Limestone Dome for Cement Plants

Limestone is the major raw material in cement plants. The limestone most suitable for cement production must have some ingredients in specified quantities like calcium carbonates, silica, alumina, and iron etc. Cement plants must insure their product has consistent properties over time, but most limestone quarries produce materials of varying chemical composition. To obtain consistent quality in the final product, quarried raw materials must be blended before being fed into the kiln, but if done in the open, blending limestone may produce large amount of dust.

Limestone Dome:

For cement production, limestone is first reduced in size by processing through a series of crushers and grinders. This fine powered form of limestone is then mixed with some mineral aggregates (siliceous, aluminous and ferrous material) and water in high temperature kiln to form clinker. After cooling the clinker will be stored in clinker dome. The nodules of cement clinker are then ground to the consistency of face powder to produce powered cement.

• Quick and Facilitating: Material handling of Limestone is based on numerous processes like loading, unloading, transportation, storing and feeding. In cement production industry, these numerous process stages may be in different locations, and each may have different feed conditions. Processing system will perform precisely only when there is a proper set up for material storage and handling. Limestone storage provides opportunity to get an efficient set up for material storage and handling process to utilize maximum space and also helpful for labor to have convenience in almost all operational works. All such facilities under single dome not only make the cement plant operation handy & hasty but also maintain energy efficiency level.
• Flexible: Flexibility of limestone dome can be seen by its capability to cater maximum space for storing limestone and how versatile it is with additional storage of various additive used in cement production. These domes not only covers a large span to facilitate storage of various additives under the same shed but also its future development can also be done if more space is needed.

About Hindustan Alcox Limited:

We at Hindustan Alcox Limited, one of the leading limestone dome and bulk storage manufacturers use the combination of geodesic domes and latest technology to make dome structure more functionally suitable and highly versatile in installation/re-installation as well as in maintenance. What can Hindustan Alcox do for you? If you would like more information, please fill our inquiry form.

Read Also – Space Frame for Roof Construction

Environmental Impacts of Coal Based Thermal Power Plants

A Captive thermal power plant is usually defined by the type of fuel used to heat the water and create system. A fossil-fuel power plant is one that burns fossil fuels such as coal, natural gas or petroleum to produce electricity. A thermal power station is a power plant in which the prime mover is steam driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical generator. After it passes through turbine, the steam is condensed in a condenser and recycled to where it was heated; this is known as a Rankine cycle.

Air Pollution:

• Burning coal releases massive amount of Toxic materials such as Mercury and Arsenic
• Coal based thermal power plants are responsible for 21% of the green house gas emission.
• Thermal power plant using coal releases 11 million tons of sulphur dioxide into the air

Water Pollution:

• Decrease in DO (Dissolved Oxygen) Levels
• Increase in Toxins
• Loss of Biodiversity
• Ecological Impact
• Increases Metabolic Rate
• Migration

Land Pollution:

• Change in Climate patterns
• Environmental Impact
• Effect on Human health
• Distraction for tourist
• Effect on Wildlife

Due to these harmful impacts of Thermal power plant, Coal storage sheds are the suitable solution to address the issues listed above. With the help of coal storage sheds, these problems can be eradicated easily without damaging the environment. These sheds also protect from spontaneous combustion of coal and installation of this structure does not impact the productivity of the plant.

About Hindustan Alcox

We at Hindustan Alcox are the leading coal storage shed manufacturer in India. We provide practical solutions to these above challenges, in most efficient and cost reducing ways and satisfy our clients with the best available solutions in storage and handling of any type of bulk storage.

Read Also – Coal – It’s Storage and Uses

Coal – It’s Storage and Uses

Coal is used as one of the fossil fuel which is combustible black/brown hard rock usually found in coal beds. Coal is composed of 65-95% carbon with quantities of other elements such as hydrogen, nitrogen, sulphur and oxygen. Extracted from the ground by coal mining, coal is the biggest source of energy for the worldwide electricity generation. In simple terms, there exist four types of coal – peat, lignite (brown coal), bituminous and anthracite (highest quality coal). Coal formation has occurred over long period of time, often under high pressure of overburden at elevated temperature.

