Professional Documents
Culture Documents
1. Introduction
The Egyptian Pollution Abatement Project (EPAP) sponsored by FINIDA has
assigned Finish and Egyptian consultants for the task of developing sectorspecific inspection and monitoring guidelines..
A General Inspection Manual, GIM, has been developed covering inspection
aspects common to all sectors. The manual :
Textile industry
Food industry
Grain milling industry
Dairy industry
Carbonated beverages industry
Confectionery industry
Fruits and vegetables industry
Metallurgical industry
1.1Preface
As a continuation of the previous effort, manuals for the following industrial
sectors are being developed
Paint industry
Fertilizer industry
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Table (1) shows the daily production of clinker according to design capacity
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Description
Are the usual products for general
construction. There are other types of this
cement, such as white, which contains less
ferric oxide, oil-well cement, quick-setting
cement, and others for special uses.
2- Moderate heat of
hardening and sulfate
resisting Portland
cements
3- High early strength
(HES) cements
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5- Sulfate resisting
Portland cements
The difference between the gray and white cement are presented in table (3)
Table (3 ) The difference between the gray and white cement
Gray cement
Raw materials
Lime stone, clay, sand
gypsum, iron oxide
Chemical composition
SiO2
21-23
Al2O3
7-9
Fe2O3
3-4
CaO
64-65
Application
Foundation
White cement
Pure lime stone, kaolin,
pure sand, gypsum
24-26
5-6
66-67
Plastering works and tile
manufacturing
Note: Defining the inputs and outputs helps predict the expected pollutants.
2.2Production lines
Table 4 presents the various production lines and service units that could be
present in a facility producing cement.
Note: Knowledge of the processes involved in each production line and units
allows the prediction of pollution hazards and expected violations and helps
determine possibilities for implementing cleaner technology.
Table (4) Production lines and service units in cement industry
Production Lines
Wet process production line.
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Service Units
Boilers
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Cement is manufactured in five kiln types: wet process, dry process, preheater,
precalciner and semi dry process kilns. The same raw materials are used in wet
and dry process kilns, however, the moisture content and processing
techniques differ, as does the kiln design. The commonly processes used in
Egypt are the dry and wet processes. Semi dry process are commonly used in
India and China.
2.2.1
Grinding
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Kiln, cooler
Finish Grinding
and Packaging
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Figure (1) Production line for Wet Cement and Related Pollution sources
In puts
Processing steps
Pollution sources
Limeemission
stone, Silica, clay, shale,
Dust
Crushing
oxides
of chalk
Proportioning
and mixing of
raw materials in
slurry mills
Raw material
Grinding
Water
Water
Homogenizing
and Blending
Fuel
Kiln
Clinker
Cooler
Gypsum
Clinker Grinding
and
Cooling
Packaging
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2.2.2
11
Kiln, Cooler
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Raw materials are fed into a rotary dryer, where they are
dried by hot air or the flue gases generated from the kiln.
The dried raw material is grinded in raw materials mill
and transported to a pre-blending silo to be
homogenized by compressed air. The raw material output from the pre-blending silo is transported to the
storage silo.
Homognized raw material is withdrawn from the bottom
of the silo, then fed to the pre-heater tower before
feeding the rotary kiln . Heat is provided by burning
fuel oil (mazot)or natural gas. Additional heat is
provided by preheated air from cooling the clinker.
High temperature combustion gas produced at the lower
end of the kiln flows upward, counter current to solids
moving down the kiln. The kilns are slightly inclined, so
that materials fed at the upper end travel slowly to the
lower firing end, taking from 1 to 3 hours. Combustion
gases preheat the raw materials at the entrance of the
kiln to 900 C, and provide the heat necessary for the
decomposition of calcium carbonate. The absence of
water in this process allows the use of shorter kilns as
compared to the wet process. Waste heat boilers are
sometimes used to conserve heat and are particularly
economical for dry process cement, since the waste
gases from the kiln are hotter than those from the wet
process. The by-pass kiln dust particulates are separated
from exhaust gases by using electrostatic precipitator.
