Subh ReportOIP 2021

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Online Internship Programme (OIP-2020)
Internship Report
On
< Chemical Process Techonology>
(Covering a Case study analysis: Life Cycle Assessment of Portland Cement Industry.)
Submitted in Partial Fulfilment of the Requirements for the mandatory Internship training
programme
Submitted by:
<Subhasis Basu >
<Department Of Chemistry >
<Institute Of Science, Visva Bharti University>
13rd February to 31st March, 2021
Indian Institute of Chemical Engineers (IIChE)

Dr. H. L. Roy Building, Jadavpur University Campus,
188 Raja Subodh Chandra Mullick Road, Kolkata 700 032
www.iiche.org.in / iichehqfb@gmail.com
OIP-2021
Certificate from the IIChE
This is to certify that .........Subhasis Basu............................................................. from …….
……….Department Of Chemistry, Institute Of Science, Visva-Bharati University.
..................has successfully completed online internship programme in our organization. The
matter embodied in this report is a genuine to the best of our knowledge and belief and has
not been submitted before, neither to this Institute nor to any other organization for the
fulfilment of the requirement of any course of study. During his internship tenure in IIChE,
we found him/her hard working, sincere, and diligent person and his behaviour and conduct
was good. We wish him all the best for his future endeavour.
Chief Coordinator, OIP-2021
Indian Institute of Chemical Engineers 2

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Acknowledgement
ACKNOWLEDGEMENT
This preface is to extend an appreciation to all those individuals who with their generous co-
operation guided us in every aspect to make this OIP Report-2021 successful.
I am deeply indebted to our guide Prof.(Dr.)Sunilbaran Kuila, Chief Coordinator, OIP-

2021,IIChE. for his excellent guidance, encouragement and support throughout our project
work. There profound theoretical knowledge as well as his practical experience that he
readily shared with us have helped us to overcome many difficulties.
I also thank our library staff of Central Library, Visva-Bharati University for supplying
necessary books, and Laboratory equipment and set up time to time as per my requirement.
SUBHASIS BASU
Date: March-2021.

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Preface
ONLINE INTERNSHIP PROGRAM (OIP-2021) BY IIChE SUBJECT: CHEMICAL

PROCESS TECHNOLOGY SYLLABUS:
Module-I Pressure Vessels Fundamentals, Fabrication & Testing:
 Fundamentals of pressure vessel
 Design Codes & fabrication basics
 Testing & Inspection
Module-II Cement Manufacturing Industry:
 Cement Manufacturing Processes, Past and Present
 Equipment Handling and Operation of Cement plants
 Environment Impact of Cement Industries and Pollution Control devices
 Efficiency improvement techniques and Cement Industries in India
Module -III Pure Terephthalic Acid (PTA) Manufacturing Industry:
 Overview of PTA Manufacturing Process & Technology: PTA Value Chain, Process Flow,
Basic Science to Engineering
 Process Controls in a PTA Plant: Process Control, General Controllers, Compressor Surge
Protection Controller
 Basic Operation Principles of Centrifugal Pumps: Pump performance curve analysis,

Impeller size-up study, NPSH calculation and interpretation, Pipeline hydraulic calculation,
Friction chart analysis. Basic Principles of Control Valves: Control valve size- up case study,
Control valve CV calculation for gas, liquid and steam application.
 Basic Operation Principles of Industrial Instruments : Concept on Flow

/Temperature/Pressure elements, Introduction with industrial elements with picture, different
flowmeter working principle, RO' sizing calculation, Introduction with industrial elements
with picture, Basic Principle for Steam Turbine Power generation, Mollier chart analysis to
calculate turbine power extraction.
Module-IV Petrochemical Industry:
 Naphtha Cracking Process & product separation
 Polymers & Principle of Polymerizations
 Process technology and operations of Poly-Propylene (PP) manufacturing.

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 Safety measures of PP process & Quality parameters of product PP.
Objectives of Online Internship Program
• Assist the student's development of employer-valued skills such as teamwork,

communications and attention to learn Engineer’s responsibilities and ethics.
• Enhance and/or expand the student's knowledge of a particular area(s) of skill.
• Expose the student to professional role models or mentors who will provide the
student with support in the early stages of the internship and provide an example of
the behaviours expected in the intern's workplace.
• To familiarize with various materials, processes, products and their applications along
with relevant aspects of technology and troubleshooting.
• To gain experience in writing technical report/project.
Course Outcome
• The basic idea of different real life industrial problems, trouble shooting, decision
making and preventive maintenance techniques and professional culture of industry,
work ethics and attitudes in industry. The different live situation, trouble shooting and
modern technological application.
• Course materials to be provided to the students for reference (in PDF format). The
study material will be shared with the students through IIChE for its record.
• Assignment will be given for the solution / conceptual idea and which may be
discussed during the tutorial class.
• Mini project will be given for developing their analytical ability which helps them to
realize the value of practical training.
• Importance will be given on the application of modern tools for the industrial
automation / up-gradation / scale-up.
• Conceptual theory for the regular class room discussion and its application is real-life
industrial problem resolution.
• Case studies based on real life application.

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Content
• Introduction
• Discussion on different industrial application
• Case study analysis
• Research and development
• Summary
• Appendix: All assignments

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1. Introduction: Overview of the Industry
The categories are industrial inorganic chemicals; plastics, materials, and synthetics; drugs;
soap, cleaners, and toilet goods; paints and allied products; industrial organic chemicals;
agricultural chemicals; and miscellaneous chemical products. he chemical
industry comprises the companies that produce industrial chemicals. Central to the
modern world economy, it converts raw materials (oil, natural gas, air, water, metals,
and minerals) into more than 70,000 different products. The plastics industry contains some
overlap, as some chemical companies produce plastics as well as chemicals.
Various professionals are involved in the chemical industry including chemical engineers,
chemists and lab technicians. As of 2018, the chemical industry comprises approximately
15% of the US manufacturing economic sector.
The Indian chemical industry produces 80,000 different chemical products. India was also
the third largest producer of plastic in 2019. As of September 2019, the alkali chemical
industry produced 71% of all chemicals produced in India. India's chemical
industry accounts about 14% of production in Indian industries. The chemical industry
of India is a major contributor to the Indian economy, contributing 7% of the country's Gross
Domestic Product (GDP). India's chemical industry ranks as sixth largest in world, and third
in Asia. The value of the chemical industry in India was estimated at 100 billion dollars in
2019. The chemical industry of India generates employment for five million people. The
Indian chemical industry mainly produces basic types of chemicals as well as knowledge type
chemicals and specialty type chemicals as of 2018.[5] In India, Gujarat was the largest state
contributor to the chemical industry of India in 2018.[6] India also produces products related
to petrochemicals, fertilizers, paints, varnishes, glass, perfumes, toiletries, pharmaceuticals,
etc. The India chemical industry is divided into six sub-segments. These sub-segments are
Basic Organic Chemicals, Specialty Chemicals, Chlor-alkali, Pesticides, Dyestuff, and
alcohol-based chemicals. India is a major producer of basic organic chemicals.
History Of Indian Industry
In India, the Council of Scientific and Industrial Research (CSIR) was established in 1942
with the aim of providing scientific and industrial research to maximize the scientific,
economic, and environmental benefits to the people of India. The Indian Chemical
Manufacture association, now called Indian Chemical Association (ICC) was founded in
1938 in by P. C. Ray, Rajmitra B. D. Amin and other Industries to promote the national
chemical industry of India. In India, the first pharmaceutical company set up was Bengal
Chemicals and Pharmaceutical. Bengal Chemicals and Pharmaceutical was set up by P.C
Ray, professor of chemistry at Calcutta University. After 9 years of settlement of this
company, one more company called Alembic Chemical works at Baroda (Now as Vadodara)
in Gujarat was set up. Before World War II, foreign companies had the domain in
the drug industry of India. After World War II, foreign company domain in drugs decreased
and more Indian drug companies were established. During this time, the Indian government
established five drug companies. The two of them are Hindustan Antibiotics Limited and
Indian Drugs and Pharmaceutical companies. After India got independence from the British
Raj in 1947, India established many units of basic chemicals, dyes, textiles and fertilizers. In
1964, a downstream plant was established in Mumbai. In the 1980s and 1990s, the petroleum
industry of India had grown faster with the development of the gas cracker, along with

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related downstream industries for polymers, synthetic fibres, aromatic and other chemicals.
In early 1980, the IPCL had established a plant-based on a cracker
in Gujarat and Maharashtra. India has been suppressed by inadequate supply and high
import duties in the petroleum industry, which led to private industry entry into the petroleum
industry.
This led to an increased role of Reliance industries in the petroleum industry. This has led to
the entry of Reliance industries into the polyester business such as purified terephthalic acid,
and polyethylene terephthalate resin. These new materials are used to make polyester
fibre, bottle and fila mentation.
Basic Organic Chemical Industry: The organic chemicals industry is one of the most
significant sectors of the chemical industry in the world. It plays a vital role in providing
inputsforotherindustriesof paints, adhesives, pharmaceuticals, dyestuffs and intermediates,lea
therchemicals, pesticides,etc. Methanol, aceticacid, formaldehyde, pyridine, phenol, alkylami
nes, ethyl acetate, and acetic anhydride are major basic organic chemicals that are produced
in India. Six major chemicals are produced in India: methanol, aniline, alkyl amines, and its
derivatives formaldehyde, acetic acid, and phenol contributing to nearly 2/3 of Indian basis
organic chemical industry. Chlor-Alkali Chemical Industry. The chlor-Alkali is an industrial
process for the electrolysis of sodium chloride solutions. In India chlor-alkali industry mainly
consists of the production of three inorganic chemicals. The mainly three inorganic
chemicals that are produced in the form of this industry are Caustic
Soda (NaOH), Chlorine (Cl2) and Soda Ash (Na2CO3). Hydrogen is also produced in this
industry in small amounts. The chlor-alkali industry inputs are mainly used in soaps
and detergents, pulp and paper, textiles, aluminium processing industry for caustic soda and
for soda ash in glass, silicate production etc apart from soaps and detergents. In the financial
year 2019–2020 of chlor-alkali industry of India over four million metric tons of alkali
chemicals were produced. The products that are produced in this industry are soda
ash, caustic soda, and liquid chlorine.

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2. Discussion on different industrial application
Industrial applications are tailor-made applications with the requirements of extremely

high reliability and high cost-effectiveness. Talking about heat pumps for industrial
applications means usually talking about MW. The dyes and pigments most commonly used
in industrial applications are derived from minerals or petroleum. ... There are several
other industrial applications that use functional dyes and pigments, such as laser dyes, ink
jet printing, photodynamic therapy, and surgery. Chemistry plays an important and useful
role towards the development and growth of a number of industries. This includes industries
like glass, cement, paper, textile, leather, dye etc. We also see huge applications of chemistry
in industries like paints, pigments, petroleum, sugar, plastics, Pharmaceuticals. for the
invention of conceptual chemical process designs have been proposed and discussed ...
During that same time, the importance of front-end engineering, especially ... This chapter
describes a framework for the industrial chemical plant ... including heat-integrated
distillation trains, multiple-effect distillation,
There are four types of industry. These are primary, secondary, tertiary and quaternary.
Types of Business Industries – Different types of Industry are within Chemical Industry
Aerospace Industry.
Transport Industry.
Computer Industry.
Telecommunication industry.
Agriculture industry.
Construction Industry.
Education Industry.
Pharmaceutical Industry.
The definition of industrial is something relating to a large-scale business or a
manufacturing business. An example of industrial equipment is a printing press. Of, relating
to, or resulting from the manufacturing industry. A company engaged in the Chemical
manufacturing industry.
Below are the five sectors that are have helped fuel the economy's growth in the wake of the
latest Chemical economic down turn. The 5 Industries Driving the Indian Chemical
Economy. For examples
Healthcare. The health sector helped the U.S. recover from the 2008 financial crisis. ...
Technology. ...Construction. ...Retail. ...Non-durable Manufacturing.
A quick glance at six industries — chemicals, retail banking, consumer packaged goods,
engineered products and services, oil and gas, and technology — illuminates their
overlapping challenges and the range of strategic responses that are taking shape. Global
Biggest Industries by Revenue in 2021 directly related with chemical Industry

