3 m. The numbers of persons working near the sources are 3
each.
The average quantity of water required for this VSK cement plant is 5,000 litres /
13.6.12 Solid Waste
Solid waste generated is practically nil.
13.6.13 Manpower
The total manpower deployed at this plant, as reported by them, is 8 staff and 9
contract labours.
13.7 Plant-7
13.7.1 History
monitoring
Manufactured
60
viz. Limestonne, Clay, Coke Breeze, and laterite are ground together to a
cooled and discharged by a rotary grate at the bottom of the kiln through
Flow sheet of Plant — 7 is shown in Exhibit —14

No. Section
1. Crushing Bags
3. Raw Mill Bags
4. Blending Bags
6. VSK Dust settling chamber
8. Clinker Tunnel -
9. Cement Mill Bags

10 Packing -

Annexure VI. Three measurements of particulate matter emisions were taken at
VSK stack and these values varying from 87 to 126 mg/Nm 3 . Particulate matter
emission rate vary from 0.30 to 0.43 Kg/hr. SO2 concentration in the flue gas
analysis vary from 6 to 7 mg/Nm 3 . The details of the stack (VSK chimney) are
given below:
• Stack dimension Dia (m) / height (m) = 0.9 / 4.5
61
• Exit gas velocity of flue gas (m/sec) = 1.6319
• Flow rate (m 3 /hr) = 3392
Stack flue gas analysis was carried out with "Flue Gas Analyser". The flue gas
for 02, CO2, CO and N2 is given at Annexure VI.
Fugitive dust emissions were measured near raw mill and are given in Annexure
VI. Ambient air quality monitoring was carried out in upwind and downwind
directions and results are given in Annexure VI.
Particle size distribution of the collected dust in thimbles (VSK Chimney Flue
Gas) was carried out and the values are given in Annexure VI.
Limestonne = 77.10%
Coke Breeze = 15.70%
Clay = 4.30%
Laterite = 2.90%
below in Table 32.
Consum tion Factor

clinker cement
2 Clay 0.26 0.247
4 Iron Ore 0.05 0.048
62
The specific thermal energy consumption is 1248 Kcals/Kg of clinker, whenever

b) Moisture (%) - 12-14
c) Fuel in Kiln Feed (%) - 15.7
Annexure VI. The distance between source of noise and point of measurement is
approximately 3 m. The numbers of persons working near the sources are 3
each.
The average quantity of water required for this VSK cement plant is 14,500 litres
13.7.12 Solid Waste
Solid waste generated is practically nil.
13.7.13 Manpower
The total manpower deployed at this plant, as reported by them, is 12 staff and
28 contract labours.
13.8 Plant - 8
13.8.1 History

monitoring
63

6. Actual Cement Production
5,121 Tonnes / Annum
8. Types of cement
Ordinary Portland Cement
Manufactured (OPC)
viz. Limestonne, Clay, Pet Coke and Laterite are ground together to a fineness of
10% residue on 170 mesh (90µ) as in dry process and immediately blended to
satisfy the chemical quality requirement for the Raw Meal. The homogenous
Raw Meal is formed into nodules of desired size (6 to 12 mm diameter) by adding
water in a pan noduliser and fed into Vertical Shaft Kiln through revolving feed
hopper inside VSK arrangement. As the material passes down the kiln, it is
dried, calcined and burnt into clinker. The clinker is then cooled and discharged
by a rotary grate at the bottom of the kiln through discharge arrangement. The
combustion air is supplied through Roots Blower, also serves the purpose of
cooling the clinker and thus avoids wastage of heat. The cooled clinker then
passes on to cement mill where it is ground with about 5% Gypsum to
manufacture Cement of Standard Quality.
Flow sheet of Plant — 8 is shown in Exhibit —16

No. Section
1. Crushing Bags
3. Raw Mill Bags
4. Blending Bags
6. VSK Dust setting chamber
8. Clinker Tunnel -
9. Cement Mill Bags

10. Packing -

Annexure VII. Three samples of particulate matter emissions were taken at VSK
stack and these values are varying from 541 to 648 mg/Nm 3 before dust setting
64
chamber and 64 to 184 mg/Nm 3 after dust setting chamber. Particulate matter
emission rate varies from 0.85 to 1.02 Kg/hr before dust setting chamber and
0.10 to 0.13 Kg/hr after dust setting chamber. SO2 ,concentration in the flue gas
analysis varies from 7 mg/Nm 3 to 8 mg/Nm 3 . The details of the stack (VSK
chimney) are given below:
• Stack dimension Dia (m) / height (m) = 0.6096 / 3...

• Flow rate (Average - m 3 /hr) = 1574
for 02, CO 2 , CO and N 2 is given at Annexure VII.
Fugitive dust emissions were measured near Jaw Crusher and are given in
Annexure VII. Ambient air quality monitoring was carried out in upwind and
downwind directions and results are given in Annexure VII.
Particle size distribution of the collected dust in thimbles (VSK Chimney Flue
Gas) was carried out and the values are given in Annexure VII.
Limestonne = 74.70%
Pet Coke = 8.70%
Clay = 13.30%
Laterite = 3.30%
below in Table 34.
65
Consumption Factor
clinker cement
2 Clay 0.15 0.143
4 Iron Ore 0.06 0.057


b) Moisture (%) - 12-14
C) Fuel in Kiln Feed (%) - 8.70
Annexure VII. The distance between source of noise and point of measurement
is approximately 3 m. The numbers of persons working near the sources are 3
each.
The average quantity of water required for this VSK cement plant is 15,000 Its /
13.8.12 Solid Waste
13.8.13 Manpower
The total manpower deployed at this plant, as reported by them, is 10 staff and 9
contract labours.
66
14.0 EMISSION STANDARDS FOR CEMENT SECTOR
The emission standards for cement plants notified under the Environment
Protection Act, 1986 are given below in Table 35.
Table 35: Particulate Matter Emission Standards in India
Emission Limit(mg/Nm 3 )
Capacity Protected Area Other Area

< 200 TPD 250 400
> 200 TPD 150 2 50
The emission standards for cement plants including grinding units locared in
critically polluted or urban areas with a population of one lakh and above
(including 5 km distance outside urban boundary) is given below.
Particulate matter emission: 100 mg/Nm 3
The emission standards for new cement kils including grinding units is given
below.
Particulate matter emission: 50 mg/Nm 3
15.0 DUST COLLECTION SYSTEMS
Particulate matter, commonly called dust, is the primary emission in the

manufacture of Portland cement. For the control of dust, the Cement Industry
employs the following dust collectors.
i) Gravity settling chambers

ii) Cyclones
iii) Fabric filters
iv) Wet Scrubbers
The basic mechanism of removing particulate matter from gas stream may be
classified as:
1. Gravitational Settling
2. Centrifugal Impaction
3. Inertial Impaction
4. Direct Interception
5. Diffusion
15.1 Gravity Settling Chambers
Gravity settling chambers will always be of importance for pre-cleaning of high

dust laden gases. They work on the principle of removing dust by reducing the
67
velocity of gas (or) air stream. The gas is directed from the dust generating
equipment into the large volume settling chamber, where the velocity drops low
enough to let large dust particles drop out by gravity. Dust settling chambers are
sometimes equipped with deflectors, to charge the direction of gas flow and so to
shorten the settling path of particles, improving collection efficiency. Because of
the simple construction, gravity-settling chambers are the lowest in cost, but at
the same time also the least effective dust collection devices.
The efficiency of gravity settling chamber 4 30 — 70%

The gas velocity in the settling chamber 4 100 ft/min
The pressure drop 4 0.2 — 1.0 mmWG
Schematic of gravity settling chambers for dust removal is shown in Fig. 8.
15.2 Cyclones
15.2.1 Operation
A cyclone consists essentially of two sections: a cylindrical and a conical one. At

the top of the cylindrical section the gas enters tangentially and spirals along the
walls downward into the conical section (outside vortex); from here it starts to
occupy the center space of the cyclone, and spirals upwards (inside vortex) to
the outlet. Centrifugal forces push the dust particles towards the wall where they
accumulate and descend down by gravity as well as under the influence of the
outer vortex. Most of the particles fall down to the bottom into a hopper from
where they are removed by rotary valves (or) screw conveyors. The ascending
gas vortex represents the clean gas, but it always contains a certain amount of
fine particulates. The Inside Vortex occupies only a small part of the cyclones
cross-section, and along its axis there is the so called neutral sector; if the size of
this sector is large, then a considerable amount of dust is taken away with the
escaping gases. From this it results that the longer distance a dust particle has
to cover for reaching the boundary gas layer, the less particles are separated in
the cyclone; therefore it can be said that the efficiency of cyclone is inversely
proportional to its diameter.
Diameter (inches) 9 16 24 124

Efficiency 96.7% 92.6% 88.2% 57.5%
Cyclones are low cost dust collectors, without moving parts, and can be
furnished with refractory linings for high temperature upto 1800°F.
The pressure drop of cyclones is in the range from 1.2 to 6.5 inches water
column and depends on
- The temperature of the gas;
- The size of the cyclone; and on
- The inlet velocity of the gas.
Design proportions of a cyclone dust separator are given in Fig. 9.
FIG. 8 SCHEMATIC OF GRAVITY SETTING CHAMBERS
A A
A
L
--I
GAS
Bc =
De =
He
Lc =
Sc =
Zc =
Jc =
DUST OUT
FIG.9 DESIGN PROPORTIONS OF A CYCLONE DUST SEPAR

70
15.2.2 Maintenance
Operational problems in cyclone are more due to process factors rather than
constructional aspects. Some of the operational problems in cyclone are given
below.
i) Plugging of cyclone either in inlet duct, cyclone body or in exit duct.
Plugging of inlet duct can occur when dust agglomerates due to fineness
or presence of moisture particularly when temperature falls below due
point of gas. Plugging of cyclone body occurs when hopper is plugged
and dust level rises in cyclone.
ii) Erosion in cyclone is caused by impingement and rubbing of dust
particles on cyclone wall due to high dust loading, high inlet velocity and
coarse dust particles.
15.3 Multiple Cyclones or Multicyclones
Multicyclones are enclosed units arranged in banks for parallel flow with feed gas
from a plenum chamber and with a common dust discharge hopper; multicyclone
units can contain upto 400 individual cyclones.
Efficiency of Multicyclones 4 85 — 94%

Pressure drop 4 5 — 7 in of water column
A disadvantage of multicyclones is plugging of small tubes.
Longitudinal section of multicyclone for dust collection is given in Fig. 10.
15.4 Fabric Filters
Particle collection in fabric filter is based on several collecting mechanisms

including inertial impaction, interception, diffusion and gravitational
sedimentation. Generally, inertial impaction, interception and diffusion
mechanisms are important for particles below one micron. Gravitational settling
and filteration by the packed bed of accumulated dust on the surface of filter
media are decisive factors for coarse particles.
The pressure drop across the fabric filter is about 100-125 mmWG and the
collection efficiency is as high as 99.99% depending on the type of fabric used. It
is a constant efficiency dust collector and minor variations in process parameters
affect the performance of fabric filter. Bag house filter media and cleaning system
constitute basic components of the fabric filter.
Fabric filter systems typically consist of a tubular bag or an envelope suspended

or mounted in such manner that the collected particles fall into a hopper when
dislodged from the fabric. The structure in which the bags hang is known as bag
house. Generally, particle-laden gas enters the bag at the bottom and passes
71
CLEAN AIR INTAKE OF DUST
DISCHARGE LADEN AIR
ACCESS DOORS
DISCHARGE FOR DISCHARGE FOR

