SUSTAINABLE PRODUCTION Sustainability Report of Cement Industry

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First and foremost, I would like to thank to our Faculty, Ms. Arti Solanki for the valuable

guidance and advice. She inspired us greatly to work in this project. Her willingness to motivate

& contributed tremendously to the project. I also would like to thank her for showing us some

example that related to the topic of our project.

Finally, an honourable mention goes to our families and friends for their understandings and

supports in completing this project.

-

Abhishek Gupta (DFT-6)

Department of Fashion Technology

National Institute of fashion Technology

2017

Gandhinagar

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CONTENTS

STEPS IN MANUFACTURE OF PORTLAND CEMENT ....................................................................... 5

ENVIRONMENTAL HAZARDS ....................................................................................................................... 11

Air Pollution ........................................................................................................................................................ 11

Particulate Matter ............................................................................................................................................. 11

PHYSICAL HAZARDS ........................................................................................................................................ 12

Noise ....................................................................................................................................................................... 12

Vibration ............................................................................................................................................................... 12

Heat Physical Hazards – Heat ....................................................................................................................... 12

Radiation ............................................................................................................................................................... 12

ENVIRONMENTAL IMPACTS ......................................................................................................................... 13

Consumption of raw materials ...................................................................................................................... 13

Consumption of energy .................................................................................................................................... 13

Consumption of water ...................................................................................................................................... 14

Emissions to water ............................................................................................................................................. 14

Emissions to air ................................................................................................................................................... 14

CRH plc ...................................................................................................................................................................... 16

Targeting Leading Class Sustainability ........................................................................................... 18

Managing Safety ................................................................................................................................................. 19

Focusing on Health ........................................................................................................................................... 21

Climate & Environment ................................................................................................................................... 21

CLOSED-LOOP ........................................................................................................................................................ 23

Utilising Externally Sourced Wastes ............................................................................................................ 23

Addressing the Challenges of Climate Change ............................................................................... 24

Manufacturing Low Carbon Cement ........................................................................................................... 25

Reducing Emissions to Air .............................................................................................................................. 26

UltraTech Cement ................................................................................................................................................ 27

Sustainability Targets & Progress ...................................................................................................... 28

CSI Dashboard ........................................................................................................................... 28

Focusing on Environmental Excellence .................................................................................... 30

Monitoring Emissions ................................................................................................................ 31

Energy Performance ................................................................................................................... 31

Constructive Use of Waste Material ........................................................................................... 32

Water Conservation Initiatives ................................................................................................... 32

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Cement is a water-based binder used to bind other building materials together. A cement is

any substance which binds together other materials by a combination of chemical processes

known collectively as ‘setting’.

Cements are dry powders and should not be confused with concretes or mortars, but they are

an important constituent of both of these materials, in which they act as the 'glue' that gives

strength to structures. Mortar is a mixture of cement and sand whereas concrete also includes

rough aggregates.

Cement production accounts for 5-6% of all man-made CO2 emissions. Around 50% of

emissions are from Decarbonation and around 40% from the fuel used.

As of 2006, about 7.5 cubic kilometres of concrete are made each year, more than one cubic

metre for every person on earth. The constant demand for all of these structures, increasingly

from the developing world, means that cement is the second most consumed commodity in

the world after water.

First cements produced by early Greeks and Romans from volcanic ash mixed with slaked

lime. This art was lost during the Middle Ages. Then, Portland cement developed in England

by bricklayer Joseph Aspdin in early 1800’s. Called “Portland” because concrete made with it

resembled natural stone from the Isle of Portland.

Portland cement is the most common type of cement in general use around the world,

used as a basic ingredient of concrete, mortar & stucco. It is a fine powder produced by

heating materials in a kiln to form what is called clinker, grinding the clinker, and adding

small amounts of other materials.

