A study environmental conservation by co-processing at Kymore Cement Works (KCW)
Student name: Mr Kamran Ahmed
Guide: Dr Prateek Sharma
Year of completion: 2012
Host Organisation: ACC Limited, New Delhi
Supervisor (Host Organisation): Ms Romita Roshan Pandita
Abstract: Co-processing is utilisation of waste materials as AFR (Alternate Fuel and Raw Material) in the
manufacturing process. In the present study different aspects of co-processing involved in
cement industry has been studied focussing on the issues of waste management, climate change
and energy conservation. Thermal substitution Rate (TSR) is used as a parameter to reflect
energy conservation. Study was carried out for Kymore Cement Works (KCW). Other objective
of the project was to study the initiatives taken by KCW for co-processing. Waste and thermal
energy consumption data of KCW for January’11 to March’12 was used for the study. It has
been found that co-processing helps in energy conservation and at KCW around 1244.53 T of
coal was saved during December’11 with TSR of ~ 3.28 because of high consumption of waste
materials. Agricultural waste shows the highest contribution towards increasing TSR which was
observed maximum (~ 4.97) during February’12 with its consumption of 2771.58 T. Observing
importance of biomass towards energy conservation further study was carried out to estimate
agricultural waste available from nearby villages. For the study 11villages within 15-20 km
radius from KCW were randomly selected and Focus Group Discussion (FGD) was carried out
with representatives of farmers. With the help of local contacts, the number of farmers included
for the discussion was 5-7. Rice and gram are the major crops grown in the area and their
respective residues expected to be available are 2350 T and 2505 T. Further it was calculated for
KCW that maximum decrease in CO2 emission was ~ 4624.38 T and that too during the month
with maximum TSR. After the study it can be concluded that KCW has been putting lots of effort
to promote co-processing and co-processing provides a solution to the problem of energy
conservation, waste management and climate change.
Key words: Co-processing, Thermal Substitution Rate (TSR), Alternate Fuel and Raw Material
(AFR), Kymore Cement Works (KCW) and Focus Group Discussion (FGD)