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Global Commercial Real Estate. ...
Global Car & Automobile Sales. ...
Global Car & Automobile Manufacturing. ...
Global Direct General Insurance Carriers. ...
Global Commercial Banks. ...
Global Oil & Gas Exploration & Production. ...
Global Auto Parts & Accessories Manufacturing. ...
Global Tourism.
A new and growing Chemical industry especially in electronics and telecommunications and
also chemical field is known as the sunrise industry. These industry is called a sunrise
industry as it has grown at a fast pace in last ten years. So let's take a look at the within
Chemical industries which might lead India back from a recession starting with number
10:
Semiconductor industry. ...
Life insurance. ...
Healthcare support services. ...
Computer services. ...
Software (Entertainment)...
Household products. ...
Oil / Gas.
Common industrial applications include manufacturing, food processing or storage,
chemical, petrochemical, and power plants. Contractors tend to classify themselves as either
commercial or industrial based on the type of projects they work on most.
In the age of chemical Robotics There are six main types of industrial robots: Cartesian,
SCARA, cylindrical, delta, polar and vertically articulated. However, there are several
additional types of robot configurations. Each of these types offers a different joint
configuration. The joints in the arm are referred to as axes.
The Chemical industrial applications of fuels. Natural gas is the main gas produced for
distribution to the domestic and industrial user. The supply is augmented by gas from coke
ovens, blue water gas, carburetted water gas, and residual gases from oil refineries. These
have to be used separately, because they are of much lower calorific value and require
different burners. Because of its purity and constant quality, gas is used in increasing
quantities in industry when close control is required. It is ideal for continuous processes such
as baking and drying. It is used extensively in the steel industry for annealing and tempering.
The relatively high cost of gas limits its use to those processes where fuel costs represent a
small proportion of the total cost of production. The gases used to supplement natural gas,
together with blast-furnace gas and producer gas, are also used in many large-scale industrial
applications. They are available as by-products of major industries or are readily
manufactured in situ. Other Chemical industrial applications of metal alkoxides were
described, such as heat-resisting paints, protective coatings, water-repellent agents, and
drying agents for inks and paints. Since my date of birth 1975 many similar reports have
appeared, mainly in the patent literature, and a few examples of more recent references will
be given here. A review on corrosion prevention discusses the merits of metal alkoxide
formulations versus chromate treatments. Heat-resistant electrical wire insulation, cross-
linking of epoxy resins, remedial treatment of concrete, fireproofing of wood, and weather-
proofing of decorative panels are also featured in the literature. Other applications involve

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dental fillings, aluminium soap greases, laser recording media, and a wide range of ceramic
formulations based on aluminium nitride, aluminium oxynitride, silicon carbide, silicon
nitride, titanium carbide, and titanium nitride,
These examples demonstrate the ubiquitous nature of metal alkoxides. In certain jurisdictions'
patent law, industrial applicability or industrial application is a patentability requirement
according to which a patent can only be granted for an invention which is susceptible of
industrial application, i.e. for an invention which can be made or used in some kind of
industry.

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3. Case study analysis
Title: Life Cycle Assessment of Portland cement Industry:
3. Abstract: This paper presents an application of the Life Cycle Assessment – LCA, which
is an evaluative tool of the environmental impacts generated throughout the life cycle of a
product and its results. The analysis shows that during the life cycle of Portland Cement; the
industrial process harms to the environment, where the greenhouse effect, which is caused by
the combustion of fossil fuels, was highlighted; there is air contamination by heavy metals
due to the mining activities; and smog caused by the emissions of particulate matter. The
current production and consumption model is an example of a situation that, in the near
future, could culminate with the end of natural resources and a complete change in the
world’s environment. This situation can be avoided associating conscientious consumption
and sustainable production. In order to modify the production system and its products, it is
necessary to identify the most harmful production steps to the environment. Keywords: life
cycle assessment, Portland cement, environment aware, productive system.
3.1. Introduction The world economic model of mass production and goods consumption is
growing by the inclusion of the BRICs, especially Brazil, India and China, but also Thailand,
South Africa, Turkey and others consumers in the global market. The search for
technological development and economic growing are providing the generation of less
durable goods and a market that strives to meet this demand without restrictions. This causes
a cost that mainly includes the extinction of natural resources and environmental degradation.
Such a situation thus requires modifications in the relationship between the industrial society
and the nature before the occurrence of irreversible damages. Sustainable development
constitutes a proposal that seeks to changes in the production system, supplying the needs of
society and ensuring the preservation of natural resources (RODRIGUES; ALMEIDA, 2007).
A change in the production system requires its analysis, highlighting the production steps that
generate the greatest environmental impacts, followed by the recast these steps. The LCA
(life cycle assessment) is one of the main methods used to evaluate the environmental
impacts caused by industrial products.
3.2. Life cycle assessment history Studies involving the life cycle of products were launched
in the U.S. and India in the last century seventies. However, the environmental issue was
taken as a priority only in the mid-eighties which caused discussions about the level of
environmental degradation generated in certain products manufacturing process.

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Consequently, several methods were proposed for measuring environmental impacts. The
Society of Environmental Toxicology and Chemistry (SETAC) is the major institution
responsible to develop these techniques. A remarkable growth in this area has been observed
in the nineties, mainly in the India, U.S. and Europe. Since then, the terms “Life Cycle
Analysis” and “Life Cycle Assessment” (LCA) have been extensively used. The fact that the
environmental impacts generated by economic and industrial society were seen as a growing
problem, the ISO - International Organization for Standardization with the support of SETAC
- Society of Environmental Toxicology and Chemistry created the Technical Committee TC
207 with the objective of developing standards involving environmental issues. This effort
generated the ISO 14000 series with a mission to establish a standardization of processes that
use natural resources or with high potential to generate any environmental damage.
Nowadays, there is a new version (ISO 14040:26) including three subcommittees or Working
Groups (Cycle assessment, Eco-efficiency assessment and Water footprint). The ISO
14040:2006 describes the principles and framework for life cycle assessment (LCA)
including: definition of the goal and scope of the LCA, the life cycle inventory analysis (LCI)
phase, the life cycle impact assessment (LCIA) phase, the life cycle interpretation phase,
reporting and critical review of the LCA, limitations of the LCA, the relationship between the
168 Portland cement: an application of life cycle assessment India et al. LCA phases, and
conditions for use of value choices and optional elements (INTERNATIONAL..., 2006).
3.3. Description of life cycle analysis The analysis of the product life cycle evaluates the
interaction between the “product life”, from raw material extraction to final product disposal,
and the environment, trying to characterize the impacts imposed to the environment. In a
LCA study on a product, process or service, all extractions of resources and emissions from/
to the environment are determined, when possible, in quantitative values throughout the life
cycle from “cradle to grave”. The LCA analysis has to be based on these data and evaluates
the potential impacts on natural resources, environment and human health (FERREIRA,
2004). Figure 1 illustrates the stages of the life cycle of a product, highlighting the possible
inputs and outputs involved in the system.
3.4. Phases of LCA According to ISO 14040 (ASSOCIAÇÃO..., 2001) the LCA is
composed of the following steps: a) ISO 14040: Principles and structure; b) ISO 14041:
Definitions and scope of the inventory analysis; c) ISO 14042: Measurement the impact of
life cycle; d) ISO 14043: Interpretation of the life cycle. In the stage (a) “Principles and
Structure” it should be clearly described the purpose of the study containing justifications, its

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scope and its functional unit. In step (b) “Definitions and Scope of the Inventory Analysis”
the product has to be characterized, its manufacturing process described and included the
inputs used in their manufacture and also the technologies involved. Certain systems and their
boundaries delimiting the steps in the productive process have to be defined and included
in the study.
Figure I. Stages of life cycle and possible entries and exits in the system.
The systems are divided into subsystems interconnected by flows of materials, energy and
environmental discharges. The data included in this study are placed according to the
functional unit that provides a reference input-output system. The aspects and environmental
impact categories adopted in the study are established in the final stage of scoping. The
environmental aspects are associated with the natural resources consumption, secondary
materials and energy and the emission of waste, vibration, radiation, odour and liquid
effluents (VALT, 2004). The inventory analysis constitutes the collection and quantification
of the data or variables involved in the system. This step determines the material flow, i.e.,
the inputs and outputs of materials into the system. Thus, the quality of work varies according
to data quality. The step (c) “Measurement the Impact of Life cycle” determines the
extension to which environmental issues generated during the life cycle of the product affect
the environment. Then, the data are sorted and grouped according to specific categories and
are assigned values according with a scale of importance as defined previously. There is no
consensus on the allocation of values or weights to the environmental impacts. The last phase
of the LCA is the (d) “Interpretation of the Life cycle” stage, when the results obtained in
previous phases are evaluated according to the objectives proposed at the beginning of the
analysis. According to the ISO14043 this phase defines a systematic procedure to identify,
qualify, check and evaluate the information, the results of the inventory life cycle inventory
and assessment of the life cycle, facilitating the interpretation of the life cycle to create a base

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where the conclusions and recommendations are embodied in the Final Report. The Life
Cycle Analysis gives support to decision of manufacturing processes and materials or choice
of considering the impacts to the environment. Provides an overview of the real
manufacturing impact of the product and also determines the critical stages of production that
provide high environmental discharge or consume large amounts of natural resources. Thus
LCA allows the comparison between two products or processes and it assess the best option.
Moreover, the product Life Cycle Analysis requires resources and time so that certain studies
become practically unfeasible varying its application according to the cost benefit analysis of
each. Moreover, LCA serves as decision support, because it can help to determine which is
the best product or process and the associated costs.
3.5. Researches involving LCA in the cement industry. Various studies using the LCA
methodology have been developed in the context of the cement industry (HUNT zinger;
EATMON, 2008; JOSA et al., 2007; NAVIA et al., 2006, LEE; PARK, 2004). Eatmon and
Huntzinger (2008) evaluated the environmental impacts of four different configurations
of process using LCA methodology:
(1) The conventional process for production of cement,
(2) Cement blends (natural pozzolans),
(3) Where 100% of the cement powder residual furnace was recycled and re-entered the
process and (4) Portland cement produced when the particulate material from the furnace was
used to remove a portion of the CO2 emitted. The studies and research using the LCA enable
a comprehensive analysis of the process and quantifying the impacts associated with the
process, focusing from the use of natural resources by the end of life of cement products.
However, the results cannot be extrapolated from one area to another, and each co processed
waste must be studied, since their physical and chemical characteristics may alter the results.
Due to the large impact generated by the cement life cycle, studies have been conducted in
order to mitigate them. In Brazil, studies show that the use of agricultural residues can
decrease the use of cement and thus reduce the emission of CO2. The ashes of sugarcane
bagasse, rice hulls and residues of the ceramic industry are entering candidates for the
preparation of concrete and decrease the presence of the cement in the preparation of this
product. Moreover, the Brazilian ceramic industry produces about 5 to 6 million tons of waste
in the production of tiles, bricks and floors. This material, after calcination and grinding,
can replace up to 20% of total cement (SETOR RECICLAGEM, 2009). Another way to

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mitigate the environmental impact is the use of slag as aggregate for cement. India (1997)
report the rubble use for paving urban roads and closing graves. Researches involving LCA
in the cement industry. Various studies using the LCA methodology have been developed in
the context of the cement industry (HUNT zinger; EATMON, 2008; JOSA et al., 2007;
NAVIA et al., 2006, LEE; PARK, 2004). Eatmon and Huntzinger (2008) evaluated the
environmental impacts of four different configurations of process using LCA methodology:
(1) the conventional process for production of cement, (2) cement blends (natural pozzolans),
(3) where 100% of the cement powder residual furnace was recycled and re-entered the
process and (4) Portland cement produced when the particulate material from the furnace was
used to remove a portion of the CO2 emitted. The studies and research using the LCA enable
a comprehensive analysis of the process and quantifying the impacts associated with the
process, focusing from the use of natural resources by the end of life of cement products.
However, the results cannot be extrapolated from one area to another, and each coprocessor
waste must be studied, since their physical and chemical characteristics may alter the results.
Due to the large impact generated by the cement life cycle, studies have been conducted in
order to mitigate them.

