28 th Septeber,2016
Cement- A Vital Input in Nation Building Communicatio n Housing for all Airports Irrigation, Water Supply Electricity High Speed Trains Make in India Dedicated Freight & Industrial Smart Cities Corridors Connectivity, Roads Construction is at the core of development and cement is at the core of construction 2
Indian Cement Industry-Overview 2 nd largest Cement producer, next to China, producing 7% of the global cement production Installed capacity of 410 Million Tonnes at present with production of 270 Million Tonnes per annum Production expected to be 500 Million Tonnes by the year 2020 and 800 Million Tonnes by 2030 under high demand scenario(@10 % Growth) Indian cement plants are comparable with the best in the world in respect of production facilities, technology, energy efficiency Indian Cement Industry is internationally recognized as one of the most energy- efficient and environmentally friendly industry 3
Geographical distribution of Cement Companies in India North East West Central South 4
Technological Scenario 99 % of installed capacity through dry process technology Kiln Capacity ranging from 4500-10000 TPD Best specific energy consumption levels achieved i.e 670 kcal/kg cl and around 68 kWh per tone cement, which are comparable with the best achieved levels in the world Proactive Cement Industry constantly improves Energy & Heat Consumption Year 1950-60 1970 1980 1990 Post 2010 Kiln Capacity 600 – 1200 2400 – 3000 3300 – 6000 4500 – 12000 300 - 600 (Tonnes/Day) Heat Consumption 900 – 1000 800 – 900 650 – 750 650 – 750 1300 - 1600 (Kcal/kg Clinker) Power Consumption 115 - 130 110 - 125 105 - 115 95 - 106 70 - 90 (Kwh/Tonne Cement) 5
Present Status of Technology Global Technology Plants Mining and Material Handling Computer aided Crushing In-pit crushing & conveying Conveying of Limestone Pipe conveyors, Overland Belt conveyors VRM’s, Roller Presses with dynamic classifier & Ball Mill Grinding Pyro- Processing Dry - 6/5 stage preheater - High Efficiency Cooler - Multi Channel multi fuel Burner - Co-generation of power - Co-processing of WDF - Low NO X /SO 2 emission technologies Blending & Storage - Continuous Blending - Multi- chamber silos Dome silos - Packing & Dispatch - Bulk - Palletizing & Shrink Wrapping Process Control - DDC - Fuzzy Logic expert system 6
Achievements of Indian Cement Industry 7
Sustainable and Green Production Long Journey - Experienced ups and downs and achieved many Milestones State-of-Art Production facility and Technology Energy Efficiency Improvement Environment protection Water Conservation GHG (CO 2 ) Emission Reduction BEE’s consistent efforts to reduce Energy Consumption Successful Implementation of PAT cycle -1(2012-15)(4.8 % reduction in Energy Consumption) Process of PAT cycle -2 started Industry’s Initiatives and Achievements acknowledged and appreciated world over - although, a lot still remains to be done 8
Progressive Reduction in Energy Consumption Best specific energy consumption levels achieved by the Indian Cement Industry Specific Electrical Energy Specific Thermal Country Consumption Energy Consumption (KW/ton of Cement) (Kcal/Kg Clinker) India 82 725 Spain 92 836 Germany 100 836 Japan 100 836 Brazil 110 884 Italy 112 908 China 118 956 Mexico 118 1003 Canada 140 1075 USA 141 1099 World Average 100-110 850-860 Source : CII Publication - Indian Cement Industry , May 2015 9
Adoption of Best Practices Leading to Reduction in Carbon Footprint Best practices – Waste Heat Recovery, Replacing Conventional Fuel with Alternate Fuels, Participating in CDM Projects under Kyoto Protocol of UNFCCC, Adopting Renewable Energy (Wind, Bio-Mass,Solar etc.), Clinker Substitution with Fly Ash and Slag CO 2 Emission Level Reduced from 1.12 per ton of Cement Produced in 1996 to 0.7 per ton of cement .Target of 0.58 per ton CO 2 Emission in 2020 and 0.50 per ton CO 2 Emission in 2030. Particulate Emission has been reduced from 400 mg/Nm 3 to 50 mg/Nm 3 over the last two decades. Efforts on for further reduction. 10