FINE DUST COURSE DUST
FIG. 10 LONGITUDINAL SECTION OF MULTICYCLONE FOR D

COLLECTION
72
through the fabric while the particles are deposited on the inside of bag. Large
bag houses are constructed with several compartments, so that one
compartment may be isolated for cleaning as needed while the other
compartments are operating. The bags should be arranged in each
compartment provided for dust collection and the dust is removed by rotary or
screw valves. The cleaning mechanisms can be mechanical shaking system,
reverse air cleaning system or high pressure pulse jet cleaning system. The
cleaning may be accomplished by shaking the bags or by increasing the air
pressure on the bag in a manner that causes the bag to collapse or otherwise
deform sufficiently to dislodge the accumulated dust.
The following advantages makes the fabric filters the best choice in many cases.
i) Very high efficiency

ii) Retention of finest particles
iii) Collection of particulates in dry form
iv) Relatively low pressure drop
Some of the disadvantages using fabric filters are:
i) Their large size

ii) High construction cost
iii) This application only to process temperature generally below 285°C
iv) High operating costs
The main operational problems of fabric filters are:
- Variation in filtration velocity

- Gas temperature below due point causing clogging of bags
- Variation in pressure drop
- Improper gas flow distribution in various compartments
- Cleaning system and its operation
- Flow control systems, inlet ducting, fans etc.
- Fire and explosion hazards.
Schematic diagram of typical bag house is given in Fig. 11.
15.5 Wet Scrubbers
15.5.1 Operation
The basic function of wet scrubbers is to provide contact between the scrubbing
liquid, usually water, and the particulate to be collected. This contact can be
achieved in a variety of ways as the particles are confronted with so called
impaction targets — which can be wetted surfaces or individual droplets.
Whether the particles encounter wetted surfaces as in packed Scrubbers or
individual droplets as in spray scrubbers, the basic mechanism are the same as
73
.EAN GAS
MECHANISM
SAGS
DUSTY GAS
ON
DUST OUTLET
FIG.1 I TYPICAL BAG HOUSE
74
in filters; inertial impaction, interception and diffusion. Generally impaction and
interception are the predominant mechanisms for particles of diameter above 0.3
µm, and for particles of diameter below 0.3µm, diffusion begins to prevail. In
addition, diffusiophoretic deposition and electrostatic precipitation also effect
particle collection. Diffusiophoretic deposition can be significant when mass
transfer within the scrubber, caused by condensation of water vapour from the
gas onto a cold liquid surface, exerts a force upon the particles and causes them
to get deposit on the surface.
There are many scrubber designs presently available where the contact between
the scrubbing liquid and the particles is achieved in a variety of ways the major
types are
i) Spray Towers
ii) Centrifugal scrubbers
iii) Packed beds and plate columns
iv) Venturi Scrubbers
Each type of design has a certain range of applicabitty. Thus low energy
scrubbers such as spray towers are most often used to handle particles largely
about 5-10 µm in diameter.
The effectiveness of the conventional spray tower ranges from 94% for 5 µm
particles to 99% for 25µm particles.
Schematic diagram of spray tower is given in Fig. 12
15.5.2 Advantages of Wet Scrubber
- Simultaneous removal of gases and particulates

- Effective performance over a wide loading range
- Equipment occupies only a moderate amount of space compared to
dry collectors such as bag house
- Hazards of explosive dust-air mixtures are reduced
- Indifference to the temperature and moisture content of gas
- Corrosive gases may be neutralized by proper choice of scrubbing liquid
15.5.3 Disadvantages of Wet Scrubber
- Relatively high energy cost

- Problem of wet sludge disposal
- Corrosion problems
- Visible wet plume, reduction in buoyancy
- Very small particles (sub-micron sizes) may not be captured.
75
CLEAN GAS OUT
II
MIST EL
WATER IN
0 SPRAYS
0
° ° o
0 0 00
DIRTY GAS IN
^ o 0
SLURRY OUT
FIG.12 SPRAY TOWER
76
16.0 SOURCES OF AIR POLLUTION
16.1 Introduction
Pollution control aspects are being given increasing attention in recent years.
Mini cement plant is basically air polluting industry. Air pollution, which basically,
can be caused by both particulates and gaseous pollutant, the CRI — MVSK
cement plant operation ensures negligible emission of the latter such as NO etc
as optimised operating conditions of the kiln generally prevents emission of such
gases. The generation of particulates, however, is inherent in the manufacturing
process and the associated unit operations, which is controlled by the application
of dust collectors wherever required. The operation of vertical shaft kiln, which is
the heart of process, is such that less emission takes place as the shaft kiln itself
acts as an effective filter.
16.2 Manufacturing Process
The manufacturing process involved in the VSK mini cement plants essentially
consists of the following steps:
• Mining and crushing of limestonne (and additives, if necessary) ;
• Proportioning of raw materials and fuel based on raw mix design;
• Grinding and blending to obtain fine homogenised black meal;
• Preparation of nodules ;
• Feeding the nodules to vertical shaft kiln wherein the drying, preheating,
calcining and sintering takes place resulting in the formation of clinker;
• Clinker cooling in the kiln;
• Grinding of clinker and gypsum in controlled proportion to produce ordinary
portland cement;
• Storage, packing and despatch of cement.
16.3 Dust Generation Sources
The various dust generation sources are given below:
16.3.1 Mining
Mostly mini cement plant sector does not have its own captive mines. They buy
limestone mostly from other agencies. Wherever captive mines are there, mining
is generally carried out manually. The level of dust generation during drilling /
blasting and loading of limestonne is generally low. Dust suppression techniques
such as water spray are generally found adequate.
16.3.2 Crushing and Raw Materials Proportioning
In crushing section, generally combinations of primary and secondary crushers

are used for size reduction. Various raw materials, i.e. crushed limestonne, clay,
riA
coke breeze, additive are stored in hoppers. These materials are extracted from
individual hoppers and are conveyed to the raw grinding section. A single
cyclone/fabric filter is mostly used to collect dust from both the crushing as well
as raw materials proportioning section and sometimes separate dust collectors
for these two sections are also recommended depending on the specific
situation.
16.3.3 Raw Material Grinding
Depending upon the raw material characteristics, air swept ball mills or vertical
roller mills are usually employed for the intergrinding of raw materials and fuel. In
both the cases, cyclones and fabrics filters are used to keep the emission low.
16.3.4 Raw Material Blending and Homogenising
The ground raw meal is blended and homogenised pneumatically in blending

silos. The generated dust is collected in fabric filters to ensure low emission.
16.3.5 Kiln Section
Raw meal is extracted from the noduliser feed hopper and is fed to noduliser
where water is also sprayed to form nodules. In order to collect dust from
noduliser a fabric filter is used.
The system design and the technology used in the CRI - Modern vertical shaft
kiln (CRI - MVSK) have adequate in built provision to restrict dust emission from
chimney. This is a unique feature performed by the MVSK, which in addition to
clinkerisation also reduce the dust generation significantly. The green bed of
moist nodules, which are constantly distributed on the top by the rotary feeder,
would trap most of the dust particles and only allow gases into the stack. In fact
when CRI — MVSKs are operated as per the norms and procedures, the emission
levels are very much within the stipulated norms. In addition, the principle of
natural draft, which is employed in the system, further ensures very little
entrainment of dust particles and even the small particles which may get into the
gas stream, would settle down on the bed due to gravity as the velocity is very
less in the stack.
Whilst, in general the operational experiences have proved that the kilns based
on CRI — MVSK technology do not pose any problem in regard to dust emission,
a dust collector of simple design has been developed by NCB which has been
successfully installed in CRI — MVSK cement plants. The flue gases from the
VSK is made to pass through the dust settling chambers, wherein the dust
particles get settled in the chamber, the dust so collected can be re-used in the
process.
7a
16.3.6 Clinker Handling
Clinker discharged from MVSK through triple air lock discharge gas / material
block tube is crushed in a jaw crusher. Clinker and gypsum stored in separate
hoppers are extracted to feed to the grinding mill. A fabric filter is used to collect
dust from discharge gate / material block tube, clinker crusher and clinker and
gypsum extraction points beneath their respective hoppers.
16.3.7 Cement Grinding
In mini cement plants based on CRI -MVSK technology, generally open circuit
tube mills are employed for cement grinding. The mill works on overflow
principle and the product is directly conveyed to the storage silo. Fabric filters
are used to facilitate dust collection to ensure very low emissions.
16.3.8 Fugitive Emission
Specific instances of fugitive dust generations include dust blown by wind from
raw materials stockpile, dust caused by vehicular traffic within the factory, dust
leakage from conveyors, conveyor transfer points, silos, storage hoppers and
packers etc. Good house keeping, proper maintenance, wetting of dusty areas,
use of enclosed storage wherever feasible etc would eliminate fugitive dust.
17.0 GUIDELINES TO CONTROL THE DUST EMISSION

As a guideline suggested air pollution control devices for various sections of
VSK based mini cement plants are given in Table 36, subject to compliance of
emission standards.
Table 36: Section wise Suggested Dust Collectors
SI' Type of Dust Collector

Section
No.
1 Crushing and Raw Materials Bag filter with proper metallic
Proportioning casing, stack height and stack
monitoring requirement
2 Raw Mill Twin cyclone & Bag filter with

proper metallic casing, stack
height and stack monitoring
requirement
3 Homogenising Silo Bag filter with proper metallic

casing, stack height and stack
79
SI.
Section Type of Dust Collector
No.
4 Noduliser Bag filter with proper metallic
5 VSK Cyclone with proper stack height

and stack monitoring
requirement
6 Clinker Crusher and Discharge Tube Bag filter with proper metallic
7 Cement Mill Bag filter with proper metallic

8 Packing House Bag Filter with proper metallic

The above air pollution control devices are indicative in nature. Cement Plant
may explore the possibilities of other devices also. The important thing which
is to be kept in mind is that in all the cases the plant has to meet the
prescribed emission standards.
80
Annexure
Al: CEMENT RESEARCH INSTITUTE OF INDIA MODERN VERTICAL

SHAFT KILN (CRI -MVSK) CEMENT PLANTS IN OPERATION
SL. No. Plant's Name and Address Year of Capacity

Commissioning (tpd)
1 Sh. M. Sivachalam
Chief Engineer,
Nilgiri Cements (P) Ltd. 1976 20
Mirduvathur, Kallakudi 621652,
—
Lalgudi Taluq, Trichy Distt.

Tamil Nadu
2 Sh. G.S. Puttabuddi

Managing Direictor
Veda Cements Ltd., 1981 90
7/2, Ilnd Cross, Palace Cross Road.
Bangalore 560020
—
3 Sh. Aravind Jawalkar

Chairman
Lokapur Cements Pvt. Ltd. 1981 90
Lokapur 587122
—
Mudhol Taluk, Bijapur Distt.,

Karnataka
4 Sh. R.N. Aggarwal

Director
Sri Durga Cement Company Ltd., 1983 100
Village Hesla
Post Box No. 6, Ramgarh Cantt.
Hazaribagh 829122
—
Jharkhand
5 Shri Praful Varia

Managing Director
Sandip Cements Pvt. Ltd., 1984 150
P. B. No. 51, Udyog Nagar,
Mahuva 364290
Bhavnagar District, Gujarat.
6 The Managing Director

Parasuram Cements Ltd.,
Tezu — 792001 1984 30
Lohit Distt.,
Arunachal Pradesh
81
SI. No. Plant's Name and Address Year of Capacity
Commissioning (tpd)
7 Shri Nim Dorji,
Managing Director
Penden Cement Authority 1983 100
P.O.Gomtu, - 734401
Siliguri R.M.S. (VIA)
Bhutan
8 Shri T.D. Katwa

Technical Director,
Katwa Cement Pvt. Ltd., 1984 30
125, Khade Bazar,
Shahpur — 590 003
Belgaum. Karnataka
9 Shri S.K. Aggarwal

Chairman & MD,
Jan Priya Cement Ltd., 1985 200
8/53, Katwa
Opp. Railway Station
Neem-ka-Thana — 332713
Sikar District
Rajasthan
10 Col R.L. Sharma (Retd.)