The low cost and widespread availability of the limestone, shales, and other naturally

occurring materials used in Portland cement make it one of the lowest-cost materials widely

used over the last century throughout the world. Concrete produced from Portland cement is

one of the most versatile construction materials available in the world

ASTM C150 defines Portland cement as "hydraulic cement” i.e. cement which not only

hardens by reacting with water but also forms a water-resistant product.

The European Standard EN 197-1 uses the following definition:

Portland cement clinker is a hydraulic material which shall consist of at least two-thirds by

mass of calcium silicates (3 CaO·SiO2 and 2 CaO·SiO2), the remainder consisting of

aluminium- and iron-containing clinker phases and other compounds. The ratio of CaO to

SiO2 shall not be less than 2.0. The magnesium oxide content (MgO) shall not exceed 5.0%

by mass.

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Basic Chemical Components of Portland cement:

Calcium (Ca)

Silicon (Si)

Aluminum (Al)

Iron (Fe)

Typical Raw Materials:

Limestone (CaCO3)

Sand (SiO2)

Shale, Clay (SiO2, Al2O3, Fe2O3)

Iron Ore/Mill Scale (Fe2O3)

Wet Process.

Dry Process - 74% of cement produced.

Preheater/Precalciner Process.

Wet process easiest to control chemistry & better for moist raw materials.

Wet process high fuel requirements - fuel needed to evaporate 30+% slurry water.

Dry process kilns less fuel requirements

Preheater/Precalciner further enhance fuel efficiency & allow for high production

rates.

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Steps in Manufacture of Portland cement The most common way to manufacture Portland cement is through a dry method. Cement

plant laboratories check each step in the manufacture of Portland cement by frequent

chemical and physical tests.

Although the dry process is the most modern and popular way to manufacture cement, some

kilns in the United States use a wet process. The two processes are essentially alike except in

the wet process, the raw materials are ground with water before being fed into the kiln.

1. Typical Quarry Operation

The first step is to quarry the principal raw materials, mainly limestone, clay, and other

materials. After quarrying the rock is crushed. This involves several stages. The first crushing

reduces the rock to a maximum size of about 6 inches. The rock then goes to secondary

crushers or hammer mills for reduction to about 3 inches or smaller.

The crushed rock is combined with other ingredients such as iron ore or fly ash and ground,

mixed, and fed to a cement kiln.

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2. Kiln Feed Operation

What’s Kiln?

Cement Kiln is the largest & hottest moving equipment in the manufacturing operation.

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The cement kiln heats all the ingredients to about 2,700 degrees Fahrenheit in huge

cylindrical steel rotary kilns lined with special firebricks.

Kiln Fuels

A typical cement kiln burns about 400# of Fuel to make a ton of Clinker (5.50mmBtu/ton of

clinker). Fuels can be any combustible Hydrocarbon such as:

Coal, Coke

Natural Gas

Used Motor Oil, Wood & Tires

Why Burn Wastes?

A cement kiln is a proven technology for recycling by beneficial REUSE of solid and

hazardous wastes. The benefits are:

energy recovery

material recovery

economics

environmental preservation

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3. Clinker & Grinding Mill

As the material moves through the kiln, certain elements are driven off in the form of gases.

The remaining elements unite to form a new substance called clinker. Clinker comes out of

the kiln as grey balls, about the size of marbles.

Clinker is discharged red-hot from the lower end of the kiln and generally is brought down

to handling temperature in various types of coolers. The heated air from the coolers is

returned to the kilns, a process that saves fuel and increases burning efficiency.

Raw material composition of Clinker

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After the clinker is cooled, cement plants grind it and mix it with small amounts of gypsum

and limestone. Cement is so fine that 1 pound of cement contains 150 billion grains. The

cement is now ready for transport to ready-mix concrete companies to be used in a variety

of construction projects.

Reduction at the source.

Recycling

Energy recovery

Incineration

Stabilization

Landfill

Benefits of a recycling Program

Allows for reuse of waste materials.

Conserves virgin fuels & raw materials.

Regulated stringently for Environmental

Protection.

