Cement Leader Improves Air Quality by 50%

Case Study: Pure Skies in a Cement Plant

Case Study Summary

Pure Skies air pollution control equipment reduced PM2.5 and PM10 and 50% and 48%, respectively, at one of the leading manufacturers in the cement industry.

The problem:

Anyone working in a factory where cement is being produced knows how poor air quality can get. Particulate pollutants – PM10 and PM2.5 – released during operations affect the well-being of workers at the plant, the plant’s residential colony, as well as surrounding communities.

Cement Plant photo

PC: rechargenews.com

One of Devic Earth’s partners, a leading manufacturer in the cement industry, wanted to improve air quality at one of their plants. The plant was already equipped with the latest air pollution control equipment and followed best practices for the management of fugitive emissions.

Despite these measures, air quality measured within the plant premises was poor. Particulate matter –PM10 – was 269 μg/m3, averaged over one week. This is much higher than what is recommended by the National Ambient Air Quality Standards (PM10 < 100 μg/m3) and 5 to 10 times higher than standards of the World Health Organization

Employees were exposed to high levels of harmful pollutants which would impact their health and productivity.


The solution:

One Pure Skies 9000 system (an earlier version of the current Pure Skies 24K model) was installed inside the factory. The installation consisted of 1 Pure Skies base station and 1 third party air quality monitors (of Airveda Pvt. Ltd., Delhi).


PC: www.constructionweekonline.in

The system was configured to handle particulate pollutants (PM10 and PM2.5) and study pollutant gases (NOx, SOx) across the entire campus of the plant – approximately 100 acres.

Outdoor air pollutant levels were monitored continuously at appropriate locations inside the plant to help the customer understand the efficacy of Pure Skies, as well as to provide real time data for optimizing the smart technology in each Pure Skies unit.

The plant manager and EHS head were given secure logins to view their property’s air quality data on a convenient app to monitor the functioning closely.

Technical Details - Installation

It took just one afternoon to complete the installation. The base station and air quality monitor were installed on either building rooftops or utility poles. No floor space was required. Equipment was plugged in and connected wirelessly to the local GSM data network in the area.

Power requirements: Routine power supply (ordinary 10A sockets). Each base station and air quality monitor comes with battery backup.

Once online, the performance of each air pollution control unit is monitored by Devic Earth 24x7.

Pure Skies built in smart technology allows each unit to understand air quality patterns at its location and optimize its output accordingly.


The outcome:

After Pure Skies was powered On, a steady improvement was observed in the air quality (Figure 1).In just four weeks, Pure Skies reduced levels of PM2.5 and PM10 by 48% and 50%, respectively.

Plant output, number of workers, and local weather patterns remained stable during this period.

Cement Industry Use case Graph

Figure 1: Change in pollution levels with Pure Skies at a cement plant. The red and green bars are the Pure Skies-Off (7-days) and Pure Skies-On periods (7-days), respectively. The successive green bars depict the incremental decrease in the levels of the pollutants over 7-day intervals. Data source: 3rd party air quality monitor (Airveda Pvt. Ltd., Gurgaon), pre-calibrated against a reference grade monitor.

Pure Skies is a state-of-the-art technology that ensured that the employees at the plant, the plant’s residential colony, and surrounding communities breathe clean air.

What’s the value of cleaner air to you and your plant?

Reduced sick days
Cleaner air means a stronger immune system. A study from several of Devic Earth’s customers showed sick days reduce by 11-13% year-on-year after installing Pure Skies!
Better productivity
Worker productivity drops by 1% for every increase in PM2.5 levels by 10 mcg/m3, according to researchers from Columbia University. For a typical factory with PM2.5 levels averaging 50-60 mcg/m3, that’s like watching productivity drop by 1-2%!
Better profitability!
Improving air quality index (AQI) to less than 50 improves the productivity of employees by 5-6%, which in turn increases the profitability of the company by 1%, according to a study published in the Harvard Business Review.
If that’s not good business sense, then we don’t know what is!

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