Managing Director
Venus Cements Ltd., 1985 100
P.O. Rani Pokhari,
Distt. Dehradun,
U.P. — 248145

Alagappa Cements Pvt. Ltd.,
Kilapaluvur — 621 707 1985 90
Ariyalur Taluq,
Trichy Distt.
Tamil Nadu
12 Shri A.V. Bagi,

Managing Director,
Sangam Cements Pvt. Ltd., 1985 20
3481, Somadevi Galli,
Belgaum 590002
Karnataka
82
Commissioning (tpd)
13 Sh. Sunil Aggarwal
Managing Director
Prominent Cement Pvt. Ltd., 1984 100
1-12/C Gandhi Nagar,
Gwalior 474002
Madhya Pradesh
14 Sh. S.B. Bhasin

Managing Director
Kalinga Cement Ltd., 1985 150
31-A, Kharvela Nagar,
Bhubaneswar — 751001
Orissa
15 Sh. V.K. Srivastava

General Manager
Ajmera Cements Pvt. Ltd., 1986 150
P.O. Bhanduri
Distt. Junagarh
Gujarat — 362248
16 Sh. S.S.M. Soundappan

Chairman & MD,
Tan India Ltd., 1986 200
P. B. No. 191
21, Gandhipuram Main Road,
Komarapalayam — 638183
Rajaji Distt. Tamil Nadu.
17 Sh. V.L. Bavishi

Managing Director
Suvin Cement Pvt. Ltd., 1988 100
Lakhanka Chotila Taluq,
Surendra Nagar Distt.
18 Sh. G. Karisiddappa
Managing Director
Shiva Minerals & Cement Inds. P. Ltd., 1985 100
409, 1s t Floor, 12` h Cross,
Sadashivanagar,
Bangalore — 560080
83
Commissioning (tpd)
19 The Managing Director,
Lakshmi Cements I& Ceramics Inds. Ltd.,
Ittigehalli 1985 100
Mattodu Hobli,
Hosadurga Taluq,
Karnataka
20 Sh.D.K. Prabhu Devaiah

Managing Director
Siddhaganga Cements Pvt. Ltd., 1985 60
B-225, 1s t Stage, 4 th cross,
Industrial Estate,
Peenya,
Bangalore 560058
—
21 Sh. N.R.A. Krishnan

General Manager
Shree Shankar Cement Works Pvt. Ltd., 1985 30
Suite 26, J.M. Chamber No. 2,
225, Nariman Point,
Bombay 400021.
—
22 Sh. Anil Sharma

Managing Director
Gwalior Cement Co. Pvt. Ltd., 1985 100
605, Eros Aptt.,
56, Nehru Place,
New Delhi 110019
—
23 Sh. Kamesh Khaitan

Managing Director
Abhishek Cements Ltd., 1986 100
Village Patnakuan,
—
Tehsil Jabera
-
Distt. Damoh,
-
Madhya Pradesh
24 Sh Manjunath
Managing Director
Bhagya Cement Pvt. Ltd., 1985 20
Village Nalwar
—
Chittapur Taluk
Gulbarga District,
Karnataka.
84
Commissioning (tpd)
25 Sh. Ashok Babu
Works Manager (A)
Annapurna Cements Pvt. Ltd., 1987 200
Samela Village,
Asifabad Taluq,
Adilabad Distt,
Andhra Pradesh

Amareswari Cements Ltd.,
Pedaveedu Huzurnagar Taluq, 1985 100
Nalgonda Distt.,
Andhra Pradesh.
27 Sh.T kona Reddy

Managing Director
S. V. Cements Ltd., 1986 100
Kanakadrilli, Koilkunta Taluq,
Kurnool Distt. 518123
Andhra Pradesh

MIC Cement Limited,
Mehta Nagar, 1987 200
Jewargi, Gulbarga Road,
P.O. Jewargi - 585310,
Gulbarga Distt,
Karnataka
29 Sh. Balwant Singh

Managing Director
Bharat Food India Ltd., 1986 100
Village Baghwar
Distt. Sirohi,
Madhya Pradesh
30 Sh. M.M. Tramboo

Managing Director
Khyber Industries (P) Ltd., 1987 200
Khayam Building, New Pora,
Srinagar, - 190001
Kashmir
85
SI. No. Plant's Name and Address Year of Capacity 1
Commissioning (tpd)
31 Sh. S.R. Sehgal
Managing Director
Calcar Producuts Pvt. Ltd., 1987 100
Bhupdeopur, Kharasia Taluq,
Raigarh Distt.
Madhya Pradesh — 496661
32 Sh. Tukaram Hanchatte

Managing Director
Chitapur Cement Works Pvt. Ltd., 1986 30
Malkhed Road,
Chitapur 585211
Gulbarga District
Karnataka
33 Sh. Vallabh Sarda

Managing Director
Sedam Cement Industry Pvt. Ltd., 1986
Humnabad Road,
Gulbarga District,
Karnataka - 585104
34 Sh. K.K. Neelakantappa

Executive Director
Kaveri Cements Pvt. Ltd., 1987 30
Kumbaranhalli Post,
Yeslur (via) Hasan District,
Karnataka — 575137
35 Sh. Ahmed Khan

Managing Director
Rayhan Minerals & Chemicals Pvt. Ltd., 1986 200
Blue Star, Yelnadu Post,
Chicknayakanahalli Taluk
Tumkur Distt., Karnataka
36 Managing Director
Marls Cements Pvt. Ltd.,
Dodda Byladakere 1986 30
Hosadurga Taluk
Chitradurga District,
Karnataka
86
Commissioning (tpd)
Devshree Cement Limited,
Kharia Mithapur 1988 100
Jodhpur Distt.
Rajasthan
38 Sh. J.S. Bagga

Managing Director
Mahendra Cements Pvt. Ltd., 1987 200
Jeerabad Village
Dhan Distt., Gandhwar Taluq,
Indore — 452001
39 Sunder Thakur
Executive Director
Varun Cements Pvt. Ltd., 1985 200
B-105, HIG Colony,
Indore — 452008
Madhya Pradesh
40 Sh. B.L. Agarwal

Executive Director
Hira Industries Limited 1987 200
Plot No. 572
Urla Industrial Area,
Urla, Raipur 493221
Madhya Pradesh.
41 Sh. J.K. Sharma

Managing Director
Jiwan Cements & Chemicals Pvt. Ltd., 1987 20
Dhaula Kuan
Sirmaur District
Himachal Pradesh
42 Annapurna Cements (P) Ltd.,

Aboo Khairani,
Distt. Tanahu, 1987 30
Kathmandu,
Nepal
87
Commissioning (tpd)
43 Sh,. Shalig Ram Parita
Managing Director
Balaghat Cements (P) Ltd., 1988 200
119, 1st Floor
Malviya Nagar,
Bhopal — 462003
Madhya Pradesh
44 Sh. K.C. Taparia

Managing Director
Sudarshan Cements & Multi Projects Ltd., 1987 100
Cement Division, D-6, Meera Marg,
Banff park Jaipur — 302006
Rajasthan.
45 Sh. G.P. Singhania

Managing Director
Singhania Cement Pvt. Ltd., 1987 30
P.O. Neora, Raipur Distt.,
Madhya Pradesh
46 Sh. K.S. Ram

Chief Executive
Rudra Cement Ltd., 1987 150
Post Box No. 10,
Pandripani — 494001
Jagdalpur Bastar
Madhya Pradesh
47 Sh. Ramesh Mandakhalli

Managing Director
Dhanalakshmi Cements (Pvt.) Ltd., 1988 30
7-1101/34, SBH Colony,
Nehru Gunj
Gulbarga — 585104
Karnataka
48 Sh. N.R. Jagadeesh

Managing Director
Ennar Cements Pvt. Ltd., 1987 60
Shivakrupa, B.H. Road,
Tumkur — 572103
Karnataka
88
Si. No. Plant's Name and Address. Year of Capacity
Commissioning (tpd)
Seetharam Cements Ltd.,
Plot No. 79, Panaji Road, 1987 100
Mehboob Nagar District,
Pin 509216
—
50 The Executive Director

Progressive Cements Ltd.,
Old Hazaribagh Road, 1988 100
Ranchi 834001
Jharkand.
51 Sh. Sanjay Modi,

Director,
Kalyan Sundaram Cement Inds. Ltd., 1985 100
Century Floor, 3rd Floor,
Dr. A.B. Road,
Worli, Bombay 400025
—
52 Sh. Navneet Agarwal

Managing Director
NECEM Cement Ltd., 1988 150
Housing Colony Road,
Rukmini Nagar,
Dispur,
Guahati 781006
—
53 Sh. Ranvir M. Khatau

Managing Director
Jagadamba Cements Ltd., 1988 100
407, Maker Bhawan No. 3,
21, New Marinelines,
Bombay 400020
—
54 Sh. S.R. Chamaria

Managing Director
Hanuman Works Pvt. Ltd., 1988 30
23/1, Tagore Castle Street,
Calcutta 700006
—
Commissioning t d
55 Sh. S.L. Poddar
Managing Director
Vallabh Cements Pvt. Ltd., 1986 50
3rd Floor, Apollo Tower,
2 M G Road,
Indore 452001
—
Madhya Pradesh
56 The Managing Direcitor,

Kohinoor Cements Pvt. Ltd.,
Raghumathapalam, 1988 100
Via Mellacheru,
Mattompally Mandal,
Distt. Nalgonda,
Andhra Pradesh
57 Sh. Mahesh Gupta

Director,
Sirohi Cement Pvt. Ltd., 1987 50
RIICO Indl. Area,
Sirohi Road,
Rajasthan.
58 Sh. P.R.K. Raju,

Managing Director,
Viswam Cement Ltd., 1988 150
503, Topaz Building,
Panjagutta,
Hyderabad 500082
—
59 Sh. N. Indorewala
Managing Director,
Suvidha Commercial Co. (P) Ltd., 1985 50
250 Maulana Azad Road (North)
Bombay 400008
—
60 Sh. V.S. Taste

Managing Director
Krishna Cement Utpadaka Sanstha Ltd., 1987 60
62, Shivaji Nagar,
Korad 415110, Satara Distt.,
Maharashtra
SI. No. Plant's Name and Address Year of
Commissi oni
61 Sh. Saibanna Bajantri -T---------
- ---- ^
Managing Director
Kirti Mini Cements Pvt. Ltd., 1986 20
Chittapur 585211
Gulbarga District
Karnataka
62 Sh. A. Sennimalai
Vice President
Dharani Cements Limited, 1987
1 Venus Colony
Second Street,
Aiwarpet,
Madras — 600018
63 Sh. M.V. Chandrasekaran

Resident Director
Belgundi Cements (P) Ltd., 1986 30
Belgundi Village
Belgaum District
Karnataka — 591139
64 Sh. R.K. Mohta

Director
Mohta Cements Pvt. Ltd., 1987 E
Sagar Matha Apartment
18, MG Road,
Indore — 452001

Yangzon Cement Industries (P) Ltd.,
Post Box No. 171, 1986 30
Phuntsholing
Bhutan
66 Sh. S.B. Sajjan Shetty

Managing Director
Vikram Cements (P) Ltd., 1988
Post Box No. 1,
Chittapur — 585211
Station Road,
Gulbarga District,
Karnataka
91
Commissioning (tpd)
67 The manaaina Director
Madurai Cements Ltd.,
14712A/1 IA, Melur Main Road, 1987 300
2 Floor,
Near K. K. Nagar Arch.
Madurai — 625020
68 Sh. Virender Singh,

Managing Director
Thar Cement Ltd., 1989 150
Sitapur, Tehsil — Nawalgarh,
Distt.- Jhunjhunu
Rajasthan — 333304
69 Sh. R.P. Agarwal,

Director
Rishi Cement Ltd., 1989 50
Bharechnagar — 829122
Hazaribagh District,
Jharkhand.
70 Shri Dinesh B. Parikh

Managing Director
Jamshedpur Cement Ltd., 1989 100
Main Road, Bistupur,
P.B. # 31,Jamshedpur — 831001
71 Sh. P. Sharat Chandra

Managing Director
Manipur Cements Ltd., 1990 50
Dept. Of Industries
Lamphalpat,
Imphal, Manipur.
72 Sh. G. Kallappa
Managing Director
Hemavathi Cements Pvt. Ltd., 1990 30
5 & 6 SSB Mutt Bldg.,
Tankbund Road,
Bangalore 560009
92
Commissioning (tpd)
73 Sh. L.R. Jajee
Managing Director
Gitanjali Cements (P) Ltd., 1990 30
8-120 Cloth Bazar,
Gulbarga 585102,
—
Karnataka
74 Sh. K. Srihari Rao,

Managing Director
Sri Satyanarayanaswamy Cements (P) Ltd., 1990 30
1-2-24 Flat No. 104
Venkata Kripa Apartments
G.M. Road, Domalguda
Hyderabad 500029
75 Sh. K.V. Narasimha Rao

Managing Director
Gautam Cements Pvt. Ltd. 1991 100
5-19-30 Brodiepet
1-2/18, Guntur 522002—
Andhra Pradesh
76 Sh. Gautam Jain

Managing Director
Utkal Cements Pvt. Ltd., 1990 30
3, Bentinck Street
Calcutta 700001
—
77 Dr. K.S.N. Prasad

Managing Director
P. R. Cements 1991 200
29-13-28
Kaleswararao Road,
Vijayawada 520002—
78 Sh. Rohit Jain

Managing Director
Virgo Cements Ltd., 1991 200
Trade House, (6 th Floor)
S. R. C. B. Road,
Fancy Bazar,
Guwahati 781001
—
Assam.
93
_ Commissi oning 1__ (tpd) ,_l
79 P.S.G. Krishnan
Managing Director
Rekha Cements & Chemicals Ltd., 1991 100
Basava Nivas
29/1 K.H. Road
Bangalore — 560027
80 Sh. Brij Kishore Sharma

Managing Director
Sorabh Cement Ltd. 1990 200
Opp. Railway Station
Neem-ka-Thana — 332713
Rajasthan
81 Sh. Mehmood-ul-Hassan
Managing Director
J. & K Minerals Ltd., 1990
The Bund
Srinagar 190001
J & K.