Because the lining of the kiln has to withstand sever
abrasion and chemical attack at the high temperatures in
the clinkering zone, the choice of a refractory lining is
difficult. For this reason high alumina and high magnesia
bricks are widely used. The final product formed consists
of hard granular masses from 3 to 20 mm in size called
clinker. The clinker is discharged
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Figure (4) Production line for dry Cement and Related Pollution Sources
In puts
Crushing
Proportioning
and mixing of
raw material
Processing steps
Pollution sources
Dust emission
Dust emission
Raw Material
Grinding
Flue gases
Pre-heater
Flue gases
Dust emission
Heat stress (work place)
Kiln
Clinker
Cooler
Gypsum
Clinker Grinding
and
Cooling
Dust emission
Noise (work place)
Dust emission
Packaging
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2.2.3
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In the shaft kiln, silica, clay, fuel is added in the pelletizing process. All process
of drying, sintering and cooling are effected in the vertical movable bed. This
concept had been conducted before the rotary kiln was spread and, recently, the
shaft kiln with a continuous discharging function installed at the furnace bottom
is mainly uses in India and China. This kilns advantage is heat economy but it
also has disadvantages since the poking work in the furnace has to be repeated
to retain a stable combustion state and nonuniformity of quality cannot be
avoided.
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Medium and large size plants will have some/all of the following service and
auxiliary units. These units can be pollution sources and therefore should be
inspected and monitored. Figure (7) shows the various units with their
corresponding raw materials and potential pollution sources.
2.3.1 Boilers
Boilers are used to produce steam for electric power generation
Boiler grade water must be low in TDS to minimize scale formation. Therefore
soft water is used as feed to the boilers.
Conventional steam-producing thermal power plants generate electricity
through a series of energy conversion stages. Fuel is burned in boilers to
convert water to high-pressure steam, which is then used to drive the turbine to
generate electricity.
The gaseous emissions generated by boilers are typical of those from
combustion processes. The exhaust gases from burning fuel oil (Mazot) or gas
oil (solar) contain primarily particulates (including heavy metals if they are
present in significant concentrations in the fuel), sulfur and nitrogen oxides
(SOx and NOx) and unburned hydrocarbon
The concentration of these pollutants in the exhaust gases is a function of firing
configuration (nozzle design, chimney height), operating practices and fuel
composition.
Gas-fired boilers generally produce negligible quantities of particulates and
pollutants.
Wastewater is generated as blowdown purged from boilers to keep the
concentration of dissolved salts at a level that prevents salt precipitation and
consequently scale formation. The blowdown will be high in TDS.
In the case of power plants, water is used for cooling the turbines and is also
generated as steam condensate. The amount of wastewater generated depends
on whether cooling is performed in open or closed cycle and on the recycling of
steam condensate. Contamination may arise from lubricating and fuel oil
More information about boilers can be found in the inspection manual for
energy generating plant (EPAP, 2002)
2.3.2 Cooling Towers
Cooling water is used extensively in industry. During the cooling process,
water heats up and can only be reused if cooled. Cooling towers provide the
means for recycling water and thus minimizing its consumption. The cooling
effect is performed through partial evaporation. This causes an increase in the
concentration of dissolved salts which is controlled by purifying some water
(blowdown). The blowdown will be high in TDS.
Process cooling is the major use for water in dry process cement manufacture
(drying equipment and air compressor operation, and cooling of kiln bearings,
mill bearings, burner pipes, etc.). Therefore, dry process water effluents should
not normally be contaminated unless poor water management is practiced.
Slurry water used to feed raw materials into the kiln for the wet process
evaporates (dissipates in the air as vapor).
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2.3.3
18
Air Compressors
Air compressors are used in cement industry for raw material pneumatic
transporting. Compressors consume a considerable quantities of lube oils for
lubricating and cooling purposes, in addition to electricity. The major
environmental impacts are noise affecting workers and spent oils.