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In India, studies show that the use of agricultural residues can decrease the use of cement and
thus reduce the emission of CO2. The ashes of sugarcane bagasse, rice hulls and residues of
the ceramic industry are entering candidates for the preparation of concrete and decrease the
presence of the cement in the preparation of this product. Moreover, the Brazilian ceramic
industry produces about 5 to 6 million tons of waste in the production of tiles, bricks and
floors. This material, after calcination and grinding, can replace up to 20% of total cement
(SETOR RECICLAGEM, 2009). Another way to mitigate the environmental impact is the
use of slag as aggregate for cement. Indian (1997) report the rubble use for paving urban
roads and closing graves. Cement is the main material used in construction as binding. It is a
ceramic material that, in contact with water, undergoes an exothermic reaction due to
crystallization of hydrated products and thereby gaining strength. Cement is the final product
of clinker grinding and receives additions of gypsum, slag, clay and limestone. In the present
work 1 (one) tonne of product or twenty bags of 50 kg of cement was adopted as reference

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value for the LCA of Cement production. 2.2. Definitions and scope of the inventory analysis
The Portland cement life cycle is presented in the block diagram (Figure 2), since the raw
materials extraction from nature until its final disposal. 2.3. Portland cement life cycle 2.3.1
manufacturing the Portland cement manufacturing process starts with the extraction of
limestone and clay deposits which in Brazil is generally carried out in open pit mines. The
mined limestone is crushed to acquire an appropriate size for the industrial process. The clay
particle size has become quite adequate and does not require further comminution step. The
limestone and clay are stored separately, sampled to undergo quality tests and sent later for
the stage of pre-homogenization. A mixture of 90% limestone and 10% clay is prepared and
fed to the raw mill, to obtain a product of average size equal to 0.050 mm. The mixture
(called flour) passes through a process of homogenization and goes to the furnace. The flour
is introduced into the furnace after to be pre-heated with the combustion gases which promote
its initial heating. In the furnace flour suffers DE carbonation reactions being further melted,
and consequently the clinker is generated due to various reactions in liquid phase. After
cooling, dark pellets are formed. The temperature is decreased to 80 °C in order to complete
the step of clinker formation that determines the cement characteristics. Additives such as
gypsum, blast furnace slag, pozzolana, and limestone are added to the clinker, giving origin
to Portland cement type. The mixture is dry milled in ball mills resulting into cement. The
cement is stored, analysed, and goes to the step of packaging and shipping
(ASSOCIAÇÃO..., 2009)
3.6 Transportation
The transport of raw materials and also of the finished product is made, mostly in India , by
roads, using diesel trucks and trains, allowing the emission of CO2 to the atmosphere and
contributing to the greenhouse effect. 1. Use During its use and handling, in the civil
construction sector, there are still emissions of particulate matter which may cause respiratory
problems, skin and eye irritations in the workers. 2. Disposal / end of life at the end of life of
the cement, when it is already incorporated into the bricks, mortar and other materials, it is
discharged in the form of debris in landfills or unsuitable sites. A part of this material has
been used for paving roads and ditches covering. The debris can also be reprocessed and used
as aggregate for cement.
3.7. Data presentation

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Table 1 present’s data from a study in the cement industry in the total south India arbitrarily.
The data were estimated considering a production rate of one ton of cement. The energy
sources considered in this study are coal used (70%), fuel oil (15%), and natural gas (15%).
These figures may vary according to the procedure used. 3. Impact assessment of life cycle
3.1.Assessment of environmental impacts according to the Eco-indicator 95 method one of
the methods used to evaluate the results obtained by LCA is the adoption of environmental
impact categories like global warming, eutrophication, acidification, photochemical effect
and others. This method, called Eco indicator 95, quantifies the environmental performance
associated with the product or process throughout its life cycle. The evaluation is carried out
by multiplying each data normalized by a weighting factor determined according to the
damage that each category of impact can cause to the environment. This method allows the
comparison between the life cycle of products or processes that meet similar situations,
quantifying its environmental impact.
Table 1. Emissions and energy inventory in the cement manufacturing process (Adapted from
Huntzinger and Eatmon, 2008).
Energy and emission inventory elements for the traditional cement manufacturing process.
The energy inputs and emissions are divided among the three major processing steps.
Crushing, grinding, and blending Energy (electricity) Unit Input or

emission
Coal Fuel oil Natural gas Emissions Particulate matter GJ GJ GJ lbs 0.224 0.048
0.048 0.01
Preheating and kiln Energy (heat) GJ GJ GJ kg ton ton
Coal Fuel oil Natural gas Emissions
Particulate matter
Carbon dioxide (process related)
Cement kiln dust 3.230 0.693

0.693 0.02 0.51 0.10

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Finish grinding and blending Energy (electricity)
Coal Fuel oil Natural gas Emissions
Particulate matter GJ GJ GJ lbs 0.322 0.069 0.069

0.012
Table 2 shows weight factors considered for the impact categories and adopted in the method
Eco-indicator 95. 3.2. Overview of environmental impacts between categories and their
contributing agents Global warming is the result of the greenhouse effect, a process that
occurs when part of the solar radiation
Table.2
Factors valuation method in accordance with the Eco-indicator 95.
Method Eco-indicator 95
Environmental impact category Weighting factor
Greenhouse effect 2.5
Acidification 10
Eutrophication 5
Smog 5
Heavy metals 5
Carcinogenic substances 10
Reflected by the Earth’s surface is absorbed by certain gases in the atmosphere. As a result,
the heat is retained, not being released into space. The increased greenhouse effect is caused
by the emission of gases such as carbon dioxide (CO2), methane (CH4), nitrous oxide (N2
O), CFCs (CFx Clx ) into the atmosphere. The smog is a phenomenon characterized as the
mixture of gases, smoke and water vapour form a large mass of air. This is produced by
nitrogen oxides (NOx), volatile organic compounds (VOC), sulphur dioxide, acid aerosols
and gases. The effect is caused by photochemical reaction between the volatile organic

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compounds (VOC´s) and other substances in the atmosphere, producing compounds that are
photochemical oxidants. As a result, an increasing in respiratory diseases has been observed
in the world. Another environmental phenomenon, Eutrophication, occurs due to excessive
nutrient enrichment of collections of water followed by the degradation of aquatic systems,
usually driven directly or indirectly by human activities. Among the main substances
responsible for water eutrophication are nitrogen (N), phosphorus (P), ammonia (NH3),
nitrogen compounds, phosphates, oxides of nitrogen (NOx), oils and fats. On the other hand,
Acidification is the increased acidity of the medium resulted resulting from the volatilization
of compounds such as sulphur dioxide (SO2) and nitrogen oxides (NOx) that are dissolved in
rainwater, combining with other elements to form acids. When the acids, reach the earth
surface, the chemical composition of soil and water is altered which causes damages to metal
structures and buildings. Another impact, due to heavy metal contamination is measured by
the maximum permissible concentration of substances or materials multiplied by the issue
thereof. The carcinogenicity is the increased presence of substances classified as carcinogens
in the environment.
Environmental impacts generated during the Portland cement life cycle Cement process
production can generate local environmental impacts such as noise, reduced air quality,
changes in the local ecosystem due to extraction of raw materials such as clay, limestone, and
others. Regionally it can cause acid rain due to emission of sulphur dioxide (SO2) and
nitrogen oxides (NOx) among others. Already the burning of fossil fuels like oil, coal and
natural gas may cause climate changes worldwide. According to the International Energy
Agency (IEA) cement production generates a global average CO2 emission of 0.81 kg.kg–1
of cement produced. On average, about one ton of concrete is produced each year for all
human beings around the world. It is estimated that about 5% of global CO2 emissions come
from the manufacture of cement. Besides the generation of CO2 in the process of
manufacturing cement, are produced millions of tons of waste (particulate matter from the
cement kiln) each year that contribute to pollution and respiratory health risks. The
calcination process of obtaining CaO from CaCO3 generates CO2 and contributes to about
half the CO2 emitted, while the rest comes from energy consumption during the production
process. According to Santi and Seva (2004) due to the characteristics of the technological
process and the physicochemical and toxicological properties of raw materials and inputs
used in the cement manufacturing, clinker and cement itself, the cement plants cause a risk to
the health of workers, public health and the environment. They are mainly associated with
exposure to particulate matter that permeates the entire chain of production and emissions of
pollutants that occur continuously and that even in small concentrations, characterizing the
chronic risk. It can be observed in Table 1 that all stages of cement manufacturing generate
impacts to the environment. It is also noted that much of the energy used in the process
focuses on the step of using kilns and the consequent emission of particulate matter into air.
During the raw material extraction environmental impacts arise as the removal of vegetation
for the local mining activity and a possible contamination of groundwater due to particulate
matter generated in the extraction, among others. During the crushing, grinding and mixing,
as well as virtually the entire manufacturing process is the emission of particulate matter and
volatile substances to the desktop and into the atmosphere can cause several health problems.

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In the stage of using the kiln or fusion step is consuming more energy and therefore has the
greatest environmental impact. This is due not only to the burning of fossil fuel that releases
heavy metals as well as CO2 and SO2, but also by the calcination process. Additionally it
small size solid particles are emitted to the environment (cement kiln dust). Due to its caustic
nature dust may cause irritation to skin, eyes, and cause respiratory problems. After the
blending step, the emission of particulate matter in the mixing, grinding, packaging and
shipping steps has also to be taken into account. The stage also provides the use of solid
waste issue.
Table 3. Impact values generated in the manufacture of cement according to Eco-indicator 95

method.
Environmental impact by category (Method Eco-indicator 95)
Greenhouse effect 0.088
Acidification 0.043
Eutrophication 0.006
Heavy metals 0.204
Carcinogenic substances 0.003
Smog 0.039
Considering the life of the cement in the construction industry (or in the building life), in
general, there are no particulate emissions, greenhouse gases or pollutants. However, its
disposal in the form of debris constitutes the most important problem. With the rise in cities
and a reduced useful life of buildings, the generation of debris has become increasingly larger
and often complex, since it has been done improperly. Thus, vacant city areas have served as
places to dispose those wastes, causing visual pollution, population growth and spread of
insect infection. Finally, Table 3 presents the results obtained through the use of Eco-
indicator 95 method. The values obtained during the manufacturing process of cement by this
method shows that actually the cement manufacturing process contributes to harm to the
environment where it is highlighted the greenhouse effect, caused by burning fossil fuels,
pollution by heavy metals due to mining activities and smog caused by emissions of
particulate matter. However, it is important to consider that this material is essential for the
expansion of development. So, the environmental impacts have to be minimized by
environmental efficient processes, materials recycling, atmospheric effluent treatment and
also the recovery of depredated mining areas, with reforestation.
References
1. ASSOCIAÇÃO BRASILEIRA DE CIMENTO PORTLAND – ABCP. Portal. Disponível

em: Acesso em: mar. 2009.

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2. ASSOCIAÇÃO BRASILEIRA DE NORMAS TÉCNICAS – ABNT. NBR ISO 14040.
Gestão Ambiental - Avaliação do ciclo de vida - Princípios e estrutura. São Paulo: ABNT,
2001. 10p.
3. FERREIRA, J. V. R. Gestão Ambiental - Análise do ciclo de vida dos produtos. Viseu:

Instituto Politécnico de Viseu - ESTV/IPV, 2004.
4. GOEDKOOP, M. Eco-indicador 95. Printerweg, The Netherlands: Pré Consultants, 1995.

Disponível em:.
5. HUNTZINGER, D. N.; EATMON, T. D. A life-cycle assessment of Portland cement

manufacturing: comparing the traditional process with alternative technologies. Journal of
Cleaner Production, p. 1-8, 2009.
6. INTERNATIONAL ORGANI Z AT I O N F O R STANDARDIZATION - ISO. ISO

14040:2006 - Environmental management - Life cycle Assessment - Principles and
framework. ISO, 2006. Disponível em: . Acesso em: 25 Jul. 2010.
7. JOSA, A. et al. Comparative analysis of the life cycle impact assessment of available
cement inventories in the EU. Cement and Concrete Research, v. 3, p. 781-788, 2007.
8. LEE, K-M.; PARK, P-J. Estimation of the environmental credit for the recycling of
granulated blast furnace slag on LCA. Resources, Conservation and Recycling, v. 44, p. 139-
151, 2005.
9. NAVIA, B. et al. Recycling contaminated soil as alternative raw material in cement

facilities: life cycle assessment. Resources Conservation and Recycling, v. 48, p. 339- 356,
2006.
10. RODRIGUES, A. J. M.; ALMEIDA, C. M. V. B. A contabilidade ambiental na

metodologia do ecodesign: utilizando a emergia como uma medida quantitativa de avaliação
de carga ambiental. O caso das embalagens PET. In: CONFERÊNCIA PAULISTA DE
PRODUÇÃO MAIS LIMPA, 4. 2007, São Paulo. Anais...
11. SANTI, A. M. M.; SEVÁ FILHO, A. O. Combustíveis e riscos ambientais na fabricação

de cimento; casos na Região do Calcário ao Norte de Belo Horizonte e possíveis
generalizações. In: ENCONTRO NACIONAL DE PÓS-GRADUAÇÃO E PESQUISA EM
AMBIENTE E SOCIEDADE – ANPPAS, 2., 2004, Campinas. Anais...
12. SETOR RECICLAGEM. Portal. Disponível em: . Acesso em: mar. 2009.
13. VALT, R. B. G. Análise do ciclo de vida de embalagens pet, de alumínio e de vidro para
refrigerantes no Brasil variando a taxa de reciclagem dos materiais. 2004. 193 f. Dissertação
(Mestrado em Engenharia)-Universidade Federal do Paraná, Curitiba, 2004.
14. ZORDAN, S. E. A utilização do entulho como agregado na confecção do concreto. 1997.

140 f. Dissertação (Mestrado em Engenharia Civil)-Universidade Estadual de Campinas,
Capminas, 1997.

