INTRODUCTION

In the most general sense of the word, a cement is a binder, a substance that sets and hardens independently, and can bind other materials together. The word "cement" traces to the Romans, who used the term opus caementicium to describe masonry resembling modern concrete that was made from crushed rock with burnt lime as binder. The volcanic ash and pulverized brick additives that were added to the burnt lime to obtain a hydraulic binder were later referred to ascementum, cimentum, cment, and cement. Concrete should not be confused with cement, because the term cement refers to the material used to bind the aggregate materials of concrete. Concrete is a combination of a cement and aggregate. Now a day, cement industry caused environmental pollution problems, the pollutants of the cement industry produced the adverse impact on Air, Water and Land. Cement industry is the one of the 17 most polluting industries listed by Central Pollution Control Board. During the last decades, the emission of dust from cement factories has been increased alarmingly due to expansion of more cement plants to meet the requirement of cement materials for construction of building. In comparison with gaseous air pollutants, many of which are readily recognized as being the cause of injure to various types of vegetation. Relatively little known and limited studies have been carried out on the effect of cement dust pollution on the growth of plants.

Cement Production Plant causing Pollution

CAUSES & EFFECTS OF CEMENT POLLUTION

The preparation of cement includes mining; crushing and grinding of raw materials (principally limestone and clay); calcining the materials in a rotary kiln; cooling the resulting clinker; mixing the clinker with gypsum; and milling, storing and bagging the finished cement. The process results in a variety of wastes, including dust, which is captured and recycled to the process. The process is very energy-intensive and there are strong incentives for energy conservation. Gases from clinker cooler are used as secondary combustion air. The dry process, using preheaters and precalciners, is both economically and environmentally preferable to the wet process because the energy consumption (200 joules per kilogram (kg) is approximately half of that for the wet process. Certain solid waste products from other industries, such as pulverized fly ash (PFA) from power stations, Slag, roasted pyrite residues, and foundry sand can be used as additives in cement production.

Essroc Cement, the 8th largest cement producer in the country

Cement contains 3-8% aluminium oxide, 0.5-0.6% iron-oxide, 60-70% calcium oxide, 1725% silicon oxide, 0.1-4% magnesium oxide and 1-3% sulphur trioxide. The pH of the cement-polluted soils was alkaline but that of the polluted soil was more alkaline.

Pollution caused during Cement Production

Environmental Impacts
Cement manufacture causes environmental impacts at all stages of the process. These include emissions of airborne pollution in the form of dust, gases, noise and vibration when operating machinery and during blasting in quarries, and damage to countryside from quarrying. Equipment to reduce dust emissions during quarrying and manufacture of cement is widely used, and equipment to trap and separate exhaust gases are coming into increased use. Environmental protection also includes the re-integration of quarries into the countryside after they have been closed down by returning them to nature or re-cultivating them. CO2 emissions Carbon concentration in cement spans from 5% in cement structures to 8% in the case of roads in cement. Cement manufacturing releases CO2 in the atmosphere both directly when calcium carbonate is heated, producing lime and carbon dioxide,] and also indirectly through the use of energy if its production involves the emission of CO2. The cement industry produces about 5% of global man-made CO2 emissions, of which 50% is from the chemical process, and 40% from burning fuel. The amount of CO2 emitted by the cement industry is nearly 900 kg of CO2 for every 1000 kg of cement produced. The high proportion of carbon dioxide produced in the chemical reaction leads to large decrease in mass in the conversion from limestone to cement. So, to reduce the transport of heavier raw materials and to mimimize the associated costs, it is more economical for cement plants to be closer to the limestone quarries rather than to the consumer centers. In certain applications, lime mortar reabsorbs the same amount of CO2 as was released in its manufacture, and has a lower energy requirement in production than mainstream.Use of the Kalina cycle during production can also increase energy efficiency.