Coal Storage

The key purpose of coal storage is to provide reserves for power plant and factories. Storage for coal is important for many reasons to ensure smooth operation of power plants and industries utilizing coal, to also allow the management to take advantage of seasonal market conditions in prices of coal. During coal storage, the coal stored has the tendency to combine with oxygen of air and during this process coal degrades its heating value and ignition quality. Due to oxidation the coal may ignite spontaneously.

Coal Storage shed is the most efficient method to prevent the coal from this problem. The significance of coal storage sheds is to produce efficient industrial result from coal by avoiding problems faced in coal stacking like oxidation of coal, spontaneous combustion, self heating of coal and many more.

 Uses of Coal

• Coal is used in captive thermal power plants for generating electricity
• Coal is indirectly used to make steel in the steel industry
• Coal is also an important ingredient in the production of specialist product such as activated carbons, carbon fibre and silicon metals.

 About Hindustan Alcox Limited

One of the premier and well-versed entity as coal shed manufacturer in India, Hindustan Alcox Limited has a vast experience of 30 years in creating Coal storage shed. We customize and engineer our projects with the best available solution in storage and handling of any type of bulk storage.

READ ALSO – Why To opt for Steel Frame Construction

Lignite Storage Shed

Lignite coal is a natural resource which is readily available. It is generally dark brown or rarely black coal that formed from peat at shallow depths and temperature lower than 100°C. The calorific value of Lignite coal ranges from 8000 KJ/kg to 15000 KJ/Kg. It also has a high moisture content in the range of 45% to 55%. Due to its High Moisture content and low calorific value, it is mostly used in generating electricity. Lignite-Generated Electricity is generally low in cost and environmentally acceptable.

Uses of Lignite:

• 79% of the total lignite coal is used to generate electricity.
• 5% of the coal is used to generate synthetic natural gas.
• 5% of lignite coal is used to produce various fertilizer products.

Issues related to Environment:

• The calorific value of lignite is low due to which, the quantity of coal needed is high.
• This has a higher CO2 emission due to high moisture content and lower carbon content as compared to black coals.
• Lignite mining involves the removal of a huge portion of water. Depending on the quality of the water, it could create agriculture or an environmental issue.

Lignite storage shed is the best possible solution to these problem related to the environment. Lignite storage sheds are often built over operating stockpiles since construction can proceed without interrupting operations.

Advantages of Lignite Storage Shed:

• Protect environmental degradation in nearby areas.
• Lesser Operation and Maintenance cost
• For achieving adequate prevention and control of potential fugitive emission
• Adhere to the current environmental guidelines by CPCB (Central Pollution control board)

About Hindustan Alcox

As a leading Lignite storage shed manufacturer, Hindustan Alcox Limited provides the complete & unique lignite storage shed ensuring best quality at every stage of its construction.

READ MORE – Reasons to Build Geodesic Dome Structures

Coal Based Thermal Power Plant: Advantages & Disadvantages

At present 75.43% of the total installed captive and non-captive power generation in India is constituted by Thermal power plants. A Captive Thermal Power Plant converts the heat energy of coal into electrical energy. Coal is burnt in the boiler which converts water into steam. The expansion of steam in turbine produces mechanical power which drives the alternator coupled to turbine. Captive Thermal Power Plants contribute maximum to the generation of Power for any country. Coal, oil and natural gas are considered as primary sources of energy in thermal generating stations.

Coal is the most favorable source of energy as coal provide usable energy at a cost of between 12% to 15% compared to oil and natural gas, and coal prices are also relatively stable. But the problems of coal storage are the biggest challenge faced in the thermal power plant which includes:

• Risk of spontaneous combustion
• Weathering
• Possibility of loss and deterioration during storage

To overcome these problems, coal sheds are being used to protect the coal storage from these kinds of problems which results in significant losses.

Advantages of coal based Thermal Power Plant:

• They can answer to rapidly changing loads without difficulty
• A chunk of the steam generated can be used as a process steam in different industries.
• Steam engines and turbines can work under 25% of overload continuously
• Fuel used is not very costly
• Economical in production cost in comparison with that of diesel power stations.

Disadvantages of coal based Thermal Power Plant:

• Maintenance and operation cost are high
• A large amount of water is required
• Great difficulty experienced in coal handling
• Unavailability of good quantity coal
• Maximum of heat energy lost
• Problems of ash removing

About Hindustan Alcox

With long –term experience of over 30 years, Hindustan Alcox limited identifies and eliminates unnecessary energy losses from the processes by providing the best choice for covering coal stockpiles under Coal storage shed. Alternatively, coal storage can also be done under dome structure sheds (like Coal dome, petcoke dome).

