Assessment of Energy Conservation in Indian Cement Industry and Forecasting of Co2 Emissions

Cement industry ranks 2nd in energy consumption among the industries in India. It is one of the major emitter of CO2, due to combustion of fossil fuel and calcination process. As the huge amount of CO2 emissions cause severe environment problems, the efficient and effective utilization of energy is a major concern in Indian cement industry. The main objective of the research work is to assess the energy cosumption and energy conservation of the Indian cement industry and to predict future trends in cement production and reduction of CO2 emissions. In order to achieve this objective, a detailed energy and exergy analysis of a typical cement plant in Kerala was carried out. The data on fuel usage, electricity consumption, amount of clinker and cement production were also collected from a few selected cement industries in India for the period 2001 - 2010 and the CO2 emissions were estimated. A complete decomposition method was used for the analysis of change in CO2 emissions during the period 2001 - 2010 by categorising the cement industries according to the specific thermal energy consumption. A basic forecasting model for the cement production trend was developed by using the system dynamic approach and the model was validated with the data collected from the selected cement industries. The cement production and CO2 emissions from the industries were also predicted with the base year as 2010. The sensitivity analysis of the forecasting model was conducted and found satisfactory. The model was then modified for the total cement production in India to predict the cement production and CO2 emissions for the next 21 years under three different scenarios. The parmeters that influence CO2 emissions like population and GDP growth rate, demand of cement and its production, clinker consumption and energy utilization are incorporated in these scenarios. The existing growth rate of the population and cement production in the year 2010 were used in the baseline scenario. In the scenario-1 (S1) the growth rate of population was assumed to be gradually decreasing and finally reach zero by the year 2030, while in scenario-2 (S2) a faster decline in the growth rate was assumed such that zero growth rate is achieved in the year 2020. The mitigation strategiesfor the reduction of CO2 emissions from the cement production were identified and analyzed in the energy management scenarioThe energy and exergy analysis of the raw mill of the cement plant revealed that the exergy utilization was worse than energy utilization. The energy analysis of the kiln system showed that around 38% of heat energy is wasted through exhaust gases of the preheater and cooler of the kiln sysetm. This could be recovered by the waste heat recovery system. A secondary insulation shell was also recommended for the kiln in the plant in order to prevent heat loss and enhance the efficiency of the plant. The decomposition analysis of the change in CO2 emissions during 2001- 2010 showed that the activity effect was the main factor for CO2 emissions for the cement industries since it is directly dependent on economic growth of the country. The forecasting model showed that 15.22% and 29.44% of CO2 emissions reduction can be achieved by the year 2030 in scenario- (S1) and scenario-2 (S2) respectively. In analysing the energy management scenario, it was assumed that 25% of electrical energy supply to the cement plants is replaced by renewable energy. The analysis revealed that the recovery of waste heat and the use of renewable energy could lead to decline in CO2 emissions 7.1% for baseline scenario, 10.9 % in scenario-1 (S1) and 11.16% in scenario-2 (S2) in 2030. The combined scenario considering population stabilization by the year 2020, 25% of contribution from renewable energy sources of the cement industry and 38% thermal energy from the waste heat streams shows that CO2 emissions from Indian cement industry could be reduced by nearly 37% in the year 2030. This would reduce a substantial level of greenhouse gas load to the environment. The cement industry will remain one of the critical sectors for India to meet its CO2 emissions reduction target. India’s cement production will continue to grow in the near future due to its GDP growth. The control of population, improvement in plant efficiency and use of renewable energy are the important options for the mitigation of CO2 emissions from Indian cement industries

