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USJE Cement Factory: Environmental Impact Mitigation and Compliance

Learn about the USJE Cement Factory in Skopje, its environmental impact, and the measures taken to mitigate it. Explore the action plan for compliance with environmental legislation and the cost/benefit analysis for implementing best available techniques (BAT).

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USJE Cement Factory: Environmental Impact Mitigation and Compliance

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  1. Prague 2004

  2. Plant Data Kilns 2 x 1,300 tpd clinker • Vertical Coal Mill 15 tph • Cement Mills 3 x 100 tph + 1 x 30 tph • Own Quarries for Marl, Limestone and Sand • Reserves of Raw Materials: Approximately 30 Years for marl and limestone • Insulation Material Production Plant • RMC Plant • Number of Employees: 574

  3. Location of “USJE” • Located in the southeastern part of Skopje • 3.5 km. from the center of the town • Surrounded by civilian houses

  4. The location of the factory brings up the: ENVIRONMENTALQUESTION

  5. The manufacturing of the cement influences the environment • Excavation of the raw materials changes the landscape • Transportation of the raw materials as a source of dust • The production of clinker has the biggest impact on the environment • Big usage of energy • Air emissions ( dust, SO2, NOx, CO…) • Storage of clinker, grinding of clinker and packing of cement are also dust sources

  6. The environmental impact of the working processes of “USJE” has been mitigated through the technical and technological interventions

  7. These improvements are accomplished through the years • 1993 – Two concrete silos for clinker (25000 tones each) with a closed belt conveyer and a complete dedusting system • 1993 – Electrostatic precipitator for clinker cooler (each kiln has it) • 1997 – Gasification of the boiler room for production of steam

  8. 1999 – Bag filters for cement mills 4, 5 & 6 • 1999 – Bag filter for rotary Kiln No. 3 • 2001 – Vertical mill for petcoke, with bag filter and system for fire protection • 2003 – Bag filter for rotary Kiln No. 4 • 2004 – Puzzolana substituted by Fly Ash

  9. Continuous Emissions Monitoring • Installation of a network which connects all measuring instruments • Instruments for dust measurement installed on: • Coal Mills • Cement Mills • Raw Mill Preparation • Exhaust Gases • Instruments for measurement of SO2, NOx, and flow installed on: • Stack

  10. August 2004 – integration of all “in – situ” signals in the network (company “SICK” has installed the software program “MEAC 2000”) • ON – LINE regular reporting on a 30 min basis

  11. Trial use of shredded tyres as an alternative fuel in rotary Kiln No. 4 Phase 1: Getting necessary permissions Phase 2: ACTION PLAN – Internal preparation of the plant Phase 3: Experimental testing: 15th – 17th September 2004 Phase 4: Results from the testing

  12. Environmental Legislation • Current Law in force • Limit values: • SO2 = 400 mg/Nm3 ( mean 67,9-USJE ) • NOx = 1300 mg/Nm3 (mean 834,6-USJE) • Dust = 50 mg/Nm3 (mean 15,8-USJE) • Proposed version that is in Parliamentary procedure adjusted to the EU Law

  13. To comply with BAT • Raw materials handling and storage • Pre-blending system • Excess clinker storage • Fuel preparation • Bag filter for the horizontal coal mill • Process • Process optimisation • NOx reduction

  14. To comply with BAT • Process (cont.) • Electricity use optimisation • ESP reconstruction or bag filters for cement mills • Bag filters for clinker coolers • Noise reduction • EMS establishing • ISO 14000

  15. Cost/Benefit Analysis for BAT compliance • Estimated total Investment costs • 6.100.000 (consultants estimation) • Estimated Difference in Operation Costs • - 475.000 /year(consultants estimation) (Only SNCR increases operation costs)

  16. Conclusion • Applying BAT will have an impact on the competitiveness of the company due to a long pay-back period • The impact can be minimised by allowing a reasonable number of years for successive investment

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