28 th Septeber,2016 Cement- A Vital Input in Nation Building - - PowerPoint PPT Presentation

28th Septeber,2016

2 Dedicated Freight & Industrial Corridors Make in India Smart Cities Electricity Connectivity, Roads Irrigation, Water Supply High Speed Trains Airports Communicatio n Housing for all

Construction is at the core of development and cement is at the core of construction

Cement- A Vital Input in Nation Building

Indian Cement Industry-Overview

• 2nd 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

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Geographical distribution of Cement Companies in India

North East Central South West

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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 (Tonnes/Day) 300 - 600 600 – 1200 2400 – 3000 3300 – 6000 4500 – 12000 Heat Consumption (Kcal/kg Clinker) 1300 - 1600 900 – 1000 800 – 900 650 – 750 650 – 750 Power Consumption (Kwh/Tonne Cement) 115 - 130 110 - 125 105 - 115 95 - 106 70 - 90

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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 Grinding VRM’s, Roller Presses with dynamic classifier & Ball Mill Pyro- Processing Dry

• 6/5 stage preheater
• High Efficiency Cooler
• Multi Channel multi fuel Burner
• Co-generation of power
• Co-processing of WDF
• Low NOX/SO2 emission technologies

Blending & Storage

• Continuous Blending
• Multi- chamber silos
• Dome silos

Packing & Dispatch

• Bulk
• Palletizing & Shrink Wrapping

Process Control

• DDC
• Fuzzy Logic expert system

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Achievements of Indian Cement Industry

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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 (CO2) 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

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• Best specific energy consumption levels achieved by the Indian

Cement Industry

Progressive Reduction in Energy Consumption

Country Specific Electrical Energy Consumption (KW/ton of Cement) Specific Thermal Energy Consumption (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

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 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

Adoption of Best Practices Leading to Reduction in Carbon Footprint

• CO2 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 CO2 Emission in 2020 and 0.50 per ton CO2 Emission in 2030.

• Particulate Emission has been reduced from 400 mg/Nm3 to 50 mg/Nm3 over

the last two decades. Efforts on for further reduction.

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Initiatives by Indian Cement Industry

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

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 BASED

POWER GENERATION

Waste Heat Recovery (WHR) based power generation may be incentivized and given Renewable Energy Status.

• 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.

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Focusing And Producing Green Cement

Energy Consumption likely to be reduced Further in second cycle of PAT Scheme

Challenges & Opportunities

• f Indian Cement Industry

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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.

Source-CSI data 15

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 Total Substitution Rate (TSR) of Indian cement industry is about 0.5- 1.0% In comparison to some developed countries where it is more than 30%. Source: CSI Data & CPCB ,Holtec & India Infrastructure Research

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Alternate Fuels and Raw Material Availability in 2014 (Mt/year) Surplus Biomass 150.00 Industrial Plastic Waste 0.20 Municipal Solid Wastes 75.00 Flyash 200.00 Used Tyres 0.83 Blast Furnace Slag 10.00 Hazardous Waste 0.65 Total 436.68

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.

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

Proposed by CPCB Industry Notified by MoEF&CC@ NOx New plants 600 800 600* Existing Plants 1000 (3 years from date of Notification) 1200/1000 800* 800 (After 3 years) SO2 All Plants 100 (plants with < 0.5% sulphur in raw material) 100 100 1000 (plants with > 0.5% sulphur in raw material) 1000 # PM Plants commissioned before notification 100/150 (critical/non-critical) 50 (two years after Notification) 100/150 30 Plants commissioned

• n/or after notification

50 50 30 # In line with European Guidelines

@ Notification No.G.S.R. 612(E) dated 28.8.2014

* @10% O2 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)

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• 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

The Way Ahead

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