Colts Cements Pvt. Ltd.,
1, Southern Avenue 1990
Maharani Bagh
New Delhi —110065
83 The Managing Director,

Katwa Cements Company
125, Khade Bazar 1987 100
Shahpur — 590003
Karnataka
84 Sh. A Venkateswara Rao,

Managing Director,
Vasudeva Cements Ltd., 1992 100
Choutapalli Mathampalli Mandal,
Nalgonda Distt.,
Andhra Pradesh.
94
Com mission ing _ td
85 Sh. B. Arya,
Managing Director,
Damoh Clinker (P) Ltd., 1992 50
Peter's Bungalow,
Civil Ward 3
Damoh 470661
—
86 Sh. N.N.P. Sinha

Managing Director
Narsing Cement Company Ltd., 1992 50
Giridih Indl. Area,
Giridih,
Jharkhand.
87 Sh. Phuntsho
General Manager
Lakhi Cement Project 1993 100
C/o. Penden Cement Authority
Gomtu,
Bhutan
88 Sh. Vikho Yshoshu

Chairman-cum-Managing Director
NSMDC Ltd., 1993 50
Kohima 797001
—
Nagaland
89 Sh. S.K. Latoo

Managing Director
Jaintia Cements Ltd., 1993 100
(Manbha Passah Building)
lawrnusiang,
Jowai 793150,
—
Meghalaya.
90 Sh. P. Lohanatha Raja,

Managing Director,
Everest Cement Limited, 1993 400
P.O. Pattambori,
Tq. Kelapur
Dt. Yavatnal,
Maharashtra 445305
—
95
Commissioning (tpd)
91 Sh. D.K. Chetiya
Managing Director
Umrangso Cements Ltd., 1993 100
Khanapara
Narangi Road,
Guwahati 781022
Assam.
92 Sh. J.D.Agrawal,
Managing Director
Quality Cement Industries Ltd., 1994 100
Sr. MIG No. 3, Sector- A,
Indrapuri
Bhopal — 462021
93 Sh. M.M. Reddy,

Executive Director
Banjara Cements Ltd., 1994 100
8-2-472/A, Road No. 1,
Opp. Post Office,
Banjara Hills,
Hyderabad — 500034.
94 Sh. M. Nageshwara Rao,

Managing Director,
Grey Gold Cement Ltd., 1994 200
6-3-655/6/B, 2n d /floor,
Somajiguda,
Hyderabad — 500482
95 Sh. A.D. Katwa

Chairman & Managing Director
Katwa Udyog Ltd. 1994 100
125, Khade Bazar
Shahapur
Belgaun — 590003
Karnataka
96 Sh. R.M. Kulloli

Managing Director
Channagiri Cements Pvt. Ltd., - 30
J-9, APMC Market Yard
Belgaum
Karnataka
96
Commissioning (t pd)
97 Sh. Arvind Bandwalkar
Managing Director
Bandwalkar Cements Pvt. Ltd. 30
'TRIMURTI'
Shahu Nagar
Ichalkaranji — 416115
Karnataka
98 Sh. Alam John,

Director
Haroon Cement Factory Pvt. Ltd. 1995 20
Naid Kadal,
Srinagar 190002
Kashmir
99 Sh. C.S. Sharma,

Managing Director
Gajwa Cement Co. Pvt. Ltd., 30
29/3, Subhash Nagar,
Indore 452003
—
Madhya Pradesh

Shiva Cement Limited,
P-25, Civil Township - 50
Rourkela 769004
—
Orissa.
101 Sh. G.P. Agarwal
Vandana Cements Pvt. Ltd.,
Dainik Bhaskar Bhawan - 100
4/54, Press Complex, A-B Road,
Indore 452008
—
Madhya Pradesh
102 Sh. Anil Dalmia

Managing Director
Dhruv Industrial Company Ltd. 1998 150
3A/92-93, Azad Nagar,
Kanpur208002

Lanco Industries Ltd.
Ground Floor, Visaka Towers 1997 250
1-8-303/69/3, S.P. Road
Secunderabad 500003
—
97
Commissioning (tpd)
104 Sh. Ashtaq Ahmed,
Managing Director
Trumboo Cement Industries (Pvt.) Ltd. 1999 200
2 Floor, Baba Building
Poloview, Srinagar
Jammu & Kashmir

Vinay Cements Ltd. (Assam)
Umrongso, N.C. Hills Distt. 2001 200
Assam
Ph. 561101, 562943
98
A 2 : CEMENT RESEARCH INSTITUTE OF INDIA MODERN VERTICAL SHAFT
KILN (CRI -MVSK) CEMENT PLANTS UNDER IMPLEMENTATION
SI. Plant's Name Location, District and Capacity

No. State (tpd)
1 Hoysala Cements & Ceramics (I) Saradgi `B' 100
Pvt. Ltd. Gulbarga
Karnataka
2 Gurling Mini Cement Plant Pvt. Ltd. Taran halli 30

Gulbarga
Karnataka
3 Vivekananda Cements Pvt. Ltd. Somkhed 30

Gulbarga
Karnataka
4 Sree Vasupuja Cements & Allied Ningapur Halki 100

Chemicals Pvt. Ltd. Bijapur
Karnataka
5 Saraf Inds & Commercial Metka 100

Enterprises Pvt. Ltd. Rajouri
Jammu & Kashmir
6 Deepti Cements Pvt. Ltd. Thimmasandra 30

Bangalore
Karnataka
7 Mahavir Silicons Pvt. Ltd. Algundi 100

Bijapur
Karnataka
8 Bhagyalakshmi Cements Pvt. Ltd. Vajinepalli 100

Nalgonda
Andhra Pradesh
9 Himalayan Foot Hills Pvt. Ltd. Rajpura Mandi 100

Poonch
Jammu & Kashmir
10 Naya Kashmir Cement Khalahar 100

Anantnag
Jammu & Kashmir
SI. Plant's Name Location, District Capacity
No. and State (tpd)
11 Chanchal Cements Pvt. Ltd. Udyog Giri Purena 50
Panna
Madhya Pradesh
12 Anand Cements Pvt. Ltd. Korumanupalli 100

Kurnool
Andhra Pradesh
13 Everest Cement Co. Pvt. Ltd. Sandrus 150

Raigarh
Madhya Pradesh
14 Basaveshwara Cements Pvt. Ltd. Matakaldevanhally 100

Bijapur
Karnataka
15 Honhally Cement Industries Pvt. Ltd. Honhalli 100

Bijapur
Karnataka
16 KKR Cements & Carbides Ltd. Ponnambarai 100

V 0 Chidambaranar
Tamil Nadu
17 Ruparel Cement Pvt. Ltd. Mahuva 200

Bhavnagar
Gujarat
18 Jewargi Cements Pvt. Ltd. Jewargi 200

Gulbarga
Karnataka
19 Milton Cements Pvt. Ltd. Patangi 200

Koraput
Orissa
20 Prominent Cements Pvt. Ltd Malanpur 50

(Expansion) Bhind
Madhya Pradesh
21 Balaghat Cements Pvt. Ltd (Expansion) Mohabatta 100

Balaghat
Madhya Pradesh
100
No. and State (tpd)
22 Janpriya Cements Pvt. Ltd. (Expansion) Neem-ka -Thana 100
Sikar
Rajasthan
23 Sree Vikas Cements Ltd. Yapalamadharam 100

Nalgonda
Andhra Pradesh
24 Sri Hukum Singh Cement Factory Bhind 50/100

Madhya Pradesh
25 Gujarat Heavy Chemicals Ltd. Sutrapada 200

Gujarat
26 National Mineral Development Corpn. Chawandia 100

Ltd. Rajasthan
27 Nagaland State Mineral Development Khonjheri 200

Corpn. Ltd. Nagaland
28 Premium Industries Ltd. Dhanbad 200

Bihar
29 Republic of Uzbekistan Kutarma 150

Dzizak Province
Uzbekistan
30 Mehr Cements Ltd Kangrail Village 100/200

Jammu & Kashmir
31 Mahendra Cements Pvt. Ltd (Expansion) Jeerabad 200

Adilabad
Andhra Pradesh
32 Jagadamba Cements Ltd. (Expansion) Mohabatgadh 50

Banaskantha
Gujarat
33 Belgundi Cements Pvt. Ltd. (Expansion) Belgundi 50

Belgaum
Karnataka
34 Abhishek Cements Pvt. Ltd. (Expansion) Patankuon 50
Damoh, MP
101
No. and State (tpd)
35 Kalinga Cement Ltd. (Expansion) Birmitrapur 50
Sundergarh
Orissa
36 Sandip Cements Pvt. Ltd. (Expansion) Mahuwa 50

Bhavnagar
Gujarat
37 Viswam Cements Ltd. (Expansion) Mallacheruvu 150

Nalgonda
Andhra Pradesh
38 Jiwan Cements Pvt. Ltd. (Expansion) Dhaula Kuan 200

Sirmour
Himachal Pradesh
39 Sangam Cements Pvt. Ltd. (Expansion) Kaladgi 200

Bijapur
Karnataka
40 Ajmera Cements Pvt. Ltd. (Expansion) Bhanduri 150

Junagarh
Gujarat
41 Sudarshan Cements Pvt. Ltd (Expansion) Danavaw 200

Sirohi
Rajasthan
42 Venus Cements Ltd. (Expansion) Rani Pokheri 100

Dehradun
Uttarpradesh
43 Suvidha Commercial Co. Pvt. Ltd. Dhar 200

(Expansion) Dhar
Madhya Pradesh
44 Lakshmi Cements & Ceramics Pvt. Ltd Ittigehalli 200

(Expansion) Chitradurga
Karnataka
45 Apex Cements Pvt. Ltd. Madhya Pradesh 50
46 Kaypee Industries Madhya Pradesh 200
102
No. and State (tpd)
47 Dhrungadhara Chemicals Ltd. Dhrungadhara 150
Sundarnagar
Gujarat
48 Arctic Cements (P) Ltd. Vallioor 100

Tamil Nadu
49 Rajapalayam Cements & Chemicals Ltd. Rajapalayam 100

Tamil Nadu
50 Sairfco Cements Pvt. Ltd. Khunmuh 200

Srinagar
J & K.
51 Raghuveer Cements West Bengal 200
103
B SABOO VSK CEMENT PLANTS IN OPERATION
:
Si No. Plant's Name and Address Year of Capacity