Read More – Types of Space Frames

Petcoke Storage: Best Practices to Control Petcoke Emissions & Spontaneous Combustion

Petcoke storage:

Similar to coal, Petcoke (a by-product of the oil refining process) is widely used in thermal power plants for power generation due to its higher carbon emissions than already carbon-intensive coal. Petcoke is also used as a complementary fuel in cement industries.

Many concerns about possible public health consequences by petcoke emission have been raised due to the establishment of large outdoor petcoke storage. Moreover during its bulk storage, many problems like spontaneous combustion, fugitive emission etc can occur at any stage of transport, storage & handling which is also a reason for the inefficient power generation at captive thermal power plant.

 

Best Practices to Control Petcoke Emissions & Spontaneous combustion:

Petcoke Storage Shed

To control Petcoke emission, a variety of procedures & techniques should be followed based on knowledge of specific facility and product conditions. Followings are the best practices that should be adopted to control petcoke emission:-

• Stockpile Handling & Maintenance: Following the “first in, first out” rule in petcoke stocking and stacking under petcoke dome or petcoke storage shed reduces the chances for hot spots in stockpiles by dissuading heat build up for portions of petcoke stockpiles so that the handling procedure may remain undisturbed for a long term. Moreover, proper maintenance of petcoke stockpiles like ‘piles compaction’, ‘piles stacking with minimum drop height’ etc will help to reduce petcoke fugitive emission.

 

• Wetting with water: The systematic application of water to petcoke helps to control fugitive dust emissions and maintain product moisture content. This periodic reapplication of water is generally needed to overcome the hydrophobic nature of petroleum coke.

 

• Maintenance of Temperature: It is better to maintain the ambient temperature near a specific threshold during plant operation not only for avoiding the problems of spontaneous combustion & fugitive emission but also for obtaining efficient power output.

 

• Electronic controls & self-checking systems: Automatic calibration with electronic equipments as well as manual calibration and checking should also be performed at regular basis to avoid Spontaneous Combustion in petcoke storage plants.

 

 

 –  Hindustan Alcox Limited, New Delhi

(Petcoke storage shed Manufacturers)

Sulphur Storage: Factors affecting losses during its storage & handling

Sulphur Storage:

Large quantities of sulphur are transported, stored, handled & comsumed as an additive in cement industry. Various storage methods are required to ensure that the sulphur is not contaminated & it doesn’t damage equipment from corrosion, fires, etc. The stored sulphur usually exist in larger pieces & posses many sharp edges due to irregularity in shapes which can be easily broken into its smaller particles.

Factors affecting losses of sulphur during its storage & handling:

Sulphur storage sheds

Being a brittle material, sulphur is easily degraded during its handling procedures. Minimum Losses will occur during the loading/unloading, transportation of sulphur due to the creation of airborne dust. The losses that occurs during its handling depends upon the following factors:

• Form of sulphur being handled
• Ambient Environmental conditions (i.e. wind speed and direction)
• Handling procedures/methods
• Exposure to air, sunlight and rain

Indoor bulk storage of sulphur is recommeded in order to minimize losses and contamination of sulphur. One of the premier and well-versed entity as sulphur storage shed manufacturer in india, Hindustan Alcox Limited has a vast experience of 30 years in creating sulphur dome & suphur storage shed. Providing storage & handling of sulphur storage, these world-class structures minimizes the issues to be faced in storage & handling of its bulk storage.

– Hindustan Alcox Limited

(Sulphur storage Sheds Manufacturer in India)

Flue gas de-sulphurized (FGD) gypsum – An Important By-product of cement industry

Role of gypsum in cement Industry:

Limestone, gypsum, slag & other additives are the most common raw materials used in cement production. Gypsum is a soft, transparent or translucent mineral composed of crystallised calcium sulphate (CaSO4), found naturally in sedimentary deposits. Gypsum is added to cement to regulate the extreme setting reaction which occurs in the presence of water. Besides influencing the setting time, gypsum also has an influence on other properties of cement such as strength development, volume stability etc.  

