Cement is one of the most vital construction materials which acts as a binder for other materials through a chemical process known as hardening and stiffening. The cement industry in India stands as the second-largest producer in the world. Out of this production, 98% is contributed by the private sector. There has been an increased demand in the market because of government infrastructure development, especially in the construction sector, which uses over 65% of the cement. Limestone is a major raw material mainly extracted in some states such as Gujarat, Andhra Pradesh, and Madhya Pradesh.
Modern Portland cement, also known as Ordinary Portland Cement (OPC), is produced from a mixture of limestone, sand, and clay heated to a temperature of 1400-1500°C. The key stages of cement manufacturing are:
Energy costs constitute approximately 40% of the OF cement industries total costs. Waste Heat Recovery Boilers (WHRBs) are crucial equipment in the cement industry for conserving energy. They recover heat from the exhaust gasses of rotary kilns and produce steam through the turbines to provide approximately 20-30% of a plant's electricity requirement, helping in cutting expenses and increasing efficiency.