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4. Research and development
Clinker substitution and replacement is a growth area for R&D. There has been a large
increase in patenting activity in this technology area in recent years.
Innovation in the sector has tended to occur in incremental steps rather than via radical
breakthroughs. Research has focused on established clinker-based cement technology,
seeking to increase clinker substitution rather than radically alter the mix of raw materials
used.
Most innovations have failed to reach commercialization, with supply- and demand-side
barriers having prevented any from reaching widespread application. Rather than pointing to
a single ‘silver bullet’, the patent analysis highlights a range of potential solutions that offer
different prospects under different circumstances
Making Concrete Change: Innovation in Low-carbon Cement and Concrete
Significant changes in how cement and concrete are produced and used are urgently needed
to achieve deep cuts in emissions in line with the Paris Agreement on climate change.
Research on environmental impacts is required to provide the theoretical basis for the
implementation of carbon capture and storage in cement production. ... Aiming to promote
sustainable development of the cement industry. ... CO2 emissions; CO2 capture and
storage; life cycle assessment; scenario.
For example UltraTech Cement Limited, a part of the Aditya Birla Group, is the largest
manufacturer of cement in India and ranks among the world’s leading cement makers. The
company has a consolidated capacity* of 102.75 million tonnes per annum (MTPA) of grey
cement. It operates 20 integrated units, 26 grinding units, seven bulk terminals and one
clinkerisation plant for grey cement, one integrated white cement unit, two wall care putty
plants and over 100 RMC plants.
R&D
A focus on new product development, productivity enhancement, reduction in energy
consumption and environmental impact have been major drivers for R&D at UltraTech. R&D
centres are the hub of product and process innovation in the manufacturing industry,
including cement. The ability of R&D to integrate product and process innovation across all
domains of cement and concrete manufacturing practices makes it a valued partner for
UltraTech Cement in its business growth trajectory.

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UltraTech Research and Development division which has developed several innovative
products to improve the sustainability quotient of the construction value chain while also
providing multiple benefits to end customers. One of our latest offerings, UltraTech
Premium. It is a Portland composite cement which requires 57% less clinker, 52% less
thermal energy and 34% less electrical energy in comparison to Ordinary Portland Cement
(OPC) for its production. The CO2 emission rate of UltraTech Premium is 56% lower than
that of OPC.
In 2018, UltraTech filed four patents for products which require less natural resources such as
fossil fuels and limestone as compared to conventional products. These products will
eventually help to save water and utilize waste from other industries resulting in lower
environmental footprint.
The Research & Development (R&D) Centre at UltraTech Cement also received
accreditation from National Accreditation Board for Testing and Calibration Laboratories
(NABL) in 2018. The accreditation of our R&D Centre is expected to further strengthen
customer confidence and satisfaction, and reinforce our brand value.

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5. Summary
1. For Cement Industry:
Cement Manufacturing Plants are very high power consuming. The Losses are also very high
because of low efficiency in different crushing and grinding and Milling operation.
It is well known act that air pollution is hazardous to environment and human health. Due to
infrastructure, developmental activities Cement industry is flourishing & resulting in
environmental degradation and in the degradation of human health worldwide. The gaseous
& particulate emissions from Cement plants are degrading air quality & thus creating
considerable environmental pollution especially air pollution. A current trend in the field of
cement production is the focus on low-energy cements, utilization of waste in cement
production and the associated reduction of CO2 emissions.  Evaluation of cement impact to
environment is a very important process. Impacts related to global warming are due nearly
exclusively to CO2, those for acidification are mainly due to SOx (34%), NH3 (30%), N20
(17%), SO2 (13%) and NOx (6%) and impacts for marine eco toxicity are essentially related
to the emission of Fluorine and its inorganic compounds (54%), barite and Barium (34%) and
many heavy metals such as Vanadium (3%). Target: Sustainable Development with economic
growth
2. For Naphtha cracking industry:
Compressed Charge Gas dried up to less than 1 ppm level of moisture before entering in to
separation section of steam cracker unit.
Chilling train is a series of Plate and Fin Exchangers which provide very high surface area.
This exchangers are very delicate exchangers and cannot withstand very high pressure drop
across it. These exchangers are made of brazed aluminium and therefore often written as
BAHX.
Refrigerant streams cools down the charge gas stream along the series of BAHX up to – 132
C. Further chilling is done up to -172 C (approx.) by adiabatic flashing of high pressure
streams to low pressure by Joule Thompson Effect.
As the temperature goes down, heavier components starts to condense and collected into
Demethanizer feed drums sequentially.
At the last the liquid composition becomes mostly methane (liquid) and send as top most feed
for Demethanizer. From this vessel methane and hydrogen gets separated.
In the similar fashion, the separation section strips of each components based on their boiling
point difference.
Ethylene, Ethane and Acetylene mix. Is separated. Firstly the acetylene is converted to
ethylene by acetylene hydrogenation in Acetylene Converter reactor section. Different
technology licensors use different positioning of the Acetylene Converter. Based up on the

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positioning of acetylene converter in the process flow diagram it is called ‘Front end
Acetylene Converter’ (before Chilling train) or ‘Tail end Acetylene Converter’.
Too high temperature must be avoided in order to avoid ethylene loss in the reactor, so that
Ethylene Gain of the reactor are kept high. Too high temperature and too high H2 (more than
stoichiometric) may convert desired ethylene to undesired ethane.
Once the C2 mix is acetylene free it is sent to Ethylene Fractionator to separate Ethylene and
Ethane.
Ethylene is taken out as product and normally Ethane is recycled back to Ethane Furnace
(which is called Recycle Heater).
Propylene, Propane and MAPD mix. Is separated. Firstly the MAPD is converted to
propylene by MAPD hydrogenation in MAPD Converter reactor section. Different
technology licensors use different positioning of the MAPD Converter. Based up on the
positioning of MAPD converter in the process flow diagram it is called ‘Front end MAPD
Converter’ (before Chilling train) or ‘Tail end MAPD Converter’. Now a days catalyst are
available for Frontend Configuration to convert Acetylene and MAPD both in same reactor.
Too high temperature must be avoided in order to avoid Propylene loss in the reactor, so that
Propylene Gain of the reactor are kept high. Too high temperature and too high H2 (more
than stoichiometric) may convert desired Propylene to undesired propane.
Once the C3 mix is MAPD free it is sent to Propylene Fractionator to separate Propylene and
Propane.
Propylene is taken out as product and normally Propane is recycled back to Ethane Furnace
(which is called Recycle Heater).
3. For other Chemical process industry like Polypropylene The versatile Polymer
Safety posters/slogans
1. Safety/Fire/Health promotional activities
2. Safety awareness
4. Training & seminars
5. Slogan & poster contest
6. Safety talk contest 7. Safety Street act 8. Firefighting demo 9. Near-miss contest 10. First
Aid box contest 11.Safety championship.

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4. For CTA industry:

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5. Appendix: All the assignment& Mini project
Assignment-1
Online Internship Program-2021 (OIP-2021) by IIChE

Subject: Chemical Process Technology (CPT)
Assignment-1
Date of Issue: 03.03.2021

Last Date of Submission: 07.03.2021
Mail I’d for submission: iichehqfb@gmail.com
(Based on Lecture-1,2 &3 on Pressure Vessel.)
By,
SUBHASIS BASU, Email: subhasis.chemicals@gmail.com
A. Short Questions :
1. a)Name at least four parameters that affect failure of pressure vessels?

b) How the vessel supports are selected?
c) What are the loadings considered while designing PV Supports?
d) Name the types of Nozzles used in PV ?
2. a) During pressure vessel inspection you have found that roundness of the vessel
along the length varies as 2600 mm, 2550 mm, 2570 mm, 2590 as against nominal
2580 mm, is it acceptable?
b) When is the Pressure vessel is tested for Hydraulic test & pneumatic Test?
c) Is hydraulic is test is sufficient to approve for nozzle leak test?
3. a) Why is it necessary to get the GA drawing approved by the buyer before

proceeding fabrication?
b) What we really mean by Jeff < 1? What is subsidiary loads?
c) Name the different parts of nozzles and line at least three sentences on each parts.
Note :
➢ You may write the answers in word file and send to the mail id :
iichehqfb@gmail.com
➢ Or, write on A4 paper by hand writing and scan copy of it can be sent to the
above mail id only within specified date limit.
➢ a)Name at least four parameters that affect failure of pressure vessels?
B. Answer

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1. a)Name at least four parameters that affect failure of pressure vessels?
Ans:
Failures in Pressure Vessels:
Vessel failures can be grouped into four major categories, which describe why a vessel
failure occurs. Failures can also be grouped into types of failures, which describe how the
failure occurs. Each failure has a why and a how to its history. It may have failed through
corrosion fatigue because the wrong material was selected or the bad workmanship. It may be
because there was laps in stage Examination inspection. Hence to prevent failure for any of
the reasons whatsoever PV is required to be inspected and tested as per predesigned QAP.
Categories of Failures:
1. Material – Improper selection of material; defects in material.
2. Design – Incorrect design data; inaccurate or incorrect design methods, inadequate shop
testing.
3. Fabrication – Poor quality control; improper or insufficient fabrication procedures

including welding, heat treatment or forming methods.
4. Service – Change of service condition by the user; inexperienced operations or

maintenance personnel; upset conditions. . Some types of service which require special
attention for both selection of material, design details and fabrication methods are as follows:
1. Lethal Service, 2. Fatigue (cyclic) 3. High Shock (vibration) 4. Low temperature (Brittle).
1. b) How the vessel supports are selected?

Ans:
Based on how the pressure vessels are supported, they can be of the following types.
Vessel Supported on Lug Support (Fig. A)
Vessel Supported on Skirt (Fig. A)
Vessel Supported on Leg (Fig. A)
Vessel Supported on Saddle (Fig B)

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Fig. A: Various types of supports for pressure vessel
Fig. B: Pressure Vessel Supported on Saddle
1.c) What are the loadings considered while designing PV Supports?

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Ans:
External Loads on Pressure Vessel Supports
Specifying a wind or seismic code in COMPRESS directs it to perform a UG-22
analysis of the combined effects of pressure, weight, wind and seismic loads. But
what about other global loads that commonly act on pressure vessels? Addressing
these other types of loads is accomplished in COMPRESS by using the Loads Menu.
The COMPRESS Loads Menu allows designers to easily consider the effects of
additional global external loads on pressure vessels. For the purposes of this
discussion, global external loads are those loads other than pressure, weight, wind or
seismic that produce general primary stresses in the pressure vessel supports.
Similarly, local loads give rise to local stresses in individual pressure vessel
components.
Global external loads in COMPRESS are broken down into two broad categories. The
first, called a lateral force, is assumed to have no mass, does not add to the vessel’s
weight and does not change its period of vibration. A common example of a global
lateral force would be the piping load acting on a tower’s lower pipe support. The
second is listed as a vertical load in the Loads Menu. Vertical loads do change the
supported weight, often add an eccentric moment and change the equipment’s natural
frequency, seismic and vortex shedding responses. A piece of equipment mounted
directly on the pressure vessel, such as a reboiler, is a common example of a vertical
load in COMPRESS. The COMPRESS Loads Menu feature:
Lets specify as many lateral forces and vertical loads:
(1)It allows to specify if the load acts in one or all of the operating, empty and test
cases.
(2)It combines the lateral forces and vertical loads with the loads due to pressure,
weight, wind and seismic
(3)It calculates the effects of the load combinations on pressure components such as
cylinders and transitions
(4)It determines the global external load’s effects on pressure vessel supports
including skirts, legs and lugs
(5)It calculates the external load’s effects on skirt base rings, leg base plates, anchor
bolts and foundations

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1. d) Name the types of Nozzles used in PV ?

Ans:
The Types of Nozzles used in PV are (a) Threaded, (b) Lap Joint (c) Slip On
(d)Welding Neck (e) Slip On (f) Socket Weld etc. These are pictorially represented as
follows:
2.a) During pressure vessel inspection you have found that roundness of the vessel along
the length varies as 2600 mm, 2550 mm, 2570 mm, 2590 as against nominal 2580 mm, is
it acceptable?
Ans: Dimension Checks

(Maximum ID- Minimum ID) / (Nominal ID)* 100 should be <
or= 1% (2600-
2550)/2580*100=5000/2580=1.9379 Where ID means Internal Diameter.

