Reducing Particulate Matter Emissions

from Cement Plants in Ariyalur District

Using Techno-Scientific Solutions

Submitted by:
[Link] (912821106025)
[Link] (912821106009)
[Link] (912821106302)
[Link] gonsaga (912821106002)
Guided by:
Dr.A. Valanarasi, ASP/ECE
OVERVIEW
• Introduction
• Existing Method
• Objectives
• Proposed Method
• Components Required
• Block Diagram
• Result
• Conclusion
• References
INTRODUCTION
• Cement production is a crucial industry that supports infrastructure development,
but it is also a significant source of environmental pollution. One of the major
concerns associated with cement plants is the emission of particulate matter (PM).
• Ariyalur District, known for its rich limestone deposits, hosts several cement plants
that contribute to both economic growth and environmental challenges.
• The emission of PM from these plants affects air quality, public health, and
ecological balance in the region.
• This project explores techno-scientific solution to reducing PM emissions in
Ariyalur's cement plants using advanced filtration, real-time monitoring, and
sustainable methods.
• Adopting these solutions will enhance industry performance, air quality, and the
well-being of local communities.
EXISTING METHOD
• Electrostatic Precipitators (ESP) devices are highly efficient in capturing fly ash and
other particulate matter, with collection efficiencies reaching up to 99.81%.
• The installation of ESPs requires significant capital investment, making them less
accessible for smaller industries.
• ESPs need a large amount of space for installation, which can be a limitation in
compact industrial setups. ESPs require a high voltage power supply, leading to
increased energy consumption.
• Water Spray Systems help control dust emissions by spraying water on roads and
other areas prone to dust generation.
• They may not be effective in capturing very fine particulate matter and require a
significant amount of water, which can be a concern in areas with water scarcity.
• Regular maintenance is needed to prevent clogging and ensure proper functioning.
OBJECTIVES
• To develop and implement techno-scientific solutions to reduce particulate matter
emissions from cement plants especially in Ariyalur District.
• Track the levels of various gaseous pollutants (e.g., ammonia, NOx, CO2) that
contribute to air pollution alongside particulate matter.
• Continuously measure the concentration of suspended particulate matter(SPM) to
assess air quality and identify pollution hotspots.
• To ensure timely audible warnings when particulate matter levels exceed safe
thresholds, enabling prompt action.
 PROPOSED METHOD
• Dust particles and SPM emissions are captured by the HEPA filter preventing their
release into the outside environment.
• Gas Detector(MQ135) is connected to the ESP32 Micro-Controller to measure gas
concentrations.
• Dust sensor() measures the suspended particulate matter(SPM) concentrations.
• Data from Dust and Gas sensors and checked for threshold values.
• Both the exhaust fan and the buzzer(alert) are activated when the SPM threshold
gets exceeded.
• Real-time air quality data, including PM concentrations, is displayed on the LCD.
COMPONENTS REQUIRED
• ESP32 dev module
• 16x2 lcd with I2c
• Buck Converter
• MQ135
• Dust Sensor
• Exhaust Fan
• High Efficiency Particulate Air (HEPA) Filter
• 1 Channel Relay Module
• Buzzer
• Power Supply Adaptern12v 1.5A
PM SENSOR
• A PM sensor (Particulate Matter sensor) is a device used to detect and measure the
concentration of tiny particles in the air, known as particulate matter
• PM sensors detect airborne particles, including pollutants like dust, smoke, and
allergens, helping monitor air quality in real-time.
• The most common method is laser scattering, where a laser beam illuminates
particles, and the scattered light is analyzed to determine their size and
concentration.
• Sensors with high accuracy are designed to precisely detect fine particulate matter,
such as PM2.5 and PM10, ensuring reliable measurements of air quality.
• By monitoring dust levels, PM sensors help optimize filtration systems, reducing
waste and improving efficiency.
MQ-135 SENSOR
• The MQ-135 air quality sensor can detect multiple gases, including ammonia,
nitrogen oxides, carbon dioxide and smoke.
• The MQ135 air quality sensor, which belongs to the series of MQ gas sensor, is
widely used to detect harmful gases.
• When hazardous gases come in contact with the sensor, the resistance of the
sensor changes, leading to a variation in the output voltage.
• Operates at 5V, consuming minimal power, which makes it suitable for battery-
powered applications.
• Users can set a threshold value using a potentiometer for customized gas
detection.
DHT-11 SENSOR
• The DHT11 sensor used to measure temperature and humidity. It’s widely used in
weather monitoring systems and industrial applications.
• The DHT11 sensor operates using two primary components: a capacitive
humidity sensor and a thermistor.
• The capacitive humidity sensor detects moisture levels in the surrounding air by
measuring changes in capacitance.
• The thermistor, a type of resistor that varies with temperature, determines the
ambient temperature.
• The sensor continuously updates data every two seconds, making it efficient for
real-time environmental monitoring.
HEPA FILTER
• A HEPA filter (High-Efficiency Particulate Air filter) is designed to capture
airborne particles as small as 0.3 microns, these filters are widely used in air
purifiers.
• Captures particles through interception, impaction, and diffusion, effectively
trapping dust, pollen and even some viruses.
• These filters are composed of a dense mat of randomly arranged fibers, often
made of materials such as fiberglass which are highly efficient.
• It also protects equipment in manufacturing plants from dust and particulate
matter that could cause damage.
• Helps maintain a cleaner indoor environment, beneficial for asthma sufferers and
allergy-sensitive individuals.
RELAY MODULE
• In this project, a 1-channel relay module is used to control an exhaust fan through
a microcontroller ( ESP32).
• This setup allows automatic or remote switching of the fan based on
environmental conditions like temperature, humidity, gas levels, etc.
• Based on a predefined threshold (e.g., temperature > 30°C), it sends a control
signal (HIGH/LOW) to the relay module.
• The relay module acts as a switch and turns the exhaust fan ON or OFF by
controlling the AC power supply to the fan.
BLOCK DIAGRAM
RESULT

A. Dust level

B. IOT based monitoring

CONCLUSION
• The issue of SPM (Suspended Particulate Matter) emissions from cement plants in
Ariyalur represents a pressing environmental and public health challenge.
• The region’s industrial growth, while economically beneficial, must be balanced
with sustainable practices to ensure long-term ecological and social well-being.
• This project has emphasized the importance of adopting pollution control
technologies and real-time monitoring systems to effectively reduce particulate
levels.
• By implementing these solutions, Ariyalur’s cement industry can serve as a model
for other regions in India striving to reduce industrial pollution.
• Through this project, it becomes evident that environmental responsibility and
industrial productivity can coexist, paving the way for a healthier and more
sustainable future.
REFERENCES
• [Link]. (n.d.). Estimation of Cement Kiln Exhaust on Air Quality of Ariyalur in
Terms of Suspended Particulate Matter – A Case Study.
• [Link]. (2021, July 2). UltraTech Cement’s Reddipalayam Plant Reaches 25%
Alternative Fuels Substitution Rate.
• Dalmia Bharat, “Dalmia Cement Ariyalur Plant Receives FICCI Safety Award 2014,”
Dalmia Bharat, 2014.
• Elion Technologies, “Elion Team carried out ventilation survey at cement manufacturer in
Ariyalur, Tamil Nadu,” [Link], Jun. 7, 2024.
• Global Cement, (2014, December 17). Cement Plants in Ariyalur Start Using Effluent
Sludge as Alternative Fuel
THANK YOU