A Cement Kiln is a proven technology for beneficial REUSE of otherwise waste

materials. The Benefits are:

Energy Recovery

Material Recovery

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ENVIRONMENTAL HAZARDS

There are 2 main types of environmental hazards associated with the cement manufacturing

process.

Air Pollution

Particulate Matter

Air Pollution

Emission of several compounds such as: NOx, SOx, CO2, and other fuel combustion

by products.

A possibility of pollutants being emitted at every stage of process.

Pyro processing stage emits a large portion of air pollutants: Nitrogen, water, CO2,

NOx, SOx, CO, and hydrocarbons.

Particulate Matter

Main source of pollution for the raw materials collection stage.

Clinker dust is the biggest issue.

Features such as bag house filters and hoods are used during the process in order to

minimize the clinker dust.

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PHYSICAL HAZARDS

Noise

Vibration

Temperature extremes

Radiation

Noise

Several factors influence the noise levels to which workers are exposed:

Type of equipment being operated

Condition/maintenance of the equipment

Other equipment running at the same time

Enclosed or partially enclosed spaces

Prolonged exposure to excessive noise levels can cause noise-induced hearing loss. When

you are exposed to excessive noise levels, the first stage is temporary hearing loss. Over time,

the hearing loss becomes permanent

Vibration

Workers can be exposed to vibration affecting the entire body or only to the hand and arm.

Whole-body vibration can occur from operating large mobile equipment, such as drillers, air

hammers, pile drivers, tractors, graders, excavators, earth-moving equipment, and other large

machinery.

Hand-arm vibration can result from using hand-held power tools, such as pneumatic drills

and hammers, and disc grinders. Whole-body vibration can occur from operating large

mobile equipment, such as drillers, air hammers, pile drivers, tractors, graders, excavators,

earth-moving equipment, and other large machinery.

Heat Physical Hazards – Heat

Prolonged work under direct sunlight in summer (e.g., asphalt paving or roofing in

summer)

Wearing impermeable protective clothing when doing heavy work.

Working in an enclosed area with a strong heat source, poor ventilation, and high

humidity (e.g., heavy equipment operators in an enclosed cab with without sufficient

ventilation)

Radiation

X-rays, gamma rays from equipment used to gauge the density and thickness of pipes,

to inspect welds, for detecting weakness of metal structures on a construction site

radioactive isotopes from flow meters

Health effects: increased risk of developing cancer and genetic disease

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ENVIRONMENTAL IMPACTS

The main environmental issues associated with cement production are consumption of raw

materials and energy use as well as emissions to air. Waste water discharge is usually limited

to surface run off and cooling water only and causes no substantial contribution to water

pollution. The storage and handling of fuels is a potential source of contamination of soil and

groundwater. Additionally, the environment can be affected by noise and odors.

The key polluting substances emitted to air are:

Dust

carbon oxides nitrogen oxides (NOx)

sulphur dioxide (SO2)

Carbon oxides, polychlorinated dibenzo-p-dioxins and

Dibenzofurans

Some forms of total organic carbon, metals, hydrogen chloride and hydrogen fluoride

are emitted as well.

The type and quantity of air pollution depend on different parameters, e.g. inputs (the raw

materials and fuels used) and the type of process applied.

Consumption of raw materials

The use of wastes as raw materials in the clinker burning process can replace a relatively

large amount of raw materials. The quantities of wastes used as raw materials in clinker

production have more than doubled since 2001.

--Lviv Polytechnic National University Institutional Repository http://ena.lp.edu.ua

Consumption of energy

The cement production needs the very high amount of energy. Energy cost represents 40% of

total production costs involved in producing of 1 tonne of cement. Thermal energy demand

(fuel) and electrical energy demand are the most important. Specific energy consumption

depends on size and plant design, raw materials properties and its moisture, specific caloric

values of fuel, throughput of kiln, type of clinker and many other factors.

Thermal energy demand is in range of 3000 - 6500 MJ per 1 tone of clinker, the electricity

demand range from 90 to 150 kWh per 1 tonne of cement.