2.3.4
Laboratories
Laboratories have an important role in the cement industry, as they are
responsible for:
Quality control of the products and comparing the findings with the
standard specifications for raw materials and final products
2.3.5
Noise
Scrap metal
Pollution in the garage area will depend upon the services offered. The
presence of a gasoline or diesel station implies fuel storage in underground or
over the ground tanks that require leak and spill control plans.
Replacing lube oil implies discharge of spent oil to the sewer lines or selling it
to recycling plants.
2.3.6
Storage Facilities
The specifications for the storage facilities depend on the stored material.
Chemicals are used as additives for the process, for treatment processes.
Fuel is used for the boilers, for the cars and delivery trucks. It is stored
in underground or over ground tanks. The types of fuel usually used are
fuel oil (Mazot), gas oil (solar), natural gas and gasoline.
Scrap metal
2.3.7
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2.3.8
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2.3.9
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Service Units
Boilers
Water
Pollution
Boiler Blow Down
(TDS)
Flue Gases
Steam
Cooling Tower Blowdown
(TDS)
Cooling Towers
Hot Water
Lube oil
Spent Oil Compressors
Noise
Wastewater Hazardous
Materials (handling)
LaboratoryChemicals
Lube Oil
Floor and equipment
rinse water
Cleaning Chemicals
Fuel
Oil
Rinse Water
Garage
Solid Wastes
Raw materials
Storage
Fuel
Chemicals
Scrap metal
Wastewater
Wastewater
Treatment Units
Restaurant and
Water
restrooms
Kraft paper
Sacks Plant
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Spills
Raw material rejects
Hazardous
material
Treated water
Sludge
Sanitary
Wastewater
Noise
Solid waste (rejected paper)
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2.4
21
Polluting parameters
Particulates (dust)
A major source of particulate matter (or dust) at most cement plants is the kiln.
Kiln rotation and high velocity flow of combustion gases entrain large
quantities of dust .
Table (7) present a total suspended solid measures for a plant at Helwan
Typical Kiln dust constituents compositions of the Egyptian cement industry
are shown in table (8).
Flue gases are resulting from fuel consumption used to generate steam for
electric power generation. The violating parameters would be: particulate
matters, sulfur oxides, nitrogen oxides and carbon monoxide.
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Process Inputs
Process Outputs
Pollution Parameters
Impact
Crushed raw
materials
Air pollution
Water
Slurry
Noise
Workplace
Fuel
Clinker
Water vapor
Workplace
Air Pollution
Temp
Workplace
Dust
Air Pollution
Gypsum
Noise
Workplace
Cement
Solid waste
Wet process
Crushing
Proportioning
and mixing of
raw materials &
Grinding
Homogenizing
and blending
Kiln and
Clinker cooler
Finish grinding
Packaging
machine
Raw meal
Clinker
Cement
Cement Dust
Air Pollution
Air Pollution
Air Pollution
Noise
Workplace
Dust
Workplace
Air Pollution
Temp
Workplace
Dry process
Crushing
Proportioning
and mixing of
raw materials
Grinding
Crushed raw
materials
Raw material
Raw meal
Homogenizing
and blending
Kiln
Fuel
Clinker
Rae meal
Clinker cooler
Hot clinker
Clinker
Finish grinding
Clinker
Cement
Packaging
machine
Kilns chimney
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Air pollution
Dust
Air Pollution
Gypsum
Noise
Workplace
Cement
Solid waste
Air pollution
Particulate
Air pollution
Exhaust gases +
particulate
Exhaust gases +
particulate
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Composition (%)
12-15
3-5
2-3
38-42
2-3
2-4
5-7
4-6
13-16
2.4.2 Effluents
Highest levels of water pollution occur when water is allowed to contact
collected kiln dusts. Three most significant sources where this contact may
occur are:
Aqueous effluents from wet scrubbers are used to wash dusts from kiln
gas emissions.
The other sources of pollution in the cement industry are
Blow down from cooling towers and boilers (high in: TDS and TSS).
Spent lube oil from garage and workshops if discharged to sewer will
give oily wastewater (O&G).