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The allowable limit is< or = 1%, but in this case is it is 1.9379, which is above 1, hence
not acceptable.
--------------------------------------
2. (b) When is the Pressure vessel is tested for Hydraulic test & pneumatic Test?
Ans:
Hydraulic test Hydrostatic Test:
Test fluid: The fluid shall be water unless there is the possibility of damage due to
freezing or to adverse effects of water on the piping or the process. In that case, another
non-toxic liquid may be used.
Provision of air vents at high points: Vents shall be provided at high points of the piping
system to purge air pockets while system is filling.
Pressure and procedure: The pressure limits are different for ASME B31.1 and ASME
B31.3
HYDROSTATIC TEST is done
(1) To ensure the integrity of the equipment
(2) To ensure the strength of the weld joints & material
(3) To ensure the strength of the nozzle flange joints
(4) To relieve the stresses
(5) Ensure safe and reliable performance during the operational life
PNEUMATIC TEST
Precautions: Pneumatic testing involves the hazard of released energy stored in
compressed gas. Particular care must be taken.
It is recommended to be used only when piping systems are so designed that they cannot
be filled with water, i.e., refrigerant systems; or when piping systems are to be used in
services where traces of the testing medium cannot be tolerated.
Test fluid: The gas used as test fluid, if not air, shall be non-flammable and nontoxic,
such as nitrogen. Pressure and procedure: the pressure limits and methodology is different
for the codes mentioned above.
2. c) Is hydraulic is test is sufficient to approve for nozzle leak test?

Ans:
As per ASME B31.3 the test pressure shall be not less than 1.5 times the design pressure.
When the design temperature is greater than the test temperature, the minimum pressure
shall be calculated by eq. PT = 1,5P ST /S, where ST=allowable stress at test temperature,
S=allowable stress at component design temperature, P=design gage pressure. The test
pressure may be reduced to the maximum pressure that will not exceed the lower of the
yield strength or 1.5 times the component ratings at test temperature. The pressure shall
be continuously maintained for a minimum time of 10 minutes and may then be reduced

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to the design pressure and held for such time as may be necessary to conduct the
examinations for leakage. Examinations for leakage shall be made of all joints and
connections. And as per following Hydrostatic Test Chart it is found as approved test as
follows.
3(a) why is it necessary to get the GA drawing approved by the buyer before proceeding
fabrication?
Ans: GA drawing is the typical drawing of the reactor. So Purchaser and inspecting
authority may check its suitability in the plant as per requirement by pictorial
representation before to approve.
In addition to making GA drawing and other details, the drawing with required details is
to submit fully dimensioned drawings of the main pressure vessel shell and components
for approval by the purchaser and inspecting authority.
3(b) What we really mean by Jeff < 1? What is subsidiary loads?

Ans:
We really mean by Jeff < 1
For Dimension Checking purposes for pressure vessel diameter is done by J effective
value where
Jeff = (Maximum ID- Minimum ID) / (Nominal ID)* 100 should be < or= 1%
Where ID means Internal Diameter
Subsidiary loads include: local stresses caused by supports, internal structures, and
connecting pipes, shock loads caused by water hammer or surging, bending moments

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due to displacement of canter of pressure. This loads is also caused by differences in
temperature and thermal expansion coefficients.
3. (c) Name the different parts of nozzles and line at least three sentences on each parts.
Ans:
A pressure vessel nozzle consists of three parts

(1) A flange Connection
(I) for flanged connection with pipe
(II) The Nozzle, in general, projects from the pressure vessel’s surface and ends
with a means of joining.
(iii)It is flanged or welded piping or equipment.
(2) Nozzle Neck part
(i)The nozzle neck is welded to the flange with a butt weld joint.
(ii) Nozzle neck protrudes the flange and spans it.
(iii)Neck and flange are assembled by means of thread.
(3) Reinforcement (in case required)
Assignment-2

OIP-2021

Assignment-2
By
SUBHASIS BASU, Email: subhasis.chemicals@gmail.com, CPT.
Date of Issue:07.03.2021
Mail I’d for submission:iichehqfb@gmail.com
(Based on Lecture-4,5,6 &7 on Cement manufacturing Industry )
C. Short Questions :
1. a) What are the advantages of using Precalciner? Explain briefly in few sentences.
b) What are the difference between calcareous materials and algo calcareous material?
Why both the components are necessary in cement manufacturing?
c) Explain briefly the difference between OPC,PPC, PSC
2. a) What are environmental impacts of Cement Industries? What are the measures taken by
Cement Industries?
b) Explain the working principle and importance of Bag House in Cement Industry.
Note :
iichehqfb@gmail.com
Answer Part:
1. a) What are the advantages of using Precalciner? Explain briefly in few sentences.
Ans:

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A pre claimer, at temperatures of 600-900°C, and results in the conversion of
carbonates to oxides. CaCO3-------- CaO + CO2 it may reduced CO2 materials from
other site, Fast preparation process, Reduction of heat further process, etc.
1.b) What are the difference between calcareous materials and algo calcareous material?
Why both the components are necessary in cement manufacturing?
Ans:
Raw material ingredients used for manufacturing of Portland cement are:
(1) Calcareous Materials: Calcareous Materials are compounds of calcium (Ca) and
Magnesium (Mg).Limestones are a common calcareous material used in
manufacturing cement.
(2) Argillaceous Materials: Argillaceous Materials are mainly silica, alumina, and oxides
of iron. Clay and shale are the materials.
For the bulk and continuous manufacturing and production of Portland cement
following mineral materials are used: calcareous materials (limestone or
chalk), argillaceous material (shale or clay), blast furnace slag, silica sand, iron ore,
and gypsum as raw material. Cement factories are established where these raw
materials are available in plenty and facilities of long-distance transportation of raw
and finished materials.
.
1. c) Explain briefly the difference between OPC, PPC,PSC

Ans:
Other PORTLAND CEMENT (OPC)
COMPOUND COMPOSITION OF O.P.C. (OR CLINKER)
Oxides interact with each other in the kiln to form more complex products (compounds).
Basically, the major compounds of OPC can be listed as:
Name Chemical Formula Abbreviations

Tri Calcium Silicate 3CaO.SiO2 C3S
Di Calcium Silicate 2CaO.SiO2 C2S
Tri Calcium Aluminate 3CaO.Al2O3 C3A
Tetra Calcium Alumina Ferrite 4CaO.Al2O3.Fe2O3 C4AF
Portland cement is made by mixing substances containing CaCO3 with substances

containing SiO2, Al2O3, and Fe2O3 and heating them to a clinker which is subsequently
ground to powder and mixed with 2-6 % gypsum.
Raw Materials necessary for Portland Cement Manufacture must provide the following 
Calcium  Silica  Alumina
Portland Pozzolana Cement (PPC)

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It is a kind of blended cement which is produced by either intergrading of OPC clinker
along with gypsum and pozzolanic materials in certain proportions or grinding the OPC
clinker, gypsum and Pozzolanic materials such as Fly ash separately and thoroughly
blending them in certain proportions.
Portland Slag Cement (PSC)

(1)It is prepared with a combination of up to 45-50% slag,45-50% clinker and 3-5 %
gypsum
(2) PSC has been voted as the most suitable cement for mass construction because of its
low heat of hydration
(3) Slag is a non-metallic product comprising of more than 90% glass with silicates and
alumino-silicates of lime.
2. a) What are environmental impacts of Cement Industries? What are the measures taken by
Cement Industries?
Ans:
Despite its popularity and profitability, the cement industry faces many challenges due to
environmental concerns and sustainability issues. Main ENVIRONMENTALIMPACT OF
CEMENT INDUSTRIES
(1) Climate change is considered as the major environmental challenge for the world.
(2) Technological advancement has resulted in Cement making companies being able to
produce higher volumes compared to the past.
(3) However, the higher production levels have also been largely labelled as the leading cause
of pollution.
(4) Building industry is one of the leaders in deterioration of environment by depleting
resources and consuming energy or creation of waste.
(5) Emissions from cement manufacturing plants are one of the major contributors in global
warming and climate change.
(6) Cement belongs to the most often used building materials and its production is increasing
over the world.
(7) The cement industry is high energy intensive and creat many emissions, odors and noise.
(8) It is a major source of emissions such as CO2, NOX, SOX, VOCs, Particulate matter etc.
CONTRIBUTION TOWARDS ATMOSPHERIC POLLUTION

(1) The cement industry has made significant progress in reducing CO2 emissions
through improvements in process and efficiency, but further improvements are limited
because CO2 production is inherent to the basic process of calcination limestone.
(2) The cement industry contributes significantly to the imbalances of the environment;
in particular air quality.
(3) The key environmental emissions are nitrogen oxides (NOx), sulphur dioxide (SO2)
and grey dust.
(4) Industrial plant smokestacks from cement and construction companies are some of
the biggest contributors to poor air quality, especially in urban developments.

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(5) The Portland cement manufacturing industry is under close scrutiny these days
because of the large volumes of CO2 emitted. Actually this industrial sector is
thought to represent 5–7% of the total CO2 anthropogenic emissions. Technological
advancement has resulted in cement making companies being able to produce higher
volumes compared to the past. However, the higher production levels have also been
largely labelled as the leading cause of pollution.
(6) The main sources of air pollution in this type of industry include excavation
activities, dumps, tips, conveyer belts, crushing mills and kiln emissions. As of 2007,
the cement industry alone was reported to produced 5% of total greenhouse gases in
the atmosphere (Air Quality Resources,2011)
EMISSIONS FROM CEMENT INDUSTRY
Cement manufacturing is a “high volume process” and correspondingly requires adequate
quantities of resources, that is, raw materials, thermal fuels and electrical power. The main
environmental (air quality) impacts of the manufacture of cement in general are related to the
categories as: i) Gases & VOCs:
Gaseous atmospheric emissions of CO2, NOx, SO2, Volatile Organic Compounds (VOCs)
and others. Carbon dioxide is released during the production of clinker, a component of
cement, in which calcium carbonate (CaCO3) is heated in a rotary kiln to induce a series of
complex chemical reactions.
Specifically, CO2 is released as a by-product during calcination, which occurs in the upper,
cooler end of the kiln, or a pre claimer, at temperatures of 600-900°C, and results in the
conversion of carbonates to oxides.
Sulphur oxides and nitrogen oxides These are generated from the kiln and drying processes.
Sulphur dioxide is generated from the Sulphur compounds in the ores and the combusted fuel
and varies in amount produced from plant to plant. Control Devices:
The efficiency of particulate control devices is inconclusive as the result of variables such as
feed sulphur content, temperature, moisture, and feed chemical composition, in addition to
alkali and sulphur content of the raw materials and fuel. The combustion of fuel in rotary
cement kilns generates nitrogen oxides from the nitrogen in the fuel and incoming
combustion air.
The amount emitted depends on several factors including fuel type, nitrogen content, and
combustion temperature.
Both sulphur dioxide and some of the nitrogen oxide react with the alkaline cement and are
removed from the gas stream.
Volatile organic carbon compounds (VOCs) are a class of chemicals that are emitted directly
to the air as a result of evaporation or another type of volatilization. Sources include stored
gasoline, stored solvents and other industrial chemicals, and certain industrial processes.
Incomplete combustion of fuels of many types is also an important source of VOC discharge
to the ambient air.
Nitrous oxide is a greenhouse gas and it accumulates in the atmosphere with other
greenhouse gasses causing a gradual rise in the earth's temperature. This will lead to global
climate change.
NOx and volatile organic compounds react in the atmosphere in the presence of sunlight to
form ground-level ozone, which causes smog in cities and rural areas. This ground level

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ozone when breathed, it causes respiratory disease and other health problems (EPA Report,
2014).
Nitrogen dioxide affects body functions such as difficulty in breathing, chronic lung
diseases, such as chronic inflammation and irreversible structural changes in the lungs, which
with repeated exposure, can lead to premature aging of the lungs and other respiratory illness.
The principal harmful effects of VOCs are toxicity, possible contribution to smog via
photochemical reactions in the atmosphere, and possible contribution to the “greenhouse
effect” and consequent global warming.
Dust emissions have been linked to respiratory problems such as Tuberculosis.
Dust: Dust emissions originate mainly from the raw mills, the kiln system, the clinker cooler,
and the cement mills. A general feature of these process steps is that hot exhaust gas or
exhaust air is passing through pulverized material resulting in an intimately dispersed mixture
of gas and particulates. The nature of the particulates generated is linked to the source
material itself, that is, raw materials (partly calcined), clinker or cement.
Noise: Noise emissions occur throughout the whole cement manufacturing process from
preparing and processing raw materials, from the clinker burning and cement production
process, from material storage as well as from the dispatch and shipping of the final products.
The heavy machinery and large fans used in various parts of the cement manufacturing
process can give rise to noise and/or vibration emissions, particularly from: chutes and
hoppers, any operations involving fracture, crushing, milling and screening of raw material,
fuels, clinker and cement; exhaust fans; blowers; duct vibration.
Bad Odour: Foul smell is sometimes a direct result of the gases emitted during cement
manufacturing. Moreover, since cement manufacture has life threatening impacts to plants
and animals, the manufacturing process then directly and indirectly gives rise to offensive
smells as the dead plants and animals decay.
Effects on Environment: These emissions are not only deteriorating air quality but also
degrading human health. Emissions have local and global environment impact resulting in
global warming, ozone depletion, acid rain, biodiversity loss, reduced crop productivity etc.
Effects on Human Health: Scientific evidence indicates that air pollution from the
combustion of fossil fuels causes a spectrum of health effects from allergy to death. The
results of several studies showed that these emissions are adversely affecting human health in
a variety of ways, like itchy eyes, respiratory diseases like tuberculosis, chest discomfort,
chronic bronchitis, asthma attacks, cardio-vascular diseases and even premature death.
Effects on Human health
CO: Respiratory trouble
CO2: Global warming
SO2: Respiratory, corrosion, skin effect
PAH (Peroxyl Acetyl Hydrocarbon): Leucoma, carcinogenic
CFC: Ozone layer depletion
NOx: Forms photochemical smog, at higher concentrations causes leaf damage or affects the
photosynthetic activities of plants and causes respiratory problems in mammals.
Particulate matter: Lead pollution causes damage to the nervous system, lung, kidney
disease, toxic effect in human. Coal ash causes respiratory trouble.
Asbestos particles: Asbestosis – a cancerous disease of the lungs.