1 Sh. N. P. Chaudhary,
Apu Industrial Enterprises
27, Western St. Jan. 1990 50
Calcutta ( Site Bangladesh)
2 Sh. Dawa Panjore,

Namgail Cement Pvt. Ltd.,

Putshillong Dec. 1991 50
Bhutan
3 Shri S. S. Dadi
Modern Cement Co. Pvt. Ltd.
Vill : Chikhodra, Taluka : Godhra April 1985 50
Distt. Panchmahal
(G ujarat)
4 Sh. D.H. Sinhar

Harekrishna Cement & Chem. P. Ltd.
Bijapur Road Feb. 1986 20
Bijapur
Distt — Junagarh
(Gujarat)
5 Shri Kirit C. Parikh

Vikki Cement Pvt. Ltd.
Vill. Hadad, Paliyad Road, April 1986 20
Taluka Botad, Distt. Bhavnagar
(Gujarat)
6 Sh. S. Sriniwasan,
Modern Portland Cement Co. Pvt. Ltd.,
Viii. Chikhodra, Taluka — Godhra Jan. 1989 30
Distt. Panchmahal
(Gujarat)
7 Shri C.M. Phaldur

Sardar Cement Pvt. Ltd.
C/o. Rajhans Agencies March 1992 50
Virani School Chowk,
Tagore Marg Rajkot
(Gujarat)
item]
Commissioning (tpd)
8 Mr. I. M. 5hekh
Star Cement Company
C/o. Royal Ice Factory Dec. 1992 50
Sikari Mohalla, Godhra
Distt. Panchmahal.
(Gujarat)
Site Vanakpur
:
9 Shri Ashwani Kumar

Shaktiman Cement Pvt. Ltd.
M-31, Behind Police Station Feb. 1993 50
Industrial Area, Yamuna Nagar-135001
(Haryana)
10 Shri S.S. Sikka

Zodaic Cements Pvt. Ltd.,
Banger Theater, Hisar Road, April 1993 50
Rohtak
(Haryana)
11 Shri J.P. Beni

M/s. Sohna Cements Pvt. Ltd.
E-1 04, Greater kailash, Enclave —1, June 1993 50
New Delhi (Site Rohtak)
:
12 Shri R.K. Bhageria

Ramuka & Bhgeria Cement Pvt. Ltd.
93/94, KM Stonne From Delhi NH-8, Nov.1993 50
Teh. Bawa; (Rewari)
(Haryana)
13 Shri Moti Singh

Garude Clays Pvt. Ltd.
79, Transport Centre June 1994 50
New Rohtak Road
New Delhi (Site: Bewari)
14 Shri R.P.Agarwal
Monchu Cements Ltd.
3103, Sangtrushan Street, 1997 50
Pharganj
New Delhi (Site: Vill- Dhulawat)
105
SI. No. Plant's Name and Address Year ofapacity
Commissioning (tpd)
15 Shri P. C. Gandhi
Satyashree Cement Udyog
Bhungarni, Distt. Paonta Sahib Dec. 1985 30
Himachal Pradeh.
16 Shri A.K. Gupta

Himachal Cement Pvt. Ltd.,
Post Box No.13, June 1986 80
Poanta Sahib
Himachal Pradesh
17 Shri Jagdish Kapoor

Sirmour Allied & Chem. Pvt. Ltd.
Vill. Mugalanwala Kartarpur Oct. 1986 20
P.O. Rajban, Paonta Sahib
Himachal Pradesh
18 Shri C.L. Jain

Radiant Cement Co. Pvt. Ltd.
Vill. Moginand Aug. 1987 30
P.O. Kala Amb, Teh. Nahan
Distt. Sirmour
Himachal Pradesh
19 Shri Gurdeep Singh

Yamuna Cement Pvt. Ltd.
86, Industrial Area April.1991 35
Paonta Sahib — 173025
Distt. Sirmour
Himachal Pradesh
20 Shri Shalin Jain

Vikram Cements Ltd.
210, Gagan Deep Jan. 1990 50
12, Rajendra Palace
New Delhi (Site: Nalagarh)
21 Shri Mallik Mohd. Qasim Shah

Allahi Cement Industries
Industrial Extension Area Nov.1985 70
Anchidora, Anantnag — 192101
(Jammu & Kashmir)
i<(II•
Si No. Plant's Name and Address Year of Capacity
Commissioning (tpd)
22 Shri G.D. Naidu
Seshasaila Cements Pvt. Ltd.
49/8, 4 th Main, 16 th Cross Oct. 1988 20
Malleshwaram,
Bangalore.
23 Shri Ravindra Sethi

Sri Gaj Mukha Cements Pvt. Ltd.
Singapura Kaval Hatti Closed 30
Chitradurga, Karnataka
24 Shri .M.L. Jain

Abu Cement Works Pvt. Ltd.
2, Sadhna Nagar, Air Port Road, March 1984 70
Indore, M.P.
25 Shri O.P. Mittal,

Pluton Cements Pvt. Ltd., May 1985 40
138, Sneh Nagar, Indore
26 Sh. J.L.T. Tiwari

Dinesh Cements Pvt. Ltd.,
Khokhali Road, June1986 20
Bhatapara Distt., Raipur,
Madhya Pradesh
27 Sh. O. P. Mittal,
Polyport Cement
138, Sneh Nagar, Jan. 1990 100
Indore, Madhya Pradesh
28 Shri Y. Singh
Chitrakut Cement Pvt. Ltd.,
128, Chanakyapuri April 1993 50
Semaria Chowk
Satna (M.P.)
(Site: Rewa)
29 Shri K.G. Somani

Apex Cements Pvt. Ltd.
Krishna Apartments, 50
Behind Gautam Nagar
Race Course Circle
Baroda (Site Alirajpur)
:
30 Sh. B.L. Hajer Patil

Vaidyanath Cement Pvt. Ltd.
Laxman Villa, Pangri Road April 1985 20
Sahu Nagar (BEED), Maharashtra
107
Commissioning (tpd)
31 Shri R.B. Agarwal
Hasi Cement Pvt. Ltd.
Cotton Market Road Jan. 1987 30
Amravati
Maharashtra
32 Shri Vishwanath Jagadale

Ichalkaranji Co-operative Cement Ltd.
10-222. Mahatma, Phule Road Feb. 1987 20
Near Shakhar Pe'Hospital
Ichalkaranji
Maharashtra
33 Shri Praveen S. Lunkad

Nay Maharashtra Portland Cement Ind..
42/43, Sankar Sheth Road May 1987 50
Pune, (Maharashtra)
34 M/s. Yuvraj Shahu Chhatrapati Cement

Utpadak Vadgani
Vill/Post : Vadgaon Jan. 1989 20
Distt. Kolhapur
(Maharashtra)
35 Shri B.L. Purohit

Purohit Cement Ltd.
13, Purohit & Company April 1993 50
New Cotton Market
Nagaur (Site : Wani, Yawatmal)
Maharashtra
36 Shri M.D. Mane

Chairman
Sidhanath Co-op. Cement Ind. Ltd. 1996 50
AT/PO. Mahuli, Tal — Khanapur
Distt. Sangi — 415310
(Maharashtra)
37 Sh. B.L. Bajaj

RKB Cements Pvt. Ltd.
Bara Bazar, G.S. Road March 1995 50
Shilong,
Meghalaya — 793002
108
St. No. Plant's Name and Address Year of Capacity
Commissioning (tpd)
38 Shri N.K. Agarwal
Krishna Cement Pvt. Ltd.,
H-3, Civil Township Oct. 1984 40
Rourkela
(Orissa)
39 Shri R.P. Gupta

Shiva Cements Pvt. Ltd.
H-6, Civil Township Dec. 1986 80
Rourkela
Orissa
40 Shri Punit Beriwala

Vimal Cement Pvt. Ltd.
M-10, Civil Township Feb. 1987 50
Rourkela
Orissa
41 Shri K.M. Sinha

Neelanchal Cement Pvt. Ltd.
2115, Ratha Road 1990 50
Bhubaneshwar
Orissa
42 Shri Ashok Mahant

B.S. Cements Pvt. Ltd.
29, Acharya Vihar 1990 50
Bhubaneshwar
Orissa
43 Shri Gopal Joshi

Shree Gopal Cements Pvt. Ltd.
Main Road June 1992 50
Rajgangpur
Orissa
44 Shri K.K. Modi

Ambica Cement Pvt. Ltd.
D-14, Civil Township June 1992 50
Rourkela
Orissa
109
Commissioning (tpd)
45 Shri P.K. Saraf,
Kanak Cement Pvt. Ltd.
OCL Approach Road Feb. 1992 50
Rajgangpur (Orissa).
46 Shri L.K. Jalan

Mukund Cement Pvt. Ltd.
P.O. Rajgangpur, 1987 20
Distt. Sundargarh (Orissa)
47 Shri R.K. Khaitan

Rampal Cements Pvt. Ltd.
C/o. Utkal Auto Syndicate March 1993 50
Panposh Road
Rourkela (Orissa)
48 Shri R.K. Sukhani

M/s. Shubham Industries Ltd.,
Premier Court, Chandni Chowk Street, 1995 140
Calcutta.
49 Shri Arun Jain

Vedvyas Cements Pvt. Ltd.
K-3, Civil Township July 1993 50
Rourkela (Site : Rourkela)
Orissa
50 Shri Sandeep Kumar

Sushila Cements Pvt. Ltd.
Gopabhandhu Marg, Jan. 1994 50
Rajgangpur, Distt. Sundargarh,
Orissa
51 Shri R.K. Lohia

M/s. Kharia Cement Works Pvt. Ltd.
Plot No. 11, Assam House 30
7, New Power House Road Closed
Jodhpur (Site: Kharia Mithapur)
Rajasthan.
52 Shri Sukumar Saboo,

Saboo Minerals Nov. 1982 30
Marudhar Inudustrial Area,
Basni, II Phase, Jodhpur,
53 Shri Ramavtar Agarwal

Agarwal Cement & Chem. Pvt. Ltd.
Near Post Office, Jan. 1984 40
Gotan Distt., Nagaur (Rajasthan)
110
Commissioning (tpd)
54 Shri G.S. Agarwal
Solar Cements Pvt. Ltd.
Vill. Barodara June 1984 20
Post — Lachmangarh
Distt. Sikar
(Rajasthan)
55 Shri Harcharan Singh Saluja

Saluja Cements Pvt. Ltd.
A-24/B, Industrial Area Oct. 1984 20-40
Behror (Distt. Alwar)
Rajasthan.
56 Shri G.0 Jain

Jain Cements Udyog Pvt. Ltd.
Cloth Market Dec. 1984 20
Kuchamancity, Dist. Nagaur
Rajasthan.
57 Shir S.P. Jain

Central Construction & Engg. Co. Ltd.
Vul/Post: Sindhrath July 1985 20 —40
Distt. Sirohi, (Site : Sindhrath)
Rajasthan
58 Shri. D.N. Tiwari

Madhu Cement Pvt. Ltd.
14, Hosppital Road, `C' Scheme June. 1985 20
Jaipur (Site : Behror)
(Rajasthan).
59 Shri G.C. Khemka

Khemka Cement Pvt, Ltd.
9, Bechum Bag, S.C. Road June 1985 40
Rajasthan
60 Shri Devilal Kothari

Shreenath Cement Ind. Pvt. Ltd.
Vill. Bhujela, PO. Bharza Oct. 1985 20
Abu Road
(Rajasthan)
111
Commissioning (tpd)
61 Shri S.N. Sharma
Om Shiv Shakti Cement Pvt. Ltd.
F-15, Industrial Area Oct. 1985 20
Sikar
(Rajasthan)
62 Shri Pradeep Sarawgi

Jodhpur Cement Ind. Pvt. Ltd.
Marudhar Industrial Area Oct. 1985 A
Basni, II-Phase,
Jodhpur
(Rajasthan)
63 S.V. Dujodwala
Maruti Cement Pvt. Ltd.
Dujodwala Sadan, Bajaj Road Nov. 1985 20
Sikar (Site : Khandela)
Rajasthan
64 Shri Natwar Krishna Harsha