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Consumption of water

Water is used at a number of stages during the production process. In only some cases, water

is used for the preparation of raw material, in clinker burning and cooling processes, such as

the cooling of gases, as well as in the technological process for slurry production. In the semi-

dry process, water is used for pelletizing the dry raw meal. Plants using the wet process use

more water (per tonne of cement produced) in preparing the kiln feed slurry and a typical

water consumption of 100 – 600 litres water per tonne clinker is reported. Furthermore, for

special applications, water is used for clinker cooling and a water usage of around 5 m3/hour

has been reported. In most cases, the water consumed is not potable water.

Emissions to water

In general, cement production does not generate effluent. In cement production by using the dry or the

semi-dry process, water is only used in small quantities, e.g. for cleaning processes.

In principle, no emissions to water occur because water is recycled back into the process.

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.

Emissions to air

Emissions to air and noise emissions arise during the manufacture of cement. Furthermore

with regard to the use of waste, odours can arise, e.g. from the storage and handling of waste.

In this section, ranges of air pollutant emissions are presented for the process of cement

production, including other process steps, such as the storage and handling of, e.g. raw

materials, additives and fuels including waste fuels.

The IPPC Directive includes a general indicative list of the main air-polluting substances to

be taken into account, if they are relevant for fixing emission limit values. Relevant to cement

manufacture including the use of waste are:

Oxides of nitrogen (NOx) and other nitrogen compounds,

Sulphur dioxide (SO2) and other sulphur compounds dust,

Total organic compounds (TOC) including volatile organic compounds (VOC),

Polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDDs and PCDFs),

Metals and their compounds,

Hydrogen fluoride (HF),

Hydrogen chloride (HCl),

Carbon monoxide (CO).

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--Lviv Polytechnic National University Institutional Repository http://ena.lp.edu.ua

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C.E.O. – Albert Manifold

Founded - Irish Cement Limited (1936), Roadstone Limited (1949) & merger (1970)

Industry - Building Materials

Headquarters - Dublin, Ireland

Sustainability Report Year- 2015

CRH plc is a leading global diversified building materials group, employing

89,000 people at over 3,900 operating locations in 31 countries worldwide.

CRH’s vision is to be the leading building materials business in the world. The Group

believes that strong Corporate Social Responsibility and Sustainability practices are

fundamental to achieving its vision and has embedded these concepts into its business model.

CRH is dedicated to extensive and transparent reporting of its sustainability performance.

This Report is CRH’s thirteenth annual Sustainability Report and covers activities during

2015.

About CRH

A Fortune 500 company, CRH is listed in London and Dublin and is a constituent member of

the FTSE 100 and the ISEQ 20 indices. CRH’s market capitalisation at 31 December

2015 was approximately €22 billion. CRH is ranked among sector leaders by a number of

Socially Responsible Investment rating agencies for its sustainability and CSR performance.

The Group’s major businesses are in the developed markets of Europe and North America,

and it has growing positions in developing economies in Asia, including India and China.

Operations focus on three closely related core businesses:

1) Primary materials,

2) Value-added building products &

3) Building materials distribution.

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Targeting Leading Class Sustainability

CRH’s vision is to be the leading building materials business in the world and in doing so to

create value and deliver superior returns. Conducting business in a responsible and

sustainable manner is identified as key to delivering this strategy.

Strategic Priority: To ensure the safety of everyone in the Workplace

Priority Areas Ambition

Policy

Implementation Continue to refine the Health & Safety & implement consistently

in acquisitions

Continuously improve Safety Performance

Safety Management Continue to develop & invest in safety management initiatives

Accident Prevention Target: zero accidents at every location

Continue +ve trend in reduction of frequency & severity of

accidents

Fatality Elimination Target: elimination of all fatalities

Continue to focus on implementation & auditing of Fatality

Elimination Plan

Contractor safety Develop a partnership approach & continue to monitor contractor

safety, implement contractor safety procedures

Employee Health Continue to implement the documented policies & procedures

that follow best practice in occupational health, including

employee health & workplace monitoring

Strategic Priority: To achieve the highest standards of environmental management

& proactively address the challenges of Climate change

Priority Areas Ambition

Policy Implementation Continue to refine the Health & Safety & implement

consistently in acquisitions

Continuously improve Environmental Performance

Sustainable Products Continue to develop & promote transformative products that

benefit the built environment

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Continue to consider & improve sustainability of products

throughout their life cycle

Climate Target: to reduce specific net cement CO2 emissions by 25%

(2020 vs.1990)

