Cement mills are sensitive to water, and water plays an important part in the production of cement, from the crushing stage through the mill equipment. Water comes from a variety of sources, including surface water from rivers and lakes, ground water from borewells, rainwater gathered, and so on, all of which have varied water qualities. This water is treated to the desired parameters, ensuring that the process is unaffected and that the product is of high quality.

The water must meet WHO standards for human consumption. Water treatment is a key component that produces water that is suitable for cement making, drinking, and other uses. To eliminate the minute particulate that remains after cement manufacture, a cement plant wastewater treatment system must be extremely effective. When in a closed system, the industry standard is in place and wastewater is reused again and over, this work becomes even more critical. Water is utilised in the cement industry for a variety of purposes, including cooling the manufacturing process.

WATER IN THE CEMENT PRODUCTION PROCESS HAS THREE BASIC USES:

1 COOLING WATER: Most cement plants use a lot of water for cooling. Bearings on the kiln and grinding machinery, air compressors, burner pipes, and finished cement all utilise cooling water. The majority of cooling is done in a non-contact manner. Both the wet and dry methods take about the same amount of cooling.

2 PROCESS WATER: Only the wet process requires process water. Water is added to the raw materials here to facilitate grinding and create a slurry for feeding the ground material to the kiln. The process water is absorbed by the slurry in the kiln and evaporated, leaving no liquid waste.

3 SERVICE AND SANITARY WATER: In some plants, water is required for the preparation of raw materials, such as washing or beneficiation. The collected kiln dust is also disposed of using water. Kiln dust is leached of soluble alkalis to recover raw materials in the wet process, which involves combining dry dust with water to make a slurry. After that, the slurry is pumped into a clarifier. The treated dust slurry is returned to be used in the manufacture of raw material slurry. Collected dust can be mixed with water and sent to a settling pond, where the settled solids are not reused and the purified water is discharged, in both wet and dry processes. Although this procedure is used, discharge of untreated waste water is not suggested. Cement dust is produced in large quantities as a result of the grinding and processing of cement. Water is sprayed on streets and parking lots to prevent cement dust, and it is also used to wash trucks.

WASTE WATER TREATMENT IN CEMENT INDUSTRY:

Water is only utilised in the cement industry to cool the manufacturing process. Some processes may produce process wastewater with a high pH and suspended particles. In most cases, the water used for cooling is recycled and reused in the process. The settling basin and clarifier are used for screening and suspended solid reduction. Water from a waste water treatment plant should be used to construct green belts. This green belt also contributes to the reduction of noise pollution. In some activities, process wastewater with a high pH and suspended particles may be created.

At times, contaminated streams of rainwater from mining sites and cement plants should be channelled to a wastewater treatment plant and used for industrial processes. Stormwater flowing through exposed pet–coke, coal, and waste material stockpiles could be contaminated.

Rainwater should be kept away from the coal depot clinker, lime, and fly ash storage areas to avoid contamination, and should be collected in a tank for later use in the plant's dust suppression system. If stormwater comes into touch with a storage yard, it might mean that there is a lot of sulphate in the soil, hazardous metals like zinc, lead, and chromium in the dust, and a lot of TDS in the ground water.

Water generated from RO plant can be used for all these procedures. Netsol customizes all commercial, industrial RO Plants as per customer’s requirement and space.