Heavy metal emissions in the air

In some circumstances, mainly depending on the origin and the composition of the raw materials used, the high-temperature calcination process of limestone and clay minerals can release in the atmosphere gases and dust rich in volatile heavy metals, a.o, thallium, cadmium and mercury are the most toxic. Heavy metals (Tl, Cd, Hg, ...) are often found as trace elements in common metal sulphides (pyrite (FeS2), zinc blende (ZnS), galena (PbS), ...) present as secondary minerals in most of the raw materials. Environmental regulations exist in many countries to limit these emissions. Heavy metals present in the clinker

The presence of heavy metals in the clinker arises both from the natural raw materials and from the use of recycled by-products or alternative fuels. The high pH prevailing in the cement porewater (12.5 < pH < 13.5) limits the mobility of many heavy metals by decreasing their solubility and increasing their sorption onto the cement mineral phases. Nickel, zinc and lead are commonly found in cement in non-negligible concentrations. Use of alternative fuels and by-products materials A cement plant consumes 3 to 6 GJ of fuel per tonne of clinker produced, depending on the raw materials and the process used. Most cement kilns today use coal and petroleum coke as primary fuels, and to a lesser extent natural gas and fuel oil. Selected waste and by-products with recoverable calorific value can be used as fuels in a cement kiln, replacing a portion of conventional fossil fuels, like coal, if they meet strict specifications. Selected waste and byproducts containing useful minerals such as calcium, silica, alumina, and iron can be used as raw materials in the kiln, replacing raw materials such as clay, shale, and limestone. Because some materials have both useful mineral content and recoverable calorific value, the distinction between alternative fuels and raw materials is not always clear. For example, sewage sludge has a low but significant calorific value, and burns to give ash containing minerals useful in the clinker matrix.

Effect on Human Health

Some of the initial studies have shown that the incremental individual risk due to emissions of the cement plant is very low not only with regard to health effects, but also in relation to toxicological and cancer risks produced by pollutants emitted by the cement kiln (see, for example,but that conclusion has been challenged. Similarly, earlier conclusion that long-term exposure to cement dust does not lead to higher morbidity of severe respiratory disease than other types of blue collar work has also been challenged. Studies have shown that adverse respiratory health effects seen in the people exposed to cement dust, exemplified in increased frequency of respiratory symptoms and decreased ventilatory function, observed among cement workers could not be explained by age, BMI and smoking, thus are likely to be caused by exposure to cement dust.

 Cement dust contains heavy metals like nickel, cobalt, lead, chromium, pollutants hazardous to the biotic environment, with adverse impact for vegetation, human and animal health and ecosystems. The population most exposed to cement dust pollution includes workers and managers in cement plants and factories, families of workers and managers living in staff houses of factories, and other neighbourhood habitations. Children studying in the schools situated in proximity to factories are particularly prone to cement dust exposure. Several studies have demonstrated linkages between cement dust exposure, chronic impairment of lung function and respiratory symptoms in human population. Cement dust irritates the skin, the mucous membrane of the eyes and the respiratory system. Its depositionin the respiratory tract causes a basic reaction leading to increased pH values that irritates the exposed mucous membranes. Occupational cement dust exposure has been associated with an increased risk of liver abnormalities, pulmonary disorders, and carcinogenesis. Decreased antioxidant capacity and increased plasma lipid peroxidation have been posed as possible causal mechanisms of disease. Total cement dust exposure has been found to be related to acute respiratory symptoms and acute ventilatory effects. Implementing measures to control dust and providing adequate personal respiratory protective equipment for the production workers are highly recommended. Chronic exposure to Portland cement dust has been reported to lead to a greater prevalence of chronic respiratory symptoms and a reduction of ventilatory capacity. The seriousness of pulmonary function impairment and respiratory disease has not been consistently associated with the degree of exposure. Diseases such as chest pain, cough, and eye problems in the villages affected by cement dust are likely to be derived due to cement dust. Indeed, the higher percentage of related diseases occurs near the source of pollutant. A relative risk ratio assessment indicates that the exposed subjects are 7.5 and 22.5 times as likely to develop the disease during the follow-up period compared to the unexposed subjects . A study to evaluate the mutagenic effects of occupational exposure to cement dust in such workers concludes that the chromosomal damage was more pronounced in the workers who are also smokers when compared with the non-smokers both in control and exposed groups. A significant increase in the frequency of chromosomal aberrations was also observed with increase in age in both control and exposed subjects. As the cement dust comes in contact with water, hydroxides are formed that impair natural water alkalinity. A fine layer of cement covers the surface of wells and ponds. The addition of salts of Ca, Na, K, Mg and Al as hydroxides, sulphates and silicates affect the hardness of the water that subsequently are responsible for the respiratory and gastro-intestinal diseases in the area