STUDY OF INFLUENCE OF SAFETY ENGINEERING AND MANAGEMENT PRACTICES IN SELECTED INDUSTRIES IN KERALA

In the twentieth century, as technology grew with it. This resulted in collective efforts and thinking in the direction of controlling work related hazards and accidents. Thus, safety management developed and became an important part of industrial management. While considerable research has been reported on the topic of safety management in industries from various parts of the world, there is scarcity of literature from India. It is logical to think that a clear understanding of the critical safety management practices and their relationships with accident rates and management system certifications would help in the development and implementation of safety management systems. In the first phase of research, a set of six critical safety management practices has been identified based on a thorough review of the prescriptive, practitioner, conceptual and empirical literature. An instrument for measuring the level of practice of these safety conduction a survey using questionnaire in chemical/process industry. The instrument has been empirically validated using Confirmatory Factor Analysis (CFA) approach. As the second step. Predictive validity of safety management practices and the relationship between safety management practices and self-reported accident rates and management system certifications have been investigated using ANOVA. Results of the ANOVA tests show that there is significant difference in the identified safety management practices and the determinants of safety performance have been investigated using Multiple Regression Analysis. The inter-relationships between safety management practices, determinants of safety performance and components of safety performance have been investigated with the help of structural equation modeling. Further investigations into engineering and construction industries reveal that safety climate factors are not stable across industries. However, some factors are found to be common in industries irrespective of the type of industry. This study identifies the critical safety management practices in major accident hazard chemical/process industry from the perspective of employees and the findings empirically support the necessity for obtaining safety specific management system certifications

A fiber optic smart sensor for studying the setting characteristics of various grades of cement

A simple, effective and inexpensive fiber optic sensor for investigating the setting characteristics of various grades of cement is described. A finite length of unsheathed multimode optical fiber laid inside the cement mix, is subjected to stress during the setting process. The microbends created on the fiber due to this stress directly influence the intensity of light propagating through the fiber. Continuous monitoring of such variations in the light output transmitted through the fiber gives a clear measure of the setting characteristics of the cement mix, thus providing a simple and elegant technique of great practical importance in the field of civil engineering. The smart fiber optic sensor described above can be incorporated into a building during the construction process itself so that continuous monitoring of the deterioration process for the entire life time of the building can be carried out.

Development of Polymer Cement Composites

Research in the field of polymer modified cement has been carried out for the last 70 years or more. Polymers are mostly used to enhance durability and sustainability of cement concrete and in combination with classical construction materials a synergistic effect is obtained. In this work different polymers were added to Portland cement in various proportions and the mechanical and chemical resistance properties of the resultant composites when exposed to chemical environments were studied. Microstructural studies were also carried out to investigate the morphology of the composite and analyse the nature of interactions taking place between the cement and polymer phases. Though most polymers did not improve the compressive strength of the cement paste, it was found that they enhanced the resistance of the virgin cement paste to external chemical environments. The polymers seal the pores in the cement matrix and bridge the microcracks within the composite. Some of the polymers underwent chemical interactions with the cement paste thereby interfering in the hydration of cement. Polymers also decreased the leachability of water soluble components of virgin cement resulting in composites having improved durability. An attempt to correlate the structure of the polymers with the properties of the resultant composites is also presented.

An Analysis of Work Related Stress Factor in Selected Industries in Kerala ,India

Occupational stress is becoming a major issue in both corporate and social agenda .In industrialized countries, there have been quite dramatic changes in the conditions at work, during the last decade ,caused by economic, social and technical development. As a consequence, the people today at work are exposed to high quantitative and qualitative demands as well as hard competition caused by global economy. A recent report says that ailments due to work related stress is likely to cost India’s exchequer around 72000 crores between 2009 and 2015. Though India is a fast developing country, it is yet to create facilities to mitigate the adverse effects of work stress, more over only little efforts have been made to assess the work related stress.In the absence of well defined standards to assess the work related stress in India, an attempt is made in this direction to develop the factors for the evaluation of work stress. Accordingly, with the help of existing literature and in consultation with the safety experts, seven factors for the evaluation of work stress is developed. An instrument ( Questionnaire) was developed using these seven factors for the evaluation of work stress .The validity , and unidimensionality of the questionnaire was ensured by confirmatory factor analysis. The reliability of the questionnaire was ensured before administration. While analyzing the relation ship between the variables, it is noted that no relationship exists between them, and hence the above factors are treated as independent factors/ variables for the purpose of research .Initially five profit making manufacturing industries, under public sector in the state of Kerala, were selected for the study. The influence of factors responsible for work stress is analyzed in these industries. These industries were classified in to two types, namely chemical and heavy engineering ,based on the product manufactured and work environment and the analysis is further carried out for these two categories.The variation of work stress with different age , designation and experience of the employees are analyzed by means of one-way ANOVA. Further three different type of modelling of work stress, namely factor modelling, structural equation modelling and multinomial logistic regression modelling was done to analyze the association of factors responsible for work stress. All these models are found equally good in predicting the work stress.The present study indicates that work stress exists among the employees in public sector industries in Kerala. Employees belonging to age group 40-45yrs and experience groups 15-20yrs had relatively higher work demand ,low job control, and low support at work. Low job control was noted among lower designation levels, particularly at the worker level in these industries. Hence the instrument developed using the seven factors namely demand, control, manager support, peer support, relationship, role and change can be effectively used for the evaluation of work stress in industries.