Domestic wastewater
The expecting polluting parameters are TDS, TSS and heavy metal
2.4.3 Solid waste
Kiln dust, raw materials, clinker and other substances are frequently stored in
piles on plant property. Unless sheltered, rainfall may percolate through these
piles, dissolve (or leach) soluble matter and carry them with the surface run-off
water. From 2000 ton/day clinker 50 ton/day dust is produced. Water
polluted in this manner can migrate through the sub-surface layers beneath the
material storage piles and contaminate ground water source.
Dust also arises from crushing, mixing, grinding and final grinding before
packaging
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Other sources of solid wastes are rejected plastic and paper Sacks from
packaging process and from the workshops and garage. The wastewater
treatment plant also generates sludge.
By-pass kiln dust
This dust is entrained with flue gases in rotary kiln. Part of by-pass cement kiln
dust is withdrawn with flue gases through chimney. Appreciable amount is fed
to electrostatic precipitator, in which high voltage charges the dust particles.
Dust is then collected at the electrode and precipitated. The disposal of
cement dust whether inside or outside the company limits causes an air
pollution problem due to wind effects. Granulation of cement dust by water
reduces this problem.
When the company uses the wet production line, part of by-pass cement kiln
dust can be recycled back to the wet production line.
2.4.4 Workplace
Noise
Heat Stress
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3.
3.1
25
Particulate
matters
Sulfur Oxides
Nitrogen Oxides
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Dust
Silicon dioxide
Tricalcium silicate
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Aluminum oxide
Ferric oxide
Kaolin Clay
Bentonite clay
Calcium sulfate
(Gypsum)
3.2
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3.3
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3.4
28
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4.
29
4.1
The use of fuel oil (mazot) and other heavy oil products, as well crude
oil shall be prohibited in dwelling zones.
The sulfur percentage in fuel used in urban zones and near the dwelling
zones shall not exceed 1.5%.
The design of the burner and fire-house shall allow for complete mixing
of fuel with the required amount of air, and for the uniform temperature
distribution that ensure complete combustion and minimize gas
emissions caused by incomplete combustion..
Gases containing carbon dioxide shall be emitted through chimneys
rising sufficiently high in order that these gases become lighter before
reaching the ground surface, or using fuel that contains high proportions
of sulfur in power generating stations, as well as in industry and other
regions lying away from inhabited urban areas, providing that
atmospheric factors and adequate distances to prevent these gases from
reaching the dwelling and agricultural zones and regions, as well as the
water courses shall be observed.
Chimneys from which a total emission of wastes reaches 7000 15000
kg/hr, shall have heights ranging between 18 36 meters.
Chimneys from which a total emission of gaseous wastes reaches more
than 15000 kg/hour, shall have heights exceeding at least two and a half
times the height of surrounding buildings, including the building served
by the chimney.
The permissible limits of emissions from sources of fuel combustion in
boilers are given in table (9).(ministerial decree no. 495,2001)
The permissible limits of emissions from Kilns are regulated according
to the limits shown in table (10)
Table (9). Maximum limits of emissions from Boilers of fuel
combustion
Pollution
Sulfur Dioxide.
Carbon Monoxide.
Volatized ashes in urban
regions.
Volatized ashes in remote
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regions.
Smoke.
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50
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4.2
10 mg/m3
5 mg/m3
Concerning Effluents
Limits for pollutants in wastewater vary depending on the type of receiving
water body. The parameters that should be monitored and/or inspected are
TSS, TDS
Table (13) presents the permissible limits for discharges to the different
recipients (sea, Nile, canals, agricultural drains, public sewer) according to the
different relevant laws.
Spent lube oil has a negative impact on water and soil and therefore its disposal
should be monitored/inspected. A record should be kept for this purpose.
4.3
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4.4
33
ppm
mg/m3
ppm
mg/m3
5000
9000
15000
27000
Carbon monoxide
50
55
400
440
Sulfur dioxide
10
Carbon dioxide
4.5
Time average
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the necessary precautions for handling hazardous materials. Storing of fuel for
the boilers is covered by the Law 4 as hazardous material.