PREVENTION OF CEMENT POLLUTION

Mechanical systems such as cyclones trap the larger particulates in kiln gases and act as preconditioners for downstream collection devices. Electrostatic precipitators (ESPs) and fabric filter systems (baghouses) are the principal options for collection and control (achieving over 99% removal efficiency) of fine particulates. ESPs are sensitive to gas characteristics (such as temperature) and to voltage variation. Baghouses are generally regarded as more reliable. Both ESPs and baghouses can achieve high levels of particulate removal from the kiln gas stream, but good operation and maintenance are essential to achieve design specifications. Two significant types of control problems can occur: complete failure (or automatic shut-off) of systems related to plant shut-down and startup, power failures, and the like, leading to the emission of very high levels of particulates for short periods of time; and gradual decrease inthe removal efficiency of the system over time because of poor maintenance or improper operation. Lime content of raw materials can be used to control sulfur oxides

Electrostatic Precipitator (ESP)

ESP control devices ionize contaminated air flowing between the electrodes. The charged particles (contaminants) travel to the oppositely charged plates. The particles on the plates are removed. These particles can be dry dust or liquid droplets (liquid droplets is more efficient). The particles that are removed from the plates are knocked off to the bottom of the ESP. ESPs have high efficiency and low pressure drops. These devices are used after the roller mill and after the cement kiln in the production of cement to reduce emissions of particulate matter such as cement kiln dust. Often spray towers are used before the ESP in order to moisten the particulates, increasing ESP efficiency.

ESP at Cement Plant

 Baghouse Filters
In these control devices, polluted air is filtered through the bags. The bags are closed at the bottom, and are exposed to a clean air chamber at the top. The bags are cleaned by short bursts of pressured air. The bags contracts and snaps which releases the particulate layer.

Baghouse at Cement Plant

Baghouses are used in cement production at the top of material storage silos and gas separators. They help prevent any particulate matter escape the process. Anything collected in the bag filters is simply release back into the process to be used in the cement making.

In-situ Monitoring Devices

SO2, NOx, and hydrocarbon emissions are monitored using in-situ monitors. The readings are transmitted to the control room. The control operator uses this information in order to adjust temperature or flow of the material in order to reduce emissions. These devices are placed near the top of the cement kiln stack.

In-situ monitoring device attached to side of cement kiln stack

 Selective Non-catalytic Reduction

At 900-1000C ammonia will reduce NOx concentrations to N2 without a catalyst. The ammonia is injected into a boiler to reduce NOx concentrations in the boiler. Proper temperatures must be achieved in order to create a fuel-rich reburn zone. The hydrocarbon radicals react with NOx to reduce NOx to N2. This system can be used to prevent NOx formation in the cement kiln.

Monitor that displays current emissions of SO2, NOx, and HCs

Green cement is a cementitious material that meets or exceeds the functional performance capabilities of ordinary Portland cement by incorporating and optimizing recycled materials, thereby reducing consumption of natural raw materials, water, and energy, resulting in a more sustainable construction material. The manufacturing process for green cement succeeds in reducing, and even eliminating, the production and release of damaging pollutants and greenhouse gasses, particularly CO2.

CONCLUSION

Cement and concrete are vital components in building construction today. Concrete has many environmental advantages, including durability, longevity, heat storage capability, and (in general) chemical inertness. For passive solar applications, concretes ability to function as a structural element while also providing thermal mass makes it a valuable material. In many situations concrete is superior to other materials such as wood and steel. But cement production is very energy intensivecement is among the most energy-intensive materials used in the construction industry and a major contributor to CO 2 in the atmosphere. To minimize environmental impact, therefore, we should try to reduce the quantity of concrete used in buildings, use alternative types of concrete (with fly ash, for example), and use that concrete wisely. The accompanying checklist provides practical suggestions for accomplishing these goals. Green cement is a cementitious material that meets or exceeds the functional performance capabilities of ordinary Portland cement by incorporating and optimizing recycled materials, thereby reducing consumption of natural raw materials, water, and energy, resulting in a more sustainable construction material. The manufacturing process for green cement succeeds in reducing, and even eliminating, the production and release of damaging pollutants and greenhouse gasses, particularly CO2.