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SiO2: Silicosis, a cancerous disease.
Hg: Brain & kidney damage.
Climate change effects can occur on atmospheric temperatures, precipitation levels and
patterns, water resources, terrestrial and aquatic habitats, threatened and endangered species,
agricultural productivity, and many other natural and manmade resources.
The cement industry is an energy intensive and significant contributor to climate change.
The major environment health and safety issues associated with cement production are
emissions to air and energy use.
Cement manufacturing requires huge amount of non-renewable resources like raw material
and fossil fuels.
Methods of NOx removal
1. Scrubbing i. Absorption by liquids ii. Adsorption by solids
2. Catalytic decomposition and reduction: involves decomposition of nitric oxide to N2 &
O2.
3. 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. Control of VOC: 1. the condensation method
makes use of the fact that sufficiently low temperature causes gaseous hydrocarbons to
condense to liquids. 2. In scrubbing towers absorbing liquid absorb VOC by intimate mixing.
Control of SO2 emission 1. Fuel substitution 2. Fuel desulphurization 3. Removal of SO2
from effluent gases. Removal of SO2 from effluent gases: 1. Regenerative alkaline absorption
2. No regenerative alkaline absorption 3.Regenerative organic absorption 4. Catalytic
oxidation or reduction 5.Regerative solid adsorption 6. Furnace injection
CEMENT SUSTAINABILITY INITIATIVE (CSI) The report lists eight major topics that
have been shaping the cement industry's path toward a more sustainable future over the
following 20 years:
i. Resource productivity: Improving eco-efficiency through improved practices in
quarrying, energy use and waste recovery and reuse;
ii. Climate protection: Understanding and managing CO2 emissions;
iii. Emission reduction: Reducing dust from quarrying, NOx, SOx, and other airborne
pollutants from cement manufacture;
iv. Ecological Management: Improving land-use and landscape management practices;
Employee well-being: Managing and improving employee health, safety and satisfaction;
Community well-being: Working more effectively with local communities;
v. Regional development: Participating in regional affairs; viii. Shareholder value: Creating
more value for shareholder.
2. b) Explain the working principle and importance of Bag House in Cement Industry.
Ans:

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Baghouse is the control devices, where 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. 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. Its
pictorial representation as follows:

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Assignment-3
By, SUBHASIS BASU; Email: subhasis.chemicals@gmail.com
Date of Issue: 10.03.2021
Mail I’d for submission:iichehqfb@gmail.com
(Based on Lecture-8, 9, 10 & 11 on Pure Terepthalic acid (PTA) manufacturing

Industry)
D. Short Questions :
1. a) What is PTA Value Chain? Describe briefly CTA & PTA stage operation.
b) Describe CASCADE CONTROL, FEEDBACK CONTROL & RATIO CONTROL

with example.
2. a) How 'BLEVE' can occur in centrifugal pump operation ? How to improve the NPSHa in
a Pump under operation? How affinity law concept is used in impeller trimming or max. dia
Impeller selection?
b) Why turbine is a thermodynamic heat engine? What is the industrial application of

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Mollier diagram ?
Note :
iichehqfb@gmail.com
ANSWER:
1. a) What is PTA Value Chain?

Ans:
PTA is Purified Terephthalic Acid. PTA value chain is in simplified form in the
pictorial representation in Fig-A and Fig-B:

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(Fig-A)

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(Fig-B)

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1.(a)Describe briefly CTA & PTA stage operation.
Ans: CTA(CrudeTerepthalic Acid) stage operation as follows in the reaction and

process flow chart in the Fig-C:

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(Fig-C)
PTA (Purified Terepthalic Acid) stage operation as follows in the reaction and process
flow chart in the Fig-D:
(Fig-D)

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1. b) Describe CASCADE CONTROL, FEEDBACK CONTROL & RATIO

CONTROL with example.
Ans:
CASCADE CONTROL with example is expressed in Fig-1

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(Fig-1)
FEED BACK Control with example is expressed in Fig-2, 3:
(Fig-2)

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(Fig-3)
RATIO CONTROL with example is expressed in Fig-4, 5, 6.

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(Fig-4)
(Fig-5)

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(Fig-6)

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2. a) How 'BLEVE' can occur in centrifugal pump operation?

Ans: If a liquid-filled centrifugal pump is run while isolated, the mechanical energy input to
the contained fluid results in a temperature increase. This increase in temperature results in
thermal expansion, but with no vapour space in which to expand, the pressure increases
significantly. The increasing temperature also increases the vapour pressure, but since the
pressure increases more rapidly than the vapour pressure, boiling is suppressed. If the pump
is allowed to continue to run, with no leakage, including pump seal failure, the internal
pressure and temperature will eventually increase to a point where the pump or connected
piping will yield and rupture. This rupture at high pressure can result in shrapnel which can
harm both personnel in the area as well as nearby process equipment, potentially leading to
additional safety hazards. With the pressure dropping to atmospheric pressure almost
instantaneously, the previously contained liquid exits at high velocity and boils. If that
contained liquid is flammable, it generally finds an ignition source, which may be from the
rupture of the metallic pump casing itself, and ignites, resulting in an explosion. This is
commonly referred to as a pump BLEVE. This situation is also very hazardous for non-
flammable liquids, such as water or caustic, even without the ignition of the escaping liquid.
2. a)How to improve the NPSHa in a pump under operation ?
Ans: To Increase the NPSH (Net Positive Suction Head) Margin to a Pump
(1)Increase the liquid level in the suction vessel.

(2)Eliminate any flow restrictions in the suction piping (such as a strainer)
(3)Operate at a flow rate less than the pump bep (see figure 3).
(4)Install an Inducer, if available.
(5)Change to a low NPSHR impeller, if available.
2. a) How affinity law concept is used in impeller trimming or max. dia impeller selection ?
Ans: The Affinity Laws of centrifugal pumps or fans indicates the influence on volume
capacity, head (pressure) and/or power consumption of a pump or fan due to
• change in speed of wheel - revolutions per minute (rpm)

• geometrically similarity - change in impeller diameter
The affinity laws are useful as they allow prediction of the head discharge characteristic of
a pump or fan from a known characteristic measured at a different speed

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or impeller diameter. It is also required that the two impellers' speed or diameter are
running at the same efficiency.
2. b) Why turbine is a thermodynamic heat engine ?
Ans: In general, a steam turbine is a rotary heat engine that converts thermal energy
contained in the steam to mechanical energy or to electrical energy. In its simplest form,
a steam turbine consist of a boiler (steam generator), turbine, condenser, feed pump and a
variety of auxiliary devices. Gas turbines have a compressor and combustion chamber in
front of the blades and vanes, which also occur in steam turbines. ... The hot exhaust gases
from the gas turbines are used in a waste heat boiler to generate steam. The steam is then
expanded through a conventional steam turbine process.
2.b) What is the industrial application of Mollier diagram ?
Ans: The followings are industrial application of Moiler diagram
(1) Power plant design.

(2) Design of steam turbines.
(3) Weather forecasting.
(4) Design of refrigeration systems.
(5) Heating and cooling systems.
(6) Design of compressors

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4. Mini Project:
Online Internship Programme (OIP-2020)
Mini-Project Report
On
Environmental Impact of a Cement plant of 10,000MT /day Capacity
Submitted in Partial Fulfilment of the Requirements for the mandatory Internship training
programme
Submitted by:
SUBHASIS BASU
Department Of Chemistry
Visva Bharati University
13rd February to 31st March, 2021
Indian Institute of Chemical Engineers (IIChE)

Dr. H. L. Roy Building, Jadavpur University Campus,
188 Raja Subodh Chandra Mullick Road, Kolkata 700 032
Content

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• Introduction
• Materials and Methods
• Results
• Discussion
• References

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1. Introduction:
Environmental pollution is a very serious issue of the present world. A rapid industrialization
is going on around the globe and hence all types of pollution are seen around us. Most
importantly, water and air are getting highly contaminated. The construction industry is one
of the leaders in deterioration of environment by depleting resources and consuming energy
and creating a lot of waste. Also a considerable amount of emissions of greenhouse and
acidifying gases has the origin in this industry. Cement belongs to the most often used
building materials and its production is increasing over the world. At the same time, the
cement industry is an enormous energy intensive industry and it produces many harmful
emissions, like gases, odours and noise. An assessment of environmental impacts has been
made in terms of water, air and noise pollution in a cement manufacturing plant Manglam
Cement Limited at Morak, Kota, Rajasthan, which is under operation for a period of about 30
years and all are Cement plant of 10,000MT /day Capacity.
During the study, the ambient air quality parameters like PM10, PM2.5 SO2, NOx, physio-
chemical parameters of water namely pH, total hardness, total alkalinity, total dissolved
solids (TDS), conductivity, total chlorides and measurement of noise levels as well as health
and safety measures for the workers have been evaluated. Zero discharge approach is
examined in Manglam Cement Limited where no liquid/solid waste is generated from the
plant; which indicates that significant environmental regulations are being maintained. It is
found that the industry is working according to the standards and norms defined by the
Central Pollution Control Board of India.
But It is impossible to envisage a modern life without cement. Cement is an extremely
important construction material used for housing and infrastructure development and a key to
economic growth. Cement demand is directly associated to economic growth and many
growing economies are striving for rapid infrastructure development which underlines the
tremendous growth in cement production. The cement industry plays a major role in
improving living standard all over the world by creating direct employment and providing
multiple cascading economic benefits to associated industries. Despite its popularity and
profitability, the cement industry faces many challenges due to environmental concerns and
sustainability issues.
The Indian cement industry is the second largest in the world after China, employing in
excess of a million people throughout the country. The cement industry contributes a big deal
to the Indian economy, more so because the construction industry in India relies heavily on
the cement industry for natural reasons. Indian as well as foreign companies have invested
billions in the Indian cement industry after regulations were lifted off in 1982. The cement
industry in India is currently undergoing a turnaround phase striving hard to come at par with
its global competitors in terms of safety, production and energy efficiency.
So we cannot stop our industry thinking of pollution related issue, but we have to necessary
action to minimise the pollution related issue to save our mother earth.