After achieving 2015 targets 3 years of schedule, continue to

implement strategic programmes aimed at reducing specific

CO2 emissions in all activities

Energy Continue with strategic energy reduction programmes at all

activities

Emissions Target: to reduce specific cement dust emissions by 80% &

NO, by 22% (2020 vs.1990)

After achieving 2015 targets 3 years of schedule, continue

progress towards achieving new targets

Natural Capital Continue to improve water & waste management &

Recycling

Currently focussing on formalising a biodiversity

management strategy at all locations within, containing or

adjacent to protected biodiversity areas

Target: 100% of quarries & pits to have reinstatement plans

Environmental

Investment Continue to develop investment plans to improve

performance & other innovative opportunities

Managing Safety CRH’s Health &

Safety Policy, applied rigorously across all Group companies, is

Comply as a minimum, with all applicable health and safety legislation and

continuously improve our health and safety stewardship, aiming all the time to meet or

exceed industry best practice.

Ensure that our companies provide a healthy and safe workplace for all employees and

contractors and take due care of customers and visitors at our locations.

Insist that all employees and contractors respect the Group’s health and safety

guidelines.

Require all employees and contractors to work in a safe manner as mandated.

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Continued Strong Safety Performance

10 %reduction in annual accident frequency rate on 2014

€138minvested in safety over the last 5 years

31,000 locations with safety audits

Preventing Accidents

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Focusing on Health

CRH continues to promote healthy work practices and to implement employee health and

wellbeing programmes.

Specific health issues within the building materials industry include occupational noise

levels, occupational levels of airborne dust and the potential for respirable crystalline silica

(RCS).

Climate & Environment

CRH’s Environment& Climate Policy, applied rigorously across all Group companies, is to:

Comply as a minimum, with all applicable environmental legislation and

continuously improve our environmental stewardship, aiming all the time to meet or

exceed industry best practice.

Optimise our use of energy and all resources.

Ensure that our employees and contractors respect their environmental

responsibilities

Promote environmentally-driven product and process innovation and new business

opportunities.

Address proactively the challenges and opportunities of climate change.

Develop positive relationships and strive to be good neighbours in every community

in which we operate

Environments Aspects by activity

Activity Climate

Change/CO2

Other Air

Emissions

Water Waste Reinstatement Biodiversity Transport

Cement

Lime

Materials

Concrete

Products

Building

Products

Distribution

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Focusing on Environmental Excellence

Sustainable Products

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CLOSED-LOOP

In 2015, a total of 22.8m tonnes of waste and 1.6m tonnes of by-products were used,

substituting 8% of virgin materials overall. Other raw materials used were 275m tonnes of

virgin raw materials, 5.4m tonnes of associated process materials, 54m tonnes of semi-

manufactured components (such as sheet metal and float glass) and 140k tonnes of packaging

material.

Utilising Externally Sourced Wastes

9.7m Tonnes of RAP & Shingles

Recycled Asphalt Pavement (RAP) materials arise when existing road or runway

surfaces are milled or crushed and reused as a raw material for new asphalt mixes.

7.3m Tonnes of C&D

Construction & Demolition (C&D) materials arise from construction and demolition

activities and can replace virgin aggregates or can be reused for fill applications.

5.8m Tonnes of Other Materials

Fly-ash, slag and other materials with cementitious properties are by-product

materials sourced mainly from external power generation and steel production and

replace virgin materials in cement, concrete and concrete products.

