The ‘Neem Ka Thana’ plant has independently obtained separate Environment Clearance from the Ministry of Environment & Forests, New Delhi and all other consents from the State Pollution Control Board. The environmental performance of the unit in terms of control on Air, Water and Land pollution is quite excellent and is being monitored by the MoEF & RSPCB.
Binani Cement for the first time in the Country successfully utilised the high carbon fly ash generated from its captive power plant in an environmentally sound manner. The high carbon fly ash’s disposal into landfill was also an environmental nuisance. Hence, a system was designed and developed to feed it into the clinker cooler from where it is carried along the gases into the calciner and finally into the kiln where the carbon is burnt to provide heat and the residual ash is then mixed up with clinker.
Binani is first in India and second only in the world to have installed the revolutionary MMX Cooler, which is based on proven SF Cross-Bar technology in its new cement plant. The Multi-Movable Crossbar Cooler delivers higher energy efficiency, low dust generation and improved transport efficiency compared to conventional clinker cooling systems. MMX coupled with 'Hydraulic Roll Breaker' (HRB) for clinker breaking, makes it a virtually 'noiseless' cooler'.
In-Line Calciner (ILS):
The newly installed ILC Low NOx Calciner renders excellent performance in terms of NOx reduction in kiln exhaust gases as it fires 100% fuel in the reduction zone and allows tangential entry of TA duct to the Calciner for better mixing.
The Duo-Flex burner causes low NOx generation due to the very short ignition distance it allows. It affords flexibility of adjustable burner positions during process control and has Low Primary Air consumption – only 6-8 % of theoretical process air requirement making it a highly energy efficient addition to the cement unit.
Air Cooled Condensers (ACCs) have been installed in both the new units of CPP. The ACC is a revolutionary cooling technology, which serves to reduce the fresh water requirement for cooling by around 90% when compared with the traditional Water Cooled Condensers. Helping in return, conserve the water needs of the surrounding community.
Ground vibrations, noise, fly rock and dust generation during blasting are greatly minimised by the use of NONEL (Non-electric) Technology. ‘Down the hole’ delays result in true bottom initiation of the explosive charge and introduction of NONEL Trunk line delays (TLDs) results in hole-to-hole delay. Quieter and cleaner limestone blasting gives the workers and community a better environment to live in.
State-of-the-art PTFE Glass Membrane filtering media & pulse jet cleaning technology has been introduced by way of Reverse Air Bag house cleaning systems in both the kilns. With the installation of Reverse Air Bag House, we have been able to maintain < 20 mg/Nm3 of stack emission from the kiln exhaust gases. Such an emission level brings us at /below par with the European Standards (25 – 30 mg/Nm3).
Residue Management in BZ:
Binani Zinc has adopted stringent measures for secure & safe disposal of any hazardous arising. The Company has installed the industry-standard Jarofix facility, which is an environment-friendly, inert & neutralised product. The technology for the same has been sourced from CE Zinc, Canada.