FGD storage sheds

Flue gas de-sulphurized (FGD) gypsum (An Important By-product of cement industry):

FGD gypsum results from the emissions cleaning process known as flue gas desulphurisation (FGD), at coal fired electricity generating stations. The cleaning of flue gases is carried out when finely ground limestone (or lime) reacts with sulphur dioxide emissions to produce a pure gypsum. In some cement industries, a multistep manufacturing process with electric utilities are carried out to meet precise product specifications for FGD gypsum. Followings are the importance of FGD gypsum, as by-product of cement industry:

• Contribution as an end product
• Environment Friendly
• Highly Economic
• Higher Purity Than Natural resources

 

Hindustan Alcox Limited take pride to be one of the top gypsum storage shed manufacturer  in India by offering world-class sheds in form of barrel vault structural sheds or gypsum domes. The Company has wide experience of about 30 years in building FGD sheds  with long span steel structure having span of up to 150 m & height of up to 40 m.

 

– Hindustan Alcox Limited, New delhi

(FGD Shed – Specialist)

 

 

Coal Gasification: Best practice to generate clean power from coal

Coal Gasification:

Coal Gasification is a process that can turn coal into clean power, chemicals, hydrogen & transportation fuels that can be further used to generate electricity or steam. These coal gasification systems are introduced in captive thermal power plants with advanced technologies to reduce the cost and increase the efficiency.

Coal Gasifiers convert hydrocarbons into a synthesis gas (syngas) at elevated pressures & temperatures and can be used to create many products such as electric power, chemical feedstock, liquid fuels, hydrogen, synthetic gas.

Why Coal Gasification is best practice to generate clean power from coal storage?

Coal Gasification is usually considered as best practice to generate clean energy from coal storage. The aim of coal gasification is to generate power which is an important consideration in the future of hydrogen fueled electricity generation.

Providing numerous opportunities for pollution control, especially with respect to emissions of sulfur, nitrous oxides, and mercury, coal gasification also increases the resource availability for power generation. Followings are the main advantages that persists with a coal power plant integrated with coal gasification:-

• Environmental Performance
• Maximizing power or efficiency
• Long life
• Reduced Volume of solid wastes
• Free from dust & noise pollution

Coal Storage Sheds

With long-term experience of 30 years, Hindustan Alcox Limited identifies and eliminates unnecessary energy losses from the processes by providing the best choice for covering coal stockpiles under Coal storage shed. Alternatively, Coal Storage and handling can also be done under dome structure sheds (like Coal dome, petcoke dome).

Hindustan Alcox Limited, New Delhi – Coal Gasification Specialist

Cement Industry Impacts & Management for Limestone and Clinker Storage

Limestone storage:

In cement plant, one of the major component for clinker or cement formation is limestone. Dispatch, storage and processing of limestone can be divided into five main operations: i.e. crushing/grinding, sizing, benefication, storage/loading-out & transport. For cement production, limestone is first reduced in size by processing through a series of crushers and grinders and then limestone storage is done under covered sheds to get rid of cement industry impacts such as environmental Issues, health & safety issues and many more.

Clinker Storage:

Clinker storage

After limestone is reduced in size by processing, the stored limestone is then mixed with some mineral aggregates (siliceous, aluminous, and ferrous materials) and water in high temperature kiln to form clinker. After cooling, clinker storage is done under covered sheds or clinker dome. The nodules of cement clinker are then ground to the consistency of face powder to produce powdered cement.

Cement Industry Impacts & Management for Limestone & Clinker Storage:

The cement maufacturing industry exhibits various issues associated with cement and lime manufacturing, which occur during the operational phase. Emissions associated with intermediate and final materials handling and storage are responsible for the followings industrial Impacts :

• Environmental issues

  • Air Emissions

  • Energy consumption and fuels

  • Wastewater

  • Solid waste generation

  • Noise

• Labor Health & Safety

  • Safety from Dust

  • Safety from Heat

  • Safety from Noise & vibrations

  • Physical Hazards

  • Safety from Radiation

• Environmetal Health & Safety

Hindustan Alcox Limited specializes in providing storage solution for limestone with long span steel structure to get rid of above-mentioned cement industry impacts. Limestone storage shed, engineered by the Hindustan Alcox Limited is the best available choice to cover limestone stockpiles for the most challenging environment. Clinker storage sheds or Limestone storage sheds are often built over operating stockpiles so that construction may proceed efficiently without interrupting operational work. 

• Hindustan Alcox Limited, New Delhi

  (Limestone Storage Shed Specialist)