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Addressing the Challenges of Climate

Change

CRH has endorsed the World Business Council for Sustainable Development (WBCSD) Low

Carbon Technology Partnership Initiative (LCTPi), a statement of ambition, which seeks a

reduction in global cement CO2 emissions in the range of 20–25% by 2030.

CRH is actively involved in global and regional discussions on the climate change agenda

through its membership of the Cement Sustainability Initiative of the WBCSD, as well as, in

Europe, CEMBUREAU and the European Lime Association, and in the US, the National

Asphalt Pavement Association and the Portland Cement Association.

Climate Change Mitigation in Diversification

% of Group

2015 CO2

Emissions

CO2 Sources Mitigation & Adaptation

Cement 82% Both from the high

temp. chemical

decarbonation of

the limestone, &

from fuel

combustion

Alternative fuels

Alternative raw

materials

Process optimisation

Plant upgrades with

energy efficient

equipment &

technology

Asphalt, aggregates

& ready mixed

concrete

9% Energy use for

drying & heating of

raw materials in

asphalt plants, in

excavation &

processing of sand

& aggregates, &

also in operation of

ready mixed

concrete plants

Process optimisation

Plant upgrades with

energy efficient

equipment &

technology

Optimising product

design

Alternative raw

materials

Recycled materials

Alternative fuels

Optimising concrete

mix design

Heat recovery

Lime 5% Both from the high

temperature

chemical

decarbonation of

Process optimisation

Plant upgrades with

energy efficient

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the limestone, and

from fuel

combustion

equipment &

technology

Manufactured

concrete & clay

products, & other

building products

2% Energy use in

factories Using carbon-fibre

reinforcement in

concrete

Developing energy

saving products &

solutions

Renewable energy

sources

Transport 2% Energy use in

vehicles Use of energy efficient

vehicles

Electric vehicles

Distribution <1% Energy use in

stores Optimising logistics

Promoting sustainable

product

Manufacturing Low Carbon Cement

The manufacture of low carbon cement is key to achieving the CO2 reduction target.

Approximately 60% of CO2 in cement production arises from decarbonation. The remaining

40% arises from the fuels used to reach the high temperatures required.

3.8m tonnes of alternative materials were used by CRH’s cement plants in 2015

1.6m tonnes of alternative fuels provided 30% of CRH’s cement plants’ fuel

requirements

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Reducing Emissions to Air

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Chairman. – Kumar Mangalam Birla

Founded - 1983

Industry - Building Materials

Headquarters – Mumbai, India

Sustainability Report Year- 2015

About UltraTech

Ultratech Cement was incorporated in 2000 as Larsen & Toubro. Later it was demerged and

acquired by Grasim and was renamed as Ultra Tech Cement in 2004. With an annual capacity

of 63 million, UltraTech Cement is the largest cement company in India and amongst the

leading producers of cement globally. UltraTech is also the largest manufacturer of white

cement and ready mix concrete (RMC) in India. It manufactures and markets Ordinary

Portland Cement, Portland Blast Furnace Slag Cement and Portland Pozzalana Cement. It

also manufactures ready mix concrete (RMC).

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Sustainability Targets & Progress

CSI Dashboard Cement Sustainability Initiative (CSI), part of World Business Council for Sustainable

Development (WBCSD), is an endeavour by 25 major cement producers spread across more

than 100 countries.

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Focusing on Environmental Excellence

During the reporting period, we made significant progress on our environment agenda and

invested INR 2,196 million (USD 35 million) across the following five pillars of our

environmental strategy:

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Monitoring Emissions

Energy Performance

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Constructive Use of Waste Material

Water Conservation Initiatives

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http://www.adityabirla.com/businesses/Profile/Ultratech-cement-limited

http://www.crh.com

http://www.globalcement.com/magazine/articles/490-cement-101-an-introduction-to-

the-worlds-most-important-building-material

https://www.linkedin.com/pulse/common-hazards-control-measures-cement-plant-

akm-aziz

http://foundationsakc.com/process/environment-impact