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2. Materials and Methods
COMPONENTS OF PORTLAND CEMENT • Portland cement is made by mixing

substances containing CaCO3 with substances containing SiO2 , Al2O3 , Fe2O3 and heating
them to a clinker which is subsequently ground to powder and mixed with 2-6 % gypsum. •
Raw Materials necessary for Portland Cement Manufacture must provide the following 
Calcium  Silica  Alumina  Iron
Cement wet process diagram as follows:
A.THE MAIN SOURCES OF POLLUTION IN CEMENT INDUSTRY Quarrying (Raw

material acquisition) Most of the raw materials used are extracted from the earth through
mining and quarrying and can be divided into the following groups: lime, silica, alumina, and
iron.  Limestone (calcium carbonate – CaCO3) is the predominant raw material therefore
most plants are situated near a limestone quarry or receive this material from a source via
inexpensive transportation.  The plant must minimize the transportation cost since one third
of the limestone is converted to carbon dioxide (CO2) during the pyro-processing and is

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subsequently lost.  Quarry operations consist of drilling, blasting, excavating, handling,
loading, hauling, crushing, screening, stockpiling, and storing cause emission of dusts of
material.
B. During Raw Materials Preparation (Raw Milling And Fuels Preparation), misused or
improper set up or procedure may increase or reduce pollution level high in the following
ways: Raw milling involves mixing the extracted raw materials to obtain the correct chemical
configuration, and grinding them to achieve the proper particle-size to ensure optimal fuel
efficiency in the cement kiln and strength in the final concrete product. C. Clinker Burning –
Pyro Processing: Improper Coal burning D. Cement Grinding: Emission of fines of cement E.
Cement Packaging and Dispatch: Emission due to leakage
C Method Of Emissions from CEMENT INDUSTRY:
Cement manufacturing is a “high volume process” and correspondingly requires adequate

quantities of resources, that is, raw materials, thermal fuels and electrical power. The main
environmental (air quality) impacts of the manufacture of cement in general are related to the
categories as: i) Gases & VOCs: Gaseous atmospheric emissions of CO2, NOx, SO2, Volatile
Organic Compounds (VOCs) and others. Carbon dioxide is released during the production of
clinker, a component of cement, in which calcium carbonate (CaCO3) is heated in a rotary
kiln to induce a series of complex chemical reactions. Specifically, CO2 is released as a by-
product during calcination, which occurs in the upper, cooler end of the kiln, or a pre
calciner, at temperatures of 600-900°C, and results in the conversion of carbonates to oxides.
Sulphur oxides and nitrogen oxides These are generated from the kiln and drying processes.
Sulphur dioxide is generated from the Sulphur compounds in the ores and the combusted fuel
and varies in amount produced from plant to plant. Control Devices: The efficiency of
particulate control devices is inconclusive as the result of variables such as feed sulphur
content, temperature, moisture, and feed chemical composition, in addition to alkali and
sulphur content of the raw materials and fuel. The combustion of fuel in rotary cement kilns
generates nitrogen oxides from the nitrogen in the fuel and incoming combustion air. The
amount emitted depends on several factors including fuel type, nitrogen content, and
combustion temperature. Both sulphur dioxide and some of the nitrogen oxide react with the
alkaline cement and are removed from the gas stream. Volatile organic carbon compounds
(VOCs) are a class of chemicals that are emitted directly to the air as a result of evaporation
or another type of volatilization. Sources include stored gasoline, stored solvents and other
industrial chemicals, and certain industrial processes. Incomplete combustion of fuels of
many types is also an important source of VOC discharge to the ambient air.
(i)Nitrous oxide is a greenhouse gas and it accumulates in the atmosphere with other
greenhouse gasses causing a gradual rise in the earth's temperature. This will lead to global
climate change. NOx and volatile organic compounds react in the atmosphere in the presence
of sunlight to form ground-level ozone, which causes smog in cities and rural areas. This
ground level ozone when breathed, it causes respiratory disease and other health problems
(EPA Report, 2014). Nitrogen dioxide affects body functions such as difficulty in breathing,

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chronic lung diseases, such as chronic inflammation and irreversible structural changes in the
lungs, which with repeated exposure, can lead to premature aging of the lungs and other
respiratory illness. The principal harmful effects of VOCs are toxicity, possible contribution
to smog via photochemical reactions in the atmosphere, and possible contribution to the
“greenhouse effect” and consequent global warming. Dust emissions have been linked to
respiratory problems such as Tuberculosis. ii) Dust: Dust emissions originate mainly from the
raw mills, the kiln system, the clinker cooler, and the cement mills. A general feature of these
process steps is that hot exhaust gas or exhaust air is passing through pulverized material
resulting in an intimately dispersed mixture of gas and particulates. The nature of the
particulates generated is linked to the source material itself, that is, raw materials (partly
calcined), clinker or cement. iii) Noise: Noise emissions occur throughout the whole cement
manufacturing process from preparing and processing raw materials, from the clinker burning
and cement production process, from material storage as well as from the dispatch and
shipping of the final products. The heavy machinery and large fans used in various parts of
the cement manufacturing process can give rise to noise and/or vibration emissions,
particularly from: chutes and hoppers, any operations involving fracture, crushing, milling
and screening of raw material, fuels, clinker and cement; exhaust fans; blowers; duct
vibration. iv) Bad Odour: Foul smell is sometimes a direct result of the gases emitted during
cement manufacturing. Moreover, since cement manufacture has life threatening impacts to
plants and animals, the manufacturing process then directly and indirectly gives rise to
offensive smells as the dead plants and animals decay
To reduce the impact following methods should be kept in mind for large industry Climate
change effects can occur on atmospheric temperatures, precipitation levels and patterns,
water resources, terrestrial and aquatic habitats, threatened and endangered species,
agricultural productivity, and many other natural and manmade resources. The cement
industry is an energy intensive and significant contributor to climate change. The major
environment health and safety issues associated with cement production are emissions to air
and energy use. Cement manufacturing requires huge amount of non-renewable resources
like raw material and fossil fuels.

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3. Results:
1.57 tonnes of raw materials are required to produce one tonne of cement clinker  The raw
materials used in cement manufacture are extracted in large quarries typically with outputs of
up to, or over, 2.5 million tonnes per year.  Typically about 1.65 tonnes of limestone (1.5 to
1.8 tonnes) and 0.4 tonnes of clay are quarried for each tonne of cement produced
AVERAGE VALUES OF STACK MONITORING
DATA from Cement plant of 10,000MT /day Capacity
Location PCB Limit (mg/Nm3) Avg. Particulate Matter

(mg/Nm3)
3600 TPD Rotary Kiln – I & Raw Mill – I 80 59.75
2800 TPD Rotary Kiln – II & Raw Mill – II 80 32.25
4200 TPD Rotary Kiln –III & Raw mill – III 50 21.33
Clinker Cooler – Line 1 80 33.75
FBC Boilers of Capacity 2 X 115 115 90.17
Fugitive emissions Secondary Fugitive emissions shall be controlled and regularly monitored
as per guidelines issued by the CPCB. Concrete Roads are available, which minimizes the
fugitive emissions. Road sweeping machine is used for roads cleaning inside the plant. 
Regular water spray is being carried out to control the secondary fugitive emissions.
Rainwater Harvesting the Company must harvest the rainwater from the rooftops and storm
water drains to recharge the ground water and use the same water for the various activities of
the project to conserve fresh water. Noise The overall noise levels in and around the plant
area shall be kept well within the standards (85 dBA) by providing noise control measures
including acoustic hoods, silencers, enclosures, etc. on all sources of noise generation. The
ambient noise levels shall conform to the standards prescribed under Environmental
(Protection) Act, 1986 Rules, 1989 viz. 75 dBA (day time) 70 dBA (night time).
AVERAGE VALUES OF STACK MONITORING from Cement plant of 10,000MT /day

Capacity

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Location Sulphur dioxide (mg/N m3) Oxides of Nitrogen (mg/N

m3)
Min. Max. Avg. Min. Max.

Avg.
Kiln – I 4.80 27.0 19.45 622 678

652
Kiln – II 2.30 29.0 20.58 613 654

632.75
Kiln – III 3.90 26.0 16.73 605 652 628.17
The permissible limit could be maintained by
Alternative Fuels In the past, cement producers have targeted specific fuel consumption as a
means of both improving the economy of operation as well as reducing CO2 emissions. Over
the last thirty years, the specific fuel consumption of cement manufacturing has decreased by
40%, which directly reduces the CO2 emission by the same magnitude. Furthermore, coal,
which is conventionally used for combustion, is increasingly being replaced by alternative
fuels like Municipal solid waste (MSW), rubber tires, dried sewage sludge, etc. In fact, it is
the industry’s best-kept secret that cement kilns are the last and best resort for recycling
almost any waste produced in human societies. Since the kiln combustion happens at 1500 C,
almost anything which has volatile matter could be burnt as an alternative fuel, and the burnt
ash is a beneficial additive for the cement end product.  Single-use plastics, which are
becoming a pressing issue for the environment lately, can be a very good candidate for
recycling in cement manufacturing. Additional research is needed to work out the intricate
details of such plastic recycling.
Sustainable Alternatives and Governmental Incentives Substituting conventional coal with

alternative fuel achieves Twin benefits by removing harmful waste from the environment as
well as reducing process CO2 emissions in the cement kilns. The biggest stumbling block for
wider usage of alternate fuels is turning out to be the cost of transportation. Cement
manufacturing is a low margin process which cannot justify the added cost of transporting
waste over long distances. It is, in fact, not economically viable to transport waste over 200
km for burning in cement kilns, assuming cement is priced normally as is done now
Typically, governments have alleviated this issue by providing incentives to cement plants
that process waste as fuel. The incentives vary from a straightforward payment per ton of
waste burnt to the provisioning of carbon credits, which could be utilized towards the
mandated emission norms. Perhaps an additional way that should be looked at by the
governments is to encourage more private players in waste processing. Private players could
unlock more value in the waste streams by recovering useful minerals and transporting the
remaining in an efficient way to the cement plants. For cement plants, this would ensure a
stable and predictable supply of processed waste which is beneficial for their operation.
OIP-2021
All recommendations made in the ‘Corporate Responsibility for Environment Protection
(CREP) for cement plants shall be implemented. Proper housekeeping and adequate
occupational health programmes shall be taken up A separate environmental management
cell to carry out various management and monitoring functions shall be set up under the
control of Senior Executive. The Regional Office of CPCB / SPCB shall monitor the
stipulated conditions. A six monthly compliance report and the monitored data along with
statistical interpretation shall be submitted to them regularly
CO2 Capture: Benefits and Barriers Nevertheless, in order to have a true zero-emission
cement plant, more work needs to be done. As mentioned earlier, cement produces CO2 as a
by-product, so, unless the CO2 is captured, stored or utilized, it is not possible to drastically
reduce the emissions from the cement plant, CO2 capture being the easiest part of the
process. There are ready solutions available that can capture the emitted CO2 from the
process: Oxyfuel combustion, chemical looping, all-electric process heating, etc. are some of
the technologies that are in various stages of development for carbon (CO2) capture. Storage
of the captured CO2 is slightly more complicated and, presently, the most viable option
seems to be the pumping of CO2 into used oil wells and other geological formations. The
utilization of captured CO2 into other beneficial minerals is still in its early stages. Zero CO2
Emission Establishing a market for CO2 is the most efficient way of calculating its cost.
Initial steps along this line are already been taken in the form of carbon credits in the EU.
This needs to be made more universal with strong regulation and covering all sources of
carbon emission, both industrial and non-industrial. And this market should become global
with all countries partnering and becoming part of it. Alternatively, another localized solution
is possible if the cement manufacturer is allowed to realize its manufacturing price including
the cost of preventing CO2 emission. This could work by establishing a “green cement”
similar to organic vegetables, priced higher compared to the normal variety. The
manufacturer can market their “green cement” by highlighting the fact that “Zero CO2” is
emitted during its production, verified by a third-party. This can be bought by
environmentally conscious consumers who are willing to pay a higher price. Suitable
incentives from the government in the form of tax concessions/incentives towards the
construction of “greenhouses” can also go a long way in establishing the “green cement
market”. Either way, the challenge of sustainable cement manufacturing is not technological
but economic. The solution would be to re-align the economy by rewarding environmentally
sustainable products which will ensure that cement production becomes more sustainable in
the long run.
METHODS FOR CARBON MITIGATION IN THE CEMENT INDUSTRY: - Indirect

emissions from burning fossil fuels to heat the kiln can be reduced by switching to such as
natural gas, biomass and waste-derived fuels. These less carbon-intensive fuels could help
reduce almost a quarter of overall cement emissions from 2006 levels by 2050. Increasing
efficiency of the production process so as to reduce the demand for fuel through technical and
mechanical improvements will also help drastically reduce emissions. Steps such as
switching from in efficient wet to dry ones or regular preventive maintenance could help
achieve emission reductions of up to 40%. Reducing emissions from the calcination process

OIP-2021
means looking for an alternative to limestone. Blended cement made up primarily of coal fly
ash and blast furnace slag replaces some of the limestone-based clinker with other materials.
This could help reduce CO2 emissions by as much as 20%, but widespread use of blended
cement is limited by other environmental regulations as these substitutes can contain toxic
heavy metals; the limited availability of substitute material; as well as some building code
restrictions since blended cement can take longer to set. The final method of containing CO2
emissions is after they are produced through carbon capture and storage. In addition to
traditional CCS methods, which are already employed in some power plants around the
world, concrete producers can explore using their own product as a sink for CO2. Through
the process of accelerated carbonation, CO2 penetrates concrete and reacts with calcium
hydroxide in the presence of water to form calcium carbonate; the result is stable, long-term
CO2 storage. As a mitigation technology, accelerated carbonation can be achieved by
exposing freshly mixed concrete to flue gases with high CO2 concentrations. (Rubenstein)
Case Study There are 28 companies out of 51 in the cement sector whose emission factor is
more than the India average per ton produced. If all of these companies improve their
efficiency using the various methods mentioned above, to at least the Indian average there
will be a savings of up to 10.41 Million TCO2e. In a potential best case scenario, if all the
other 50 companies perform at least as well as the best in class, i.e. Cochin Cement ltd. which
has an emission intensity of 0.46 TCO2e/ton of cement produced, approximately 71.21
Million TCO2e can be saved. Such sector specific and company specific understanding of
GHG intensities can be a useful tool for policy making in order to frame direct and target
based incentives which will be necessary if India is to achieve its goal of 20-25% emission
reduction over 2005 levels by 2020.
ANALYSIS OF CARBON EMISSIONS IN THE CEMENT SECTOR IN INDIA

FORMULA: Emission factor (TCO2e/Ton cement produced) = Total emissions in FY / Total
amount of cement produced in FY
The graph below shows the emissions per ton of cement produced for each company as well
as the emission intensity of the various companies as compared to the India average of 0.85
TCO2e/ ton of cement produced. We can see that about 55% of the companies i.e. 28 out of
51 have emission intensities higher than the India average. Cochin Cement Ltd. has the
lowest emission factor of 0.46 TCO2e/ton while the company with the highest factor is Rishi
Cement Ltd. at 2.92 TCO2e/Ton cement. The range of the intensity with respect to the
average varies from 0.54 of Cochin Cement Ltd. to 1.97 of Rishi Cement Ltd.