Performance of District Industries Centers in Kerala : An Application of augmented solow Model

This thesis "Entitled performance of district industries centres in kerala :An application of augmented solow model.The first chapter deals with evolution of approaches for promoting small scale production and the growth of small scale industries in india.the developing countries face the problems like sluggish growth capital shortages high levels of unemployment,enoromous rural-urban economic disparities regional inequalities increasing concentration of capital and chronic difficulities in the export sector.Review of literature and methodology of the study are presented in the second chapter. In the third chapter an attempt has been made to make an in-depth study of the emergence and growth of district of district industries centres.In the chapter four an attempt was made to study the organisational structure of DICs functions and responsibilities assigned to the functional managers and performance of the functionaries.

Performance of District Industries Centres in Kerala

This thesis "Entitled performance of district industries centres in kerala :An application of augmented solow model.The first chapter deals with evolution of approaches for promoting small scale production and the growth of small scale industries in india.the developing countries face the problems like sluggish growth capital shortages high levels of unemployment,enoromous rural-urban economic disparities regional inequalities increasing concentration of capital and chronic difficulities in the export sector.Review of literature and methodology of the study are presented in the second chapter. In the third chapter an attempt has been made to make an in-depth study of the emergence and growth of district of district industries centres.In the chapter four an attempt was made to study the organisational structure of DICs functions and responsibilities assigned to the functional managers and performance of the functionaries.

Characterization of Wastes from Natural Rubber and Rubber Wood Processing Industries and Their Utilization for Biomethanation

The research work which was carried out to characterization of wastes from natural rubber and rubber wood processing industries and their utilization for biomethanation. Environmental contamination is an inevitable consequence of human activity. The liquid and solid wastes from natural rubber based industries were: characterized and their use for the production of biogas investigated with a view to conserve conventional energy, and to mitigate environmental degradation.Rubber tree (flevea brasiliensis Muell. Arg.), is the most important commercial source of natural rubber and in india. Recently, pollution from the rubber processing factories has become very serious due to the introduction of modern methods and centralized group processing practices.The possibility of the use of spent slurry as organic manure is discussed.l0 percent level of PSD, the activity of cellulolytic, acid producing,proteolytic, lipolytic and methanogenic bacteria were more in the middle stage of methanogenesis.the liquid wastes from rubber processing used as diluents in combination with PSD, SPE promoted more biogas production with high methane content in the gas.The factors that favour methane production like TS, VS, cellulose and hemicellulose degradation were favoured in this treatment which led to higher methane biogenesis.The results further highlight ways and means to use agricultural wastes as alternative sources of energy.

"Profile of Industrial workers in Kerala - A Comparative Study of the Socioeconomic Profile of Workers in Traditional and Modern Industries

The objective of this study is to assess the changes that have been taking place in the socio-economic profile of organized industrial workers of Kerala in the context of the changes that have been taking place in the state's industrial structure. with this object in view, the study seeks to find out the similarities and differences in the profile of workers belonging to two Segments of factory sector industries in Kerala viz., modern and traditional segments. It also seeks to examine the factors leading to the differences in profile, if any, and their consequences. As noted earlier, the profile of workers may be influenced both by external societal factors and by internal factors like the difference in industrial structure and the technologies used. It is proposed to assess the relative importance of these two groups of factors. In drawing up the profile, we seek to find out whether the workers belonging to the organised sector of industry in Kerala particularly the more modern sector have begun to form a ‘select group‘ in the Kerala society and the total work force. Wherever possible, it is proposed to compare the profile of the Kerala workers with those of workers in other states of India. As an incidental objective, it is also proposed to find out to the extent possible, whether trends towards labour embourgeoisement and class shifting have begun to set in among the industrial workers of Kerala, particularly among the workers in the modern industries as a result of their relative affluence and their middle class socioeconomic background. besides, the study seeks to find out whether there is any difference in the class consciousness of workers belonging to these two segments of organized industry, arising from the differences in their economic status and social background.