Initiatives by Indian Cement Industry 11
WASTE HEAT RECOVERY BASED POWER GENERATION Area for energy saving is generation of power through waste-heat-recovery (WHR) system which is well established now. Offers a very high potential for reducing burden on National grid. Saves significant energy through reduced coal consumption, and consequent reduction in equivalent carbon dioxide. Present Generation 135 MW In Process 200 MW Potential 500 MW Waste Heat Recovery (WHR) based power generation may be incentivized and given Renewable Energy Status. 12
Focusing And Producing Green Cement Eco-friendly Use Of Hazardous Industrial Wastes Consumes Around 27% Of Fly Ash Generated From Thermal Power Plants. Consumes Almost 100% Slag Generated By Steel Plants. Energy Consumption likely to be reduced Further in second cycle of PAT Scheme 13
Challenges & Opportunities of Indian Cement Industry 14
Reduction in Clinker factor To reduce clinker factor by using Blended Cements & New Materials The current clinker factor is 0.77. The clinker factor is further targeted to reduce to 0.70 by the end of 2020 and to 0.64 by the end of 2030 which ultimately will reduce CO2 emissions. Maximizing fly ash content in PPC and modification of existing standards for enhancing fly ash content Increasing usage of different waste materials like lead zinc slag, copper slag, marble slurry etc. 15 Source-CSI data
Alternate fuel Utilization Uses waste materials as fuel including those from other industry – e.g., Pet Coke, Rice Husk, Bagasse, Cut Tyres and Municipal solid waste AFR Usage Alternate Fuels and Raw Material Availability in 2014 (Mt/year) Total Substitution Rate (TSR) of Indian cement Industrial industry is about 0.5- Surplus Biomass 150.00 0.20 Plastic Waste 1.0% In comparison to some developed Municipal Solid Wastes 75.00 Flyash 200.00 countries where it is Blast Furnace more than 30% . Used Tyres 0.83 10.00 Slag Hazardous Waste 0.65 Total 436.68 16 Source: CSI Data & CPCB ,Holtec & India Infrastructure Research
NOx & SOx Control Technologies for low nitrogen oxide (NOx) emissions & SOx have not penetrated significantly, though a few installations have been put up in the country . Proposed by CPCB Industry Notified by MoEF&CC @ New plants 600 800 600* 1000 (3 years from date of NO x Notification) Existing Plants 1200/1000 800* 800 (After 3 years) 100 (plants with < 0.5% 100 100 sulphur in raw material) SO 2 All Plants 1000 (plants with > 0.5% 1000 # sulphur in raw material) 100/150 (critical/non-critical) Plants commissioned 50 100/150 30 before notification (two years after PM Notification) Plants commissioned 50 50 30 on/or after notification @ Notification No.G.S.R. 612(E) dated 28.8.2014 # In line with European Guidelines * @10% O 2 There is an urgent need to identify and implement the technologies available globally and do the minimum adoptive research to establish their suitability in Indian context and facilitate their adoption in a time bound manner 17
Technology Gaps in Indian Cement Industry Efficient Nox & Sox technologies. Pre-processing and co-processing technologies for alternate fuels usage Use of Alternate Materials Further Improvement in Energy Efficient Grinding Systems. Technology required for developing product differentiation and Use of Low Grade Limestone Implementation of Better and Advanced Control systems Latest innovative technologies to use stack gases for Algae making(part of fuel) 18
The Way Ahead To meet the targets set for PAT cycle -II Increase Thermal Substitution Rate (TSR %) To Further Reduce Clinker Factor Increasing Co-generation through Waste Heat Recovery (WHR) Increasing Use of Renewable Energy Sourcing of Technology, Equipment's & Training on rapid implementation in use of AFR & Alternate Material 19
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