4.6
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5.
35
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5.1
36
Air pollution
Flue gases
Dust
Dust-Source
Reduction
Dust-Recycling
and Reuse
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The best practices for air pollution control are summarized in table (15). The
main techniques used are described below.
Table (15) Best Practices in Air Pollution Control
Air Pollution Control
Capture of kiln dust
Electrostatic precipitator
Baghouse filter
Cyclone
Nodulizer system
Capture of dust from
clinker cooler
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5.2
41
End-of-pipe
treatment
5.3
5.4
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Heat energy
conservation
measures
42
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6.
44
Industrial inspection
The inspection of the cement industry will follow the procedures described in
the General Inspection Manual (GIM, EPAP 2002). This chapter presents a
summary of the inspection process regarding the purpose and scope of various
types of inspection, and the proposed inspection procedure for the Cement
Industry.
The overall purpose of inspections is to enforce environmental laws. Table 17
lists the various types of inspections and the objectives that have to be fulfilled
for each type.
Table (17) The different types of inspections and their objectives
Inspection type
Site Inspection
1. Comprehensive
2. Specific
3. Follow-up
Inspection campaign
1. Geographic
2. Sector specific
Objectives
Evaluate compliance status regarding all aspects of
Law 4
Evaluate compliance status regarding some aspects
of Law 4 Review special conditions set by EEAA in
EIA studies.
Investigate complaints
Check environmental register and implementation of
compliance measures
Check pollution sources to specific receiving media
Check aspects relevant to specific sector
As evident from the above table, comprehensive inspection deals with all
aspects of environmental laws and therefore is considered in this manual. Other
inspection types can be tailored accordingly.
Developing an inspection strategy and quarterly and/or monthly plans are the
responsibility of the inspectorate management. Developing site-specific
inspection plans for carrying out the scope of work that fulfills inspection
objectives is the responsibility of the inspection team. Planning for inspections
is presented in more detail in the General Inspection Manual, GIM (EPAP2002).
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7.
45
7.1
The dust generated from grinding, crushing, kiln flue gases and by-pass
cement dust from electrostatic precipitator
7.2
7.3
Providing Resources
The required personnel, tools and equipment depend on the size of the facility
to be inspected. The inspection team leaders, in coordination with the
inspectorate management, are responsible for assessing the inspection needs.
The number of inspectors required depends on the size of the facility and the
planned activities.
Usually the team members are split and assigned different tasks during the field
visit to allow the required activities to be performed in parallel. Each task is
rotated among the inspectors to diversify their experience.
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8.
46
8.1
The type of receiving body for the industrial wastewater and review
relevant Egyptian laws (Chapter 4).
The scope of inspection and related activities based on the type and
objectives of inspection required by the inspectorate management.
8.2
For large cement facilities, the inspection team could be divided into
smaller groups. Each group will be responsible for inspecting a number
of production lines and service units.
At the beginning of the field visit, the inspection team should check the
environmental register for completeness using the checklist provided in
Annex (g) of the General Inspection Manual, GIM (EPAP-2002).
Notes to inspector:
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8.3
47
Draw the block flow diagrams for the production lines with their
pollution sources as presented in figures 1 and 4.
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8.4
48
Legal aspects
As evident from chapter 2, a large cement facility is expected to be in violation
of several environmental laws, specifically with respect to air if no abatement is
applied. The inspection team should be prepared for legally establishing such a
violation.
Note to inspector:
It is the responsibility of the inspector to assess the seriousness of the
violation upon which the enforcement action will be based. His information
about the nature and cause of the violation must be well documented and the
evidence sound. The case could be contested in court and the inspector will
be asked to defend his technical judgement.
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9.
49
9.1
9.2
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Production Lines
Wet Process
production line
Dry Process
production line
Service Units
Water treatment
units
Boilers
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Cooling towers
Garage, and
Workshops
Storage facilities
WWTP
Effluent analysis
Receiving body
Sampling
9.3
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10.
52
Decide on the sanctions and send the legal report to the judicial
authority.
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