OIP-2021
4. Discussion:
Effects on Environment: These emissions are not only deteriorating air quality but also
degrading human health. Emissions have local and global environment impact resulting in
global warming, ozone depletion, acid rain, biodiversity loss, reduced crop productivity etc.
Effects on Human Health: Scientific evidence indicates that air pollution from the
combustion of fossil fuels causes a spectrum of health effects from allergy to death. The
results of several studies showed that these emissions are adversely affecting human health in
a variety of ways, like itchy eyes, respiratory diseases like tuberculosis, chest discomfort,
chronic bronchitis, asthma attacks, cardio-vascular diseases and even premature death.
Effects on Human health  CO : Respiratory trouble  CO2: Global warming  SO2:

Respiratory, corrosion, skin effect  PAH(Peroxyl Acetyl Hydrocarbon): Leucoma,
carcinogenic  CFC : Ozone layer depletion  NOx : Forms photochemical smog, at higher
concentrations causes leaf damage or affects the photosynthetic activities of plants and causes
respiratory problems in mammals.  Particulate matter: Lead pollution causes damage to the
nervous system, lung, kidney disease, toxic effect in human. Coal ash causes respiratory
trouble.  Asbestos particles: Asbestosis – a cancerous disease of the lungs.  SiO2: Silicosis,
a cancerous disease.  Hg: Brain & kidney damage.
Following ways we can minimise the effects of pollutants as follows for a Cement plant of
10,000MT /day Capacity to reduce the effect of pollutants.
Methods of NOx removal 1. Scrubbing i. Absorption by liquids ii. Adsorption by solids  2.

Catalytic decomposition and reduction: involves decomposition of nitric oxide to N2 & O2.
3. 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 4.NOx to reduce NOx to N2. This system can be used to
prevent NOx formation in the cement kiln. Control of VOC: 1. the condensation method
makes use of the fact that sufficiently low temperature causes gaseous hydrocarbons to
condense to liquids. 2. In scrubbing towers absorbing liquid absorb VOC by intimate mixing.
5. Control of SO2 emission 1. Fuel substitution 2. Fuel desulphurization 3. Removal of SO2

from effluent gases Removal of SO2 from effluent gases: 1. Regenerative alkaline absorption
2. No regenerative alkaline absorption 3.Regenerative organic absorption 4. Catalytic
oxidation or reduction 5.Regerative solid adsorption 6. Furnace injection. 6. Baghouse In
these control devices, polluted air is filtered through the bags. The bags are closed at the

OIP-2021
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.
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. A
Cement plant of 10,000MT /day Capacity always need such Bag house to reduce the effect
of pollutants.
7. 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. A
Cement plant of 10,000MT /day Capacity always need such ESP to reduce the effect of
pollutants.
Installation of 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.
Steps to undertake 1. On-line continuous stack monitoring facilities for all the stacks and
adequate air pollution control systems shall be provided to keep emission levels below 50
mg/Nm3 and data submitted to the SPCB and CPCB regularly. ESP to kiln / raw mill, clinker
and CPP shall be provided to control air emissions. 2. Total water requirement from the
reservoir of abandoned mine pit shall not exceed 1,895 m3/day. No water from other surface
or ground water sources shall be used. All the treated wastewater shall be recycled and reused
in the process and/or for ash quenching, dust suppression, green belt development and other
plant related activities etc. No process wastewater shall be discharged outside the factory
premises and ‘zero’ discharge shall be adopted. Treated domestic effluent shall be used for
green belt development within the plant premises. 3. The fly ash from the power plant shall
be stored in silos and pneumatically transferred to the cement plant and used in the process
itself for manufacturing Pozollona Portland Cement (PPC). Bottom ash shall be disposed off
in abandoned mines or utilized in road making or given to brick kiln manufacturers. All the
cement dust collected from pollution control devices shall be recycled and reused in the
process and used for cement manufacturing. Sludge from domestic sources shall be used as

OIP-2021
manure for green belt development. Waste oil shall be sold to authorized recyclers/ re-
processors only. 4. High calorific value hazardous waste shall be utilized in the cement kiln
from Ranga Reddy, Medak and Patancheru Districts. Alternate & Biomass fuels (Rice Husk,
Cotton Stalk, Black Carbon, Pet coke) are being used in the plant. 5. Out of total 425.89 acre,
green belt shall be developed in 216.09 acres (51%) as per the CPCB guidelines to mitigate
the effects of air emissions in consultation with local DFO. 6. Green Belt shall be developed
along the boundary of the cement plant. 7. Regular annual medical examination of all the
employees shall be carried out from the occupational health point of view and records should
be maintained. 8. The gaseous and particulate matter emissions from various units shall
conform to the standards prescribed by the Pollution Control Board. At no time, the
particulate emissions from the cement plant shall exceed SPCB limit. Interlocking facility
shall be provided in the pollution control equipment, so that in the event of the pollution
control equipment not working, the respective unit(s) is shut down automatically. 9. One
Ambient Air Quality Monitoring Station shall be installed in downwind direction. Ambient
air quality including ambient noise levels shall not exceed the standards stipulated under EPA
or by the State authorities. Monitoring of Ambient Air Quality and Stack Emissions shall be
carried out regularly in consultation with SPCB and report submitted to the SPCB quarterly
and to the Ministry’s Regional Office at Bangalore half-yearly. 10. The company shall install
adequate dust collection and extraction system to control fugitive dust emissions at various
transfer points, raw mill handling (unloading, conveying, transporting, stacking), vehicular
movement, bagging and packing areas, etc. Asphalting/concreting of road and water spray all
around the stockyard and loading / unloading areas shall be carried out to control fugitive
emissions. Covered sheds for storage of raw materials and pneumatic conveying system for
fly ash and bed ash for conveying ash from boiler shall be provided. Coal, cement, fly ash
and clinker shall be stored in silos. Adequate number of bag filters. Total Number of
Pollution Control Equipment is as follows: ESPs – 7, Bag Filters – 99. All the transfer points
equipped with bag filters. Dump hoppers are equipped with water sprinkler system. Venting
systems are available for pneumatic Conveying System. All the circuits are having venting
system. Truck mounted Water Spraying system arranged in the plant to control fugitive
emissions. Concrete roads were laid down. Covered Sheds are available for storing raw
materials & fuel. Pneumatic conveying system provided for fly ash from ESP to Fly ash Silo.
Storage silos are available for in process materials and finished products.

OIP-2021
CEMENT SUSTAINABILITY INITIATIVE (CSI) The report lists eight major topics that
have been shaping the cement industry's path toward a more sustainable future over the
following 20 years: i. Resource productivity: Improving eco-efficiency through improved
practices in quarrying, energy use and waste recovery and reuse; ii. Climate protection:
Understanding and managing CO2 emissions; iii. Emission reduction: Reducing dust from
quarrying, NOx, SOx, and other airborne pollutants from cement manufacture; iv. Ecological
Management: Improving land-use and landscape management practices; v. Employee well-
being: Managing and improving employee health, safety and satisfaction; vi. Community
well-being: Working more effectively with local communities; vii. Regional development:
Participating in regional affairs; viii. Shareholder value: Creating more value for shareholder
research.
SUMMARY & CONCLUSION: It is well known act that air pollution is hazardous to
environment and human health. Due to infrastructure, developmental activities Cement
industry is flourishing & resulting in environmental degradation and in the degradation of
human health worldwide. The gaseous & particulate emissions from Cement plants are
degrading air quality & thus creating considerable environmental pollution especially air
pollution. A current trend in the field of cement production is the focus on low-energy
cements, utilization of waste in cement production and the associated reduction of CO2
emissions. Evaluation of cement impact to environment is a very important process. Impacts
related to global warming are due nearly exclusively to CO2, those for acidification are
mainly due to SOx (34%), NH3 (30%), N20 (17%), SO2 (13%) and NOx (6%) and impacts
for marine eco toxicity are essentially related to the emission of Fluorine and its inorganic
compounds (54%), barite and Barium (34%) and many heavy metals such as Vanadium (3%).
By adopting appropriate technology and computer modelling, industry will not only reduce
production waste but also comply with legislation to do with environmental protection,
control used for air and looks at how computer modelling can be adopted for the
classification, quantification and control of particulate matter; and how efficient energy use
can contribute to better air quality.

OIP-2021
References:
1. S K Mandal, S Madheswaran
Environmental efficiency of the Indian cement industry: An interstate analysis

Energy Policy, p. 1108 - 1118
Posted: 2010
2. R Rehan, M Nehdi
Carbon dioxide emissions and climate change: policy implications for the cement industry
Environmental Science & Policy, p. 105 - 114
Posted: 2005
Crossref
3. Paliwal Ritu
EIA practice in India and its evaluation using SWOT analysis

Environmental impact assessment review, p. 492 - 510
Posted: 2006
4. Ernst Worrell, Lynn, Nathan Price, Chris Martin, Leticia Hendriks, Ozawa, Meida
Carbon dioxide emissions from the global cement industry

Annual Review of Energy and the Environment, p. 303 - 329
Posted: 2001
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< Chemical Process Techonology>

<Subhasis Basu >

<Department Of Chemistry >

<Institute Of Science, Visva Bharti University>

13rd February to 31st March, 2021

Indian Institute of Chemical Engineers (IIChE)

Certificate from the IIChE

This is to certify that .........Subhasis Basu............................................................. from …….

……….Department Of Chemistry, Institute Of Science, Visva-Bharati University.

..................has successfully completed online internship programme in our organization. The

Chief Coordinator, OIP-2021

Indian Institute of Chemical Engineers 2

I am deeply indebted to our guide Prof.(Dr.)Sunilbaran Kuila, Chief Coordinator, OIP-

Indian Institute of Chemical Engineers 3

ONLINE INTERNSHIP PROGRAM (OIP-2021) BY IIChE SUBJECT: CHEMICAL

Module-I Pressure Vessels Fundamentals, Fabrication & Testing:

 Fundamentals of pressure vessel

 Design Codes & fabrication basics

 Testing & Inspection

Module-II Cement Manufacturing Industry:

 Cement Manufacturing Processes, Past and Present

 Equipment Handling and Operation of Cement plants

 Environment Impact of Cement Industries and Pollution Control devices

 Efficiency improvement techniques and Cement Industries in India

Module -III Pure Terephthalic Acid (PTA) Manufacturing Industry:

 Basic Operation Principles of Centrifugal Pumps: Pump performance curve analysis,

 Basic Operation Principles of Industrial Instruments : Concept on Flow

Module-IV Petrochemical Industry:

 Naphtha Cracking Process & product separation

 Polymers & Principle of Polymerizations

 Process technology and operations of Poly-Propylene (PP) manufacturing.

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Objectives of Online Internship Program

• Assist the student's development of employer-valued skills such as teamwork,

Indian Institute of Chemical Engineers 5

• Discussion on different industrial application

• Case study analysis

• Research and development

• Appendix: All assignments

Indian Institute of Chemical Engineers 6

History Of Indian Industry

Indian Institute of Chemical Engineers 7

Indian Institute of Chemical Engineers 8

Industrial applications are tailor-made applications with the requirements of extremely

Indian Institute of Chemical Engineers 9

Indian Institute of Chemical Engineers 10

Indian Institute of Chemical Engineers 11

Title: Life Cycle Assessment of Portland cement Industry:

Indian Institute of Chemical Engineers 12

Indian Institute of Chemical Engineers 13

Indian Institute of Chemical Engineers 14

(1) The conventional process for production of cement,

(2) Cement blends (natural pozzolans),

Indian Institute of Chemical Engineers 15

Indian Institute of Chemical Engineers 16

Indian Institute of Chemical Engineers 17