Shree Shakti Cement Pvt. Ltd.
E-24/25, Ambaji Industrial Area Feb. 1986 A
Post Box No. 27,
Abu Road,
Rajasthan
65 Shri Sarad Kaushik

Rajdhani Associates Pvt. Ltd.
A-22-B Industrial Area Feb.. 1986 20
Behror (Distt. Alwar)
Rajasthan
66 Shri J.C. Sodani

Sodani Cement & Chem. Pvt. Ltd.
E-88/89, Arbuda Industrial Area Jan. 1986 40
Abu Road
Rajasthan
67 Shri Bhawani Singh

Rajputana Cement Pvt. Ltd.
High Court Colony Road 1986 40
Panchwati, Jodhpur
(Site: Buchkala)
Rajasthan
112
Commissioning (tpd)
68 Shri Umesh Dhoot
Silver Cements Pvt. Ltd.
C/o. Gulab Dass Jaggnath Agencies 20
Nahata Building, Chopasni Road Closed
Jodhpur (Site : Abu Road)
Rajasthan
69 Shri S.N. Todi,

Shaunak Industries Pvt. Ltd.
B-25, Industrial Area 1986 40
Behror (Distt : Alwar)
Rajasthan
70 Shri G.C. Jain

Jawai Cement Pvt. Ltd.
E-13/14, Ambaji Industrial Area Jan. 1987 20
Abu Road
Rajasthan
71 S.G. Saboo
Saboo Minerals Pvt. Ltd.
Marudhar Industrial Area June 1985 50
Basni, II-Phase,
Jodhpur
Rajasthan
72 Sh. S.K. Jain

Sarawgi Cement Pvt. Ltd.
Opp. New Sabji Mandi, Dec.1987 50
Sujangarh, Distt. Churu
(Rajasthan)
73 Shri N.K. Goenka

Swati Cement Pvt. Ltd
Vill Biramsar, Teh. Ratangarh May 1988 50
Distt. Churu
Rajasthan
74 Shri N.D. Maheshwari

Soni Ceramics Pvt. Ltd.
14,15,16, Industrial Area March 1988 20
Nagaur
Rajasthan
113
Commissioning (tpd)
75 Shri Mukesh Gajaraia
Unilinks Cements Pvt. Ltd.
Vill. Kiverli, By Pass Road July 1988 30
Abu Road,
Rajasthan
76 Shri V.K. Bhatnagar

Bhatnagar Cement Co. Pvt. Ltd.
A-1, & NDSE-I, Ring Road Dec. 1989 30
New Delhi
(Site: Behror)
77 Shri Vinodji
Durga Cement Pvt. Ltd
Vill. Bhujela, P.O. Bharrja Feb. 1990 30
Distt — Abu Road
Rajasthan
78 Shri S.K. Jain

Raj Cements Pvt. Ltd.
E-90/91, RIICO Industrial Area July 1990 30
Churu
Rajasthan
79 Shri S.K. Jain

Sumati Cements Pvt. Ltd.
Vill. Biramher, Teh. Ratangarh April 1989 80
Distt. Churu
Rajasthan
80 Shri Nathu Ramji

K.D. Cements Pvt. Ltd.
D-84, Gheeya Marg, Bani Park June 1990 30
Jaipur — 302016
(Site : Bidasar)
81 Shri R.A. Agarwal

Meera Cements Pvt. Ltd
Vul/Post: Gotan April 1991 50
Distt. Nagaur
Rajasthan
114
Commissioning t d
82 Shri Duli Chanji
Superfine Cement Pvt. Ltd.
E-32 Industrial Area Sept.1991 50
Mertacity, Distt. Nagaur
Rajasthan
83 Shri Maheshji Ajmera

Sukhsa Cement Pvt. Ltd
Hiswal Industrial Area Jan. 1991 50
Bikaner
Rajasthan
84 Shri Sirish Jain

Arvind Construction Co. Ltd.
L-43, Cannaught Circle Sept . 1991 50
New Delhi
(Site : Kotputli)
85 Shri Bhagwan Sahay

United CementsPvt.Ltd.
C/o. Gopal Bhagwan & Cc'. April 1992 50
A-3, Govind Marg, Adarsh nagar
Jaipur (Site: Shreemadhopur)
Rajasthan
86 Shri Ashok Chaudhary

Shreemadhopur Cement Pvt. Ltd.
Surani Bazar Jan. 1992 50
Shreemadhopur, Distt. Sikar
Rajasthan
87 Shri J.C. Khandelwal

Pan Asia Industries Ltd.
C-1/33, Safdarjang Development Area, Feb. 1992 50
New Delhi (Site: Behror)
88 Shri Deelip Bajaj

Chirag Cement Pvt. Ltd.
32, Vansthali Marg March 1992 50
Rajasthan
115
Si. No. Plant's Name and Address Year of Capacity
Commissioning (tpd)
89 Shri Yoaesh Pal Tanari
Jyoti Cement Pvt. Ltd.
F-68, E-70, Industrial Area March1992 50
Behror
Rajasthan
90 Shri Ravinder Bahal

Gunjan Cements Pvt. Ltd.
9B, Deepali Pitampura May 1992 50
Delhi (Site: Behror)
91 Shri C.P. Jain

Siddha Cements Pvt. Ltd.
Jaipur Towers, Opp. A.I.R. June . 1992 50
M.I. Road, Jaipur
(Site: Behror)
Rajasthan
92 Shri R. Prakash
Javeline Cement Pvt. Ltd:
E-21 1, Greater kailash-I I June 1992 50
New Delhi —110048
(Site : Sujangarh)
93 Shri Mahendra Chaudhary

Hanumant Cement Pvt. Ltd
Marwar, Mundwa Sept.1992 50
Rajasthan.
94 Shri Jagdish Chaudhary

Pratibha Cements Pvt. Ltd.
C/o. Chaudhary Tours & Travels May 1992 50
1-C, Road, Sardarpura
Jodhpur
(Site: Ransi) (Rajasthan)
95 Shri Shreechand Agarwal

Prime Cements Pvt. Ltd.
C/o. Jugal Kishore & Co. July 1992 50
C-1 3, Nai Anaj Mandi, Chandpole Bazar
Jaipur (Site: Behror)
Rajasthan
116
SI. No. Piss Nam. and Address Year of Capacity
Commissioning
96 Shri Shreechand Jain
Bothra Contractors & Builders
E-121, Shastri Nagar July 1992 50
Jaipur (Site: Beewar)
Rajasthan
97 Shri S.K. Khandelwal

Shubham Cement Pvt. Ltd.
Shubh Sadan, Adarsh Colony Aug.1992 50
Teh. Sujangarh,
Distt. Churu
Rajasthan
98 Shri Mahaveer Prasad Prajapati

Kuber Cement Pvt. Ltd.
Tak Sadan, Ward No. 25 Aug. 1992 50
Churu (Site: Ratangarh)
99 Shri P.R. Mundhra

Anita Cements Pvt. Ltd.
33-E, Block Dec. 1992 4.x+7
Sriganganagar
(Site: Beewor)
Rajasthan
100 Shri Vinod Kumar Jindal

Vijeta Cements Pvt. Ltd.
E-104, Industrial Area, Feb.1993 50
Behror (Rajasthan)
101 Shri Ravi Goyal

M/s Shri Modi Cements ( raj) Pvt Ltd
Vidyadhar Ka Rasta Dec. 1992 50
Jaipur ( site : Behror)
102 Shri Sandeep Karwa

M/s Basera Cements Pvt Ltd
F-8 to F-13, Riico Indl. Area, Aug. 1992 50
P.O. Shrinadhapur
Sikar — Distt.
Rajasthan.
117
SI. No. T Plant's Name and Address Year of
Com missi oning
Capacity
103 Shri. Kaushal Dhoot

M/s. Metro Cement Pvt. Ltd.
1 5` Floor, Mahesh Hotel Corn plex Jan. 1993 50
Opp. Bombay Motors
5 th Chopasani Road,
Jodhpur (Site : Near Gotan)
Rajasthan
104 Shri Anil Jain

M/s. R. Sidharth & Co. (India) Pvt. Ltd.
P-1/2, Pal Jaw, New Ambedkar Circle Feb.1993 50
Pali Manwar (Site: Ransi)
Rajasthan
105 Shri Rajendra ji Chandak

M/s. Tiger Cements Pvt. Ltd.,
Sarawati Sadan, TD (A) Feb. 1993 50
Sardujganj, Bikaner (Site : Nokha)
Rajasthan
106 Shri R.B. Gadia

Sakambari Cements Pvt. Ltd.
C/o. Dwarka Prasad Ramesh Kumar March. 1993 50
Cloth Market, Jhunjhunu
(Site : Jhunjhunu)
Rajasthan
107 Shri Bhagwan Singhji Parihar

Laxmi Oil Field Services Pvt.Ltd.
C/o. Laxmi Udyog 50
22-23, Light Industrial Area
Jodhpur (Site : Sojat Road)
Rajasthan
108 Shri Darbar Singh

Padam Cements Pvt. Ltd.
435, A-Block, Padampur
Sriganganagar March . 1993 50
(Site : Ratangarh)
Rajasthan
109 Shri Mahesh Kumar

Bhagirath Cements Pvt. Ltd.
C/o. Sikar Hardware & Co. Sept. 1993 50
Opp. Main Post Office
Sikar (Rajasthan)
118
Commissioning (tpd)
110 Shri Ram Prasad Dhoot
Rajasthan Cement Udyog
RIICO Industrial Area April. 1993 50
Phulera, Distt. Jaipur
Rajasthan
111 Shri Mahesh Pareekh

Tirupati Cement Pvt. Ltd.
E-37. RIICO Industrial Area May.1993 50
Behror (Alwar)
Rajasthan
112 Shri Basant Kumar Tater

Jineshwar Cement Pvt. Ltd.
C/o. Basant Tater April 1993 50
G-8, Housing Board Colony,
Bhagat Ki Kothi
Jodhpur (Site: Boranda)
Rajasthan
113 Shri J.C. Khandelwal

Panasia Industries Ltd
1520, Market Chamber — V, May 1993 40
1221, Nirman Point
Bombay
(Site Kotputli)
:
114 Shri Ganesham Dass Lohahti

Shyam Cements Pvt. Ltd.
116, Sarwagi Mansion —1 April 1993 50
M.I. Road, Jaipur
(Site :Bikaner) Rajasthan
115 Shri D.C. Jain

Uttam Cements Pvt. Ltd.
D-711A, Sawar Area
Paras Marg, Bapu Nagar Sept. 1993 50
Jaipur (Site Abu Road)
:
Rajasthan
116 Shri Jitendra Surana

Surana Cements Pvt. Ltd.
D-146, Savitri Path June1993 50
Bapu Nagar, Jaipur
(Site: Gotan)
Rajasthan
119
Commissioning t d
117 Shri Girish Gupta
Gupta Cements Pvt. Ltd.
22, New Rajdhani Enclave, Vikas Marg April. 1994 50
New Delhi (Site: Chirawa)
118 Shri S.K. Jain

Sargam Cement Pvt. Ltd
A-79, Gopalbadi April1993 50
Jaipur (Site : Ratangarh)
Rajasthan
119 Shri R.K. Tangri

Umesh Cement Pvt. Ltd.
322-A, Matasya Industrial Area, Aug. 1993 50
Alwar (Site : Alwar)
Rajasthan
120 Shri B.C. Agarwal

Moti Cement Pvt. Ltd.
A-114, Ganesh Nagar Aug. 1993 50
New Delhi (Site: Behror)
121 Shri R.P. Jain

Mradul Cement Works Pvt. Ltd.
G-84, RIICO Industrial Area 1994 50
Ratangarh
122 Shri N.K. Geonka

Maharan Cements Pvt. Ltd.
E-24, Industrial Area
Sikar 1995 50
Rajasthan
123 Sh. D.P.Agarwal

Teesta Cement Pvt. Ltd.
3, 2 d Floor, Anukampa Mansion,
" Sept. 1993 50
Opp. Raymonds Showroom
M.I. Road, Jaipur — 302001
Rajasthan
120
Commissioning (tpd)
124 Shri B.L. Maheswari
Sarvottam Cement Pvt. Ltd.
Charkara, Nokha Nov.. 1993 50
Distt. Bikaner (Site: Nokha)
Rajasthan
125 Shri Mahendra S. Kachhawa

M.G.T. Cements Pvt. Ltd.
Chemicals Lime Compound Dec. 1993 50
Marwar Mundwa (Site: Marwar Mundwa)
Rajasthan
126 Shri S.P. Agarwal

Mahal Cements Pvt. Ltd
630, Vivek Vihar, New Sanganer Road, Jan. 1994 50
Jaipur (Site : Viii — Sarrund )
Rajasthan
127 Shri Pratap Rai Panjwani

Gemini Cements Pvt. Ltd.
H/o. WH-84, Mayapuri Indl. Area, Dec. 1993 50
1st Phase, New Delhi
(Site : Alwar)
128 Shri Prabhuji

Jajodia Cements Pvt. Ltd.
C/o. Navyug Oil & Dall Mill June 1993 50
21, Industrial Area, Nagaur
(Site: Ratangarh) Rajasthan
129 Shri A.K. Jalan

Chinar Cements Pvt. Ltd.
P-7, Tilak Marg, 'C Scheme
Jaipur (Site : Jhunjunu) Dec.1993 200
Rajasthan
130 Shri O.P. Gyal

Mehta Cements Pvt. Ltd.
Marte Road — 341511 June 1994 50
Distt. Nagaur
Rajasthan
121
Commissioning (tpd)
131 Shri V.B. Agarwal
Gujarat Filaments Limited
1005, Raheja Centre June 1995 140
Nariman Point
Bombay — 400021
(Site : Kotputli)
132 Shri S.P..Agarwal

Chokani Cements Pvt. Ltd
D-140 Durga Marg 1996 50
Bani Park, Jaipur (Site : Jhunjunu)
Rajasthan
133 Shri S.K. Jain

Sharhad Cements Pvt. Ltd.
C/o. Swati Cements Pvt. Ltd. 1997 50
Vill. Biramsar, Teh. Ratangarh
Distt. Churu (Site: Shahpura)
Rajasthan
134 Shri S.K. Jain

Suparbhat Cement Pvt. Ltd.
C/o. Swati Cements Pvt. Ltd. 1997 50
Vill. Biramsar, Teh. Ratangarh
Distt. Churu (Site : Shahpura)
Rajasthan
135 Shri Murlidhar Rathi

Nokha Cements Pvt. Ltd.
Bikasar Road, Nokha June 1994 50
Bikaner (Site : Nokha)
Rajasthan
136 Shri B.K.Atijsaria

Enkay Agro Pvt. Ltd.
109, A/1-A, Biplabi Basu Road Jan.1994 50
Calcutta (Site: Near Behror)
137 Shri Manoj Agarwal

Castle Cements Pvt. Ltd.
D-25, Calcutta Form 1997 50
Shyam Nagar, New Sanganer Road
Jaipur (Site: Kotputali)
Rajasthan
122
Commissioning (tpd)
138 Shri R. Agarwal
Namo Cement Pvt. Ltd.
77, N.S. Road, Jan 1994 50
Suite No. S-8, 4 th Floor
Calcutta (Site: Kotputli)
139 Shri. A.R. Chaudhary

Kinker Cement Pvt. Ltd.
B-228, Road No. 9E, 1997 50
Vishkarma Ind. Area
Jaipur-302001
(Rajasthan)
140 Shri B.P. Singhania

Jagdish Construction Pvt. Ltd.
190 Mohan Colony July 1995 50
Banswara
Rajasthan
141 Shri Anurag Jain

Devshree Cement Ltd.
Vill. Kharia Meethapur 1995 50
Teh. Bilara — 342602
Distt. Jodhpur
Rajsathan
142 Shri S.M. Arif

Arif Cement Industries
`Skylark' 28, Naval Kishore Road, Dec.1984 120
Hazratganj, Lucknow
Uttar Pradesh
143 Shri A.P. Jain

Nirmal Cement Factory
157, Avas Vikas Colony Feb.1985 30
Civil Lines, Moradabad
Uttar Pradesh
144 Shri Ajay Kumar

Ashish Cement Pvt. Ltd.
786, Subhash Bazar Oct. 1985 30
Mawane — 250401
Distt. Meerut
Uttar Pradesh
123
Commissioning (tpd)
145 Shri Prem Sheth
Vikram Cement Pvt. Ltd.
4/283, Vishnupuri Aug.1987 50
Kanpur
Uttar Pradesh
146 Shri Radha Krishan Agarwal

Indra Steels Pvt. Ltd.,
Indra Palace, Connaught Circus July 1987 30
New Delhi
(Site: Gaziabad)
147 Shri R.K. Gupta

R.A. Cements Pvt. Ltd.
117-H-1 /296, Model Town 50
Pandu Nagar
Kanpur
Uttar Pradesh
148 Shri Jay Lalwani

Indus Laminators Pvt. Ltd.
Matra Chaya, Basant Vihar 40
Kanpur Closed
Uttar Pradesh
149 Shri Vijay Arora

Brahmavarta Cements Pvt. Ltd.
190-B, Co-operative Industrial Estate Oct. 1988 30
Dada Nagar, Kanpur
Uttar Pradesh
150 Shri Mukesh Keswani

Jagadishpur Cement Pvt. Ltd.
4A, Park Road, Ramjang Building 1989 30
Lucknow — 296001 (Site : Jagdishpur)
Uttar Pradesh
151 Shri D.Y. Pichanvthu,

Almora Magnesite Limited
Vill. Matela, Post Bilari April 1980 50
Distt — Almora
Uttar Pradesh
124


152 Shri Basant Lai
Krishna Fertilizers Pvt. Ltd.
60/45, Nayaganj 1990 30
Kanpur
Uttar Pradesh
153 Shri Manmohan Arora

Arpit Cement Pvt. Ltd
4-A, New Mandi Aug.1992 50
Muzaffarnagar
Uttar Pradesh
154 Shri S. Bhushan

Sonu Udyog
1-B, `N' Block Aug. 1992 50
Govind Nagar
Kanpur
Uttar Pradesh
155 Shri V.K. Gupta

Vikrant Cements Pvt. Ltd.
Baghpat, Nov. 1993 50
Meerut
Uttar Pradesh
156 Shri D.N. Gupta

Delta Erectors Pvt. Ltd
117/H-2/165, Pandu Nagar July 1995 50
Kanpur (Site: Kanpur Dehat)
Uttar Pradesh
157 M/s. Champion Cement Ind. Ltd.

2, BBD Bag (East)
Calcutta 700001
— Jan. 1994 100
158 Shri S.L. Moondra

Director
R.T. Udyog
A-19, RIECO Industrial Area
Behror, Distt. Alwar
Rajasthan.
125
I. No. Plant's Name and Address Year of Capacity
Commissioning (tpd)
159 M/s. Pankaj Cements Pvt. Ltd.
416, Kucha Brijnath
Chandni Chowk Dec. 1993 50
New Delhi
160 M/s.Modern Industries

Kalol Gohdra Highway
Popatpura — 389001 Jan.1991 50
Tq. Godhra, Panchmahal Distt.
Gujarat
161 M/s. Samrat Cement Pvt. Ltd. July 1994 50

Gujarat
162 M/s. Krishna Building Cement (I) Pvt. Ltd May1995 50

Gandhi Chambers, Gonda Road,
Rajkot — 360002
Gujarat
163 M/s. Orient Abrasive Ltd.

Gujarat 1995 50
164 M/s. Trilok Cement Pvt. Ltd.

Gujarat Aug.1995 50
165 M/s. Krishan Build Cement Pvt. Ltd. 1996 100

Gujarat
166 M/s. Gautam Industry, 1996 35

Bhavnagar
Gujarat
167 M/s. Mahakali Cement Pvt. Ltd. 1996 50

Gujarat
168 M/s. Gujarat Minerals Development 150

Corpn. Ltd. (Rotary)
Gadhsisa
Gujarat
126
Commissioning (tpd)
169 M/s. Katni Cement Pvt. Ltd.
M.P. 1993 50
170 M/s. Aditya Lime Industries

Maharashtra 1997 75
171 M/s. Kuber Cements Pvt. Ltd. Aug.1992 50

Orissa
172 M/s.Gori Cements Pvt. Ltd. June 1993 50

Rajasthan
173 M/s. Delhi Cements Pvt. Ltd. Feb.1994 50

Rajasthan
174 M/s. Mosar Cements Pvt. Ltd. Sept.1995 50

Rajasthan
175 Mts. Shree Madho Cements Pvt. Ltd. 1996 50

Rajasthan
176 M/s. Patodia Cements Ltd. 1996 100

Rajasthan
177 M/s. Basera Cements Ltd. 1997 350

Rajasthan
178 M/s. Vishwakarma Cement Ltd. 1997 100

Pathredi Road, Kotputli 303108
—
Jaipur Distt. (Rajasthan)
179 M/s. K.C. Cement Pvt. Ltd.

Rajasthan 1996 50
180 M/s. Vikram Cement Pvt. Ltd. Aug. 1987 50

Uttar Pradesh
127
I. No. Plant's Name and Address Year of Capacity
Commissioning (tpd)
181 M/s.Nirmal Cement Pvt. Ltd. 1996 100

U.P.
182 M/s. Ramuka & Bhagaria Cement Pvt. Ltd.

Uttar Pradesh 1996 100
183 M/s.Bahubali Cements Pvt. Ltd. Aug.1994 50

Bihar
184 M/s. Mata Cements Pvt. Ltd. May 1993 50

Andhra Pradesh
185 M/s.Vishwa Cements Pvt. Ltd. Feb.1995 50

Andhra Pradesh
186 M/s.Nirman Cements Pvt. Ltd. 1996 100

Bihar
187 M/s. Cresent Cements 1997 350

Kerala
188 M/s.Pennco Cement Industries Pvt. Ltd. 1996 100

West Bengal
189 M/s. Mittal Cement Pvt. Ltd. 1997 75

West Bengal
190 Shri Anil Sharma

Director 50
M/s. Gwalior Cement Company Pvt. Ltd.
1 5t Floor, Krishna Mandir
Phalka Bazar,
Gwalior — 474001
191 M/s. Sangam Cements Pvt. Ltd. 50

R.S. No. 346, Kaladgi Village
Tal: Bagalkot, Distt. Bijapur — 587204
128
Commissioning (tpd)
192 M/s. Jayshree Cement
Rajasthan March1993 50
193 M/s. Ved Vyas Cement Ltd.

Orissa 1996 200
194 M/s. Champion Cement Ltd. Jan.1994 100

Orissa
195 M/s.Bombay Mineral Pvt. Ltd 1995 50

Gujarat
196 M/s. Garuda Cements 100

Huzura Nagar, Nalagonda Distt.
Andhra Pradesh
197 M/s. Heritage Cements Pvt. Ltd. 100

P.G. Padu, Piduguralla
Konanki, Pidugurala Mandal
Guntur Distt.
Andhra Pradesh
198 M/s. Suji Cements Ltd. 100

Guddapotharam Village
Jinnaram Village, Medak Distt.
Andhra Pradesh
199 M/s. Shakti Cements Ltd. 100

p.b. No. 51, Udyog Nagar
Mahuva 364290
—
Bhavnagar Distt.
200 M/s. Chetan Cement Pvt. Ltd. 100

GAT 78-84, Near Girno Rly. Bridge,
—
Bambhori Village,
Erandon Tq.
201 M/s. Sita Cements Ltd. 100

Telighana
P.O. Kutra, Distt. Sundergarh
129
SI. No. I Plant's Name and Address I Year of
Commissioning
Capacity
(tod)
202 M/s. Pithe Cement & Ind. Ltd.
Prithvipura Village 100
(Bilara Jaitaran Highway)
Jaitaran Tehsil, Pali Distt.
203 M/s. Vijay Cements Ltd.,

Keela Mathur, 100
Ariyalur — 621713
204 M/s. Bomber Cement Plant

Umbang, Sumer
Barapani
Ph. 260158, 260051 Assam
205 M/s. A.M.S. Cement Pvt. Ltd

Mawpdang Vill.
East Khasi W
Hills Distt. Meghalaya
Ph. (0364) 223285
206 M/s. Cement India Ltd.
Khaliamani
Dibrugarh — 786001 30
Distt. Dibrugarh Assam
207 M/s. Jumbo Cements (I) Pvt. Ltd.
C/o. A.D. Waklin
(Beside Continental Tours & Travels)
Dr. B. Barvan Road
Guwahati — 781007
208 M/s. North Cachar Cement Ltd.
Vill Korai Bari 30
Changsari Chowki Gate,
Amingoon, Guwahati — 781031
209 M/s. Prag Shiva Cements Pvt. Ltd.

Beltola Tinali 30
Guwahati — 781028
210 M/s. Panchavatha Cement (P) Ltd.
Titabar, Jorhat
Assam Tel: 48538.
211 M/s. Sagar Cements Ltd.

Bayya Varam
Anaka Palli
Andhra Pradesh
Ph. 561782
130
Commissioning (tpd)
212 M/s. Bangur Cement Pvt. Ltd.,
Abu Road, 50
(Rajasthan)
213 M/s. Shree Mahadev Cement Pvt. Ltd.

Nagour 50
214 M/s. Sumo Cement Pvt. Ltd.

Gujarat 50
215 M/s. Kangaroo Cement Pvt. Ltd.

Gujarat 50
216 M/s. Prince Cement Co. Ltd.

Morbi,
Gujarat. 100
217 M/s. New Kishan

50
218 M/s. K.G.N. Cement Pvt. Ltd.

Rajgangpur 50
Orissa
219 Yuvraj Sahu Chhatrapah Cement

Utpadak,
Vadgon
220 M/s. Athulya Cement (P) Ltd.

Kerala. 100
221 Mis. Sidhnath Co. Operative Pvt. Ltd.

Haryana 50
222 M/s. Samudra Cement Ltd.

A P 150
. .
223 M/s. Desai Cement Limited,

Goa 200
131
C1 : REGIONAL RESEARCH LABORATORY (RRL) VSK MINI CEMENT PLANTS IN
OPERATION
SI. No. IP
lant's Name and Address Capacity (t pd)
1 Kutch Cements Pvt. Ltd.,
Hari Kripa
Station Road, Bhuj
Kutch — 370001 25
(Gujarat)
2 Shakti Cement Co. Pvt. Ltd.,

Coins Corner, 1 s' Floor
Dr. Yagnic Road, 100
Rajkot — 360001
(Gujarat)
3 Patel and Lalka Cement Pvt. Ltd.,

Naktrana
Kutch 35
Gujarat
4 Bharat Cement Industries

Plot No. 56, Phase I,
GIDC Estate Vatva, 25
Ahmedabad
(Gujarat)
5 Somani Cement Co. Pvt. Ltd.,

Krishna Apartments
Behind Gautam Nagar 25
Race Course,
Baroda — 390007
(Gujarat)
6 Kalyani Cements Pvt. Ltd.

12-2-37/2/3,
Murad Nagar
Hyderabad 25
Andhra Pradesh
7 J.K. Cement Pvt. Limited

13, Nanabhai Court 35
Govindjikanny Road,
Hindmata Dadar
Bombay (Maharashtra)
132
SI. No. Plant's Name and Address Capacity (tpd)
8 Subidha Commercial Con. Pvt. Ltd.,

250, Maulana Azad Road (North),
Bombay — 400008 25
Maharashtra
9 Swarajya Cement Industries Pvt. Ltd.

H.O. Anand Niketan,
Shona, Gurgaon (Haryana) 25
80, Bungalow Road,
Kamla Nagar,
Delhi —110007.
10 Saraswati Cement Pvt. Ltd.,

Manthapal (Kala-Amb)
Distt. Sirmaur 25
Himachal Pradesh
11 Venkateswara Cement Ltd.

1132, P. H. Road,
Madras — 600003 25
Tamil Nadu
12 Anuj Cement Industries Pvt. Ltd.

59, Darya Ganj 25
New Delhi
13 Tara Cement Pvt. Limited

694, 2n d Floor,
Chawri Bazar 25
Delhi — 110006.
14 R.R. Cement Pvt. Ltd.

P. Box —10,
Bala Mandi 25
Paonta Sahib
Himachal Pradesh —173025
133
15 Eastern India Cement Pvt. Ltd.

123, Cooperative Colony,
Bokaro Steel Plant City, 25
Bokaro — 827001
Bihar
16 Priti Cement & Chemicals

M-22 (DS)
Harmn Housing Colony, 25
Ranchi — 834 012
Bihar
17 Durga Cement Pvt. Ltd.

3, Tha, 5 Housing Board,
Shastrinagar 25
Jaipur
Rajasthan
134
C 2: REGIONAL RESEARCH LABORATORY (RRL) VSK CEMENT PLANTS UNDER
IMPLEMENTATION

1 Baba Cement Pvt. Ltd.
A-16, Shellanagar, 25
Visakhapatnam — 530 012.
(A. P.)
2 Shilpa Cement Pvt. Ltd.

15/218, College Road, Sanjeeva Nagar,
Tadpatri — 515 411 25
Anantpur Distt.
(A. P.)
3 Bhaskar Cement Pvt. Ltd.

Garladenne Village
Dhone (H.O.) 25
Kurnool Distt.
(A. P.)
4 L C K Cement Pvt. Ltd.

Nehru Nagar, Maouerla (TQ)
Guntur Distt. 25
(A. P.)
5 Cuddapah Chemicals & Minerals Pvt. Ltd.

House No. 1/583 (1)
Nagarajpet 25
Cuddapah —516 001
(A. P.)
6 Rajdhani Cements Pvt. Ltd.

3-6-729/8, Himayat Nagar,
Hyderabad — 500 029. 25
(A.P.)
7 Amba Cement Pvt. Ltd.,

House No. 14.11.981
BIR Ban Bagh 25
Hyderabad
(A.P.)
8 Bhagyanagar Cements Pvt. Ltd.,

11-5-409 Red Hills 25
Hyderabad
(A.P.)
135
SI. No. IP
lant's Name and Address Capacity (tpd)
9 Swastic Cement Industries Pvt. Ltd.
Thakar Chambers 25
Bedi Gate, Jamnagar —1
(Gujarat)
10 Shree Laxmi Cement Pvt. Ltd.

6-1, 44-47 RIICO Industrial Area,
Hindaun City - 322 230 25
(Rajasthan)
11 Prag Shiva Cement Industries

Capital Road, Dispur
Assam Sachibalaya 25
Post Box No. 13
Guwahati — 781 006
(Assam)
12 Udayana Cement Pvt. Ltd.

Village Basisthapur
Guwahati — 781 006 25
(Assam)
13 Radharani Chemicals (P) Ltd.,

Maralla Gardens, Rivi Road,
Berhampur — 760 005 25
Ganjam,
(Orissa)
14 Aravalli Cements Pvt. Ltd.

WZ-109, Shadipur, 25
New Delhi.
15 Javellin Cements Pvt. Ltd.,

E-484, Greater Kailash-II,
New Delhi 25
16 Ranchi Cement & Chemicals Pvt. Ltd.,

Balakrishna Bhawan, 25
Manohar Land
P.O. Sindri — 828 122
Dhanbad
(Bihar)
17 Rachho Commerce & Cement Industries (P) Ltd.

11 th Lane,
Ittarsi — 461 111 25
Distt. Hoshabgabad
(M.P.)
136
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Exhibit - 1
N
JMMU a KASHMIR .
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UTTARANCNAL
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118
ASSAY 1
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ARABIAN SEA BAY OF BENGAL
ANDHRA PRADESH
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LEGEND
0 Mini cement plants in operation
❑ Mini cement plants Installed
* No. included in Uttar Pradesh

** No. included in M.P.
*** _ No. included in Bihar
( NOT TO SCALE)
DISTRIBUTION OF MINI CEMENT PLANTS IN INDIA

149
S C AWNG IS PROPERTY OF NATIONAL COUNCIL FOR CEMENT
.%J RJ LD'NG MATERIALS. ANtr ITS COPY RIGHTS SOLELY WITH
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CENTRAL POLLUTION CONTROL BOARD

^f+G^ & VA gyp

CENTRAL POLLUTION CONTROL BOARD

8` h February, 2007 (J. M. Mauskar)

'Parivesh Bhawan C.B.D.-cum-Office Complex, East Arjun Nagar, Delhi-110 032

EXECTIVE SUMMARY i — iii

10.0 OPERATION OF A CRI -MODERN VERTICAL SHAFT KILN 29

Fig 2 (b): Gas Flow in Reba Process 10

Fig 3: Lurgi Sinter Grate II

Fig 4: Flow Sheet of Dry Process Rotary Kiln Cement Plant 13

Fig 6: General Arrangement - CRI Modem Vertical Kiln 17

Fig 7: Flow Sheet of CRI - MVSK Cement Plant 19

Fig 7C Flow Sheet of Dry Process Rotary Kiln Cement Plant 28

Fig 8: Schematic of Gravity Settling Chambers 69

Fig 9: Design Proportions of A Cyclone Dust Separator 70

Fig 10: Longitudinal Section of Multicyclone 72

Fig 1 l : Typical Bag House 74

Table 1: Status of Mini Cement Plants at a Glance as on March 31, 2001 2

Annexure- 1 List of VSK Mini Cement Plants 81

Exhibit-- I Distribution of Mini Cement Plants in India 149

6 The methodology adopted for collection of data and information includes:

a) Visit to VSK mini cement plants

O Clinker crusher and discharge section - Bag Filter

2.0 OBJECTIVES OF THE STUDY

In the absence of definite techno-economic control devices, air pollution control

3.0 GROWTH OF MINI CEMENT PLANT

The prevailing scenario of acute cement scarcity in mid seventies with

As a result of the Government's encouragement backed by the technological

Status of mini cement plants at a glance as on 31 March 2001 and 31 March

Table 1: Status of Mini Cement Plants at a Glance as on March 31, 2001

4 Saboo-VSK 202 3.449 78 1.378 0.689

Table 2: Status of Mini Cement Plants at a Glance as on March 31, 2006

Originally Set Up No. of Cement Plants Operating

4.0 WORLD SCENARIO OF MINI CEMENT PLANT

5.0 COMPARISON OF LARGE AND MINI CEMENT PLANTS

- Large enough deposits of the basic raw material i.e. limestonne is

Table 3: Global Survey of Vertical Shaft Kilns in Operation

SI Country No. of VSK No. of Active Production

- Small countries, which intend to develop their own cement industry to

Mini cement plants have following advantages.

- Lowers capital investment per unit production without sacrificing quality of

6.0 CEMENT MANUFACTURING TECHNOLOGIES

i) Fluidized Bed Process (Fuller Pyzel)

In a nutshell, in all these five alternative schemes of technological lines, there is

Increase in investment per annual tonne of installed capacity

6.1 Fluidised Bed Process

6.1.1 Process Details

Cement clinker being almost refractory, coarse clinker particles of 0.8 to 8 mm

FIG. 1 FLUID BED PROCESS

6.2 Reba Process

In this process, the feed operation requires crushing of limestonne to — 15 mm

6.3 Travelling Grate (Lurgi Sinter Grate)

In this process, the feed operation requires crushing of limestonne to — 15mm

6.4 Small Rotary Kiln

HG. 2(a) MATERIAL FLOW IN REBA PROCESS

FIG. 2(b) GAS FLOW IN REBA PROCESS

6.5 Vertical Shaft Kiln

Later after the development of continuous pan type noduliser, a significant

6.5.1 Black Meal Process

FIG. 4 FLOW SHEET OF DRY PROCESS RBTARY KILN CEMENT PLANT

6.5.2 Coal Slurry Process