Cleaner Technologies Resource Conservation By R Bhargava Chief
Cleaner Technologies & Resource Conservation By R. Bhargava Chief Climate & Sustainability Officer Shree Cement Limited
Contents • • • SCL Overview Indian Cement Industry Drivers for Technology Development Advancement in Cement Industry Cleaner Technologies and Resource Conservation • Technologies Need Way to India
Shree Cement Profile Shree Cement Limited is a rapidly growing and one of the most efficient and environment friendly Companies in India. 29. 3 million tons per annum Cement production capacity 612 MW total power generation capacity Among the top 3 cement groups in India Largest WHRP in the global cement industry excluding china Highest 5 - star rating - first time to any cement company in the world by Whitehopleman, UK 5 star rating for Beawar and Ras limestone mines for sustainable development by IBM An Energy & Environment Conscious Sustainable Organization
Our Vision “Lead in Creating Prosperity & Happiness for all Stakeholders through Innovation & Sustainable Practices” Enforce good corporate governance practices Encourage socially responsible behavior Encourage integrity of conduct Guiding Principle Remain accountable to all stakeholders Ensure clarity and unambiguity in communication
Total Prosperity Management A Culture The Aim To take Company from good to great. Changing Scenario Total Productivity Management Total Profit Management Total Prosperity Management
Management Systems ISO-50001 ISO-14001 SA-8000 ISO-9001 OHSAS 18001 • Energy Management System • Environmental Management System • Social Accountability • Quality Management System • Occupational Health & Safety Assessment Series
India Cement Industry The Indian cement industry is one of the most efficient in the world Cement Production projected to increase between 3. 6 and 6. 3 fold between 2010 and 2050 By 2050, India’s Cement Production is expected to be around 20% to 30% of Global production
Indian Cement Industry Projected CO 2 Emissions If current trajectories were to continue without intervention, by 2050, emissions from cement manufacture in India would reach between 488 Mt. CO 2 and 835 Mt. CO 2, a 255% to 510% increase compared to today’s level.
Indian Cement Industry Cement industry is an energy intensive industry and third largest coal consumer in the country requiring both electrical and thermal energy for its operation Break up of Manufacturing Cost Manpower, Others, 13% 12% Break-up of ELectrical Energy Consumption Others, 7% Factory Overhead, 4% Coal Mill, 4% Crushing, 2% Raw Material, 26% Raw Material, 25% Energy Cost, 46% Kiln & Cooler, 31% Cement Mill, 30% The table below show the progressive reduction in specific thermal energy reduction Year Heat Consumptions (k. Cal/kg Clk) 1950 -60 1970 s 1980 s 1990 s Post 2000 1300 -1600 900 -1000 800 -900 750 -800 650 -750
Definition of Clean Technology – Services of similar or better quality to existing technologies – Cost-competitive with existing technologies, in the long run. – Environmentally superior to existing technologies
Definition of Resource Conservation Resource conservation is the proper management of a natural resource to prevent its exploitation, destruction or degradation. Need for conservation of resources: – To maintain ecological balance for supporting life – To preserve different kinds of species – To make the resource available for present and future generation – To ensure the survival of human race.
Drivers for Technology Development Clean Technologies - Locations Fugitive Emissions Water Consumption Noise SOx NOx PM Crushing Noise Prehomogenisation Grinding of Raw material and Fuel Noise SOx NOx Energy Consumption Mining PM Pyro Processing PM Clinker Production Cement Grinding Noise Waste Management Storing and Packaging
Drivers for Technology Development • Economic considerations – Environment management Regulatory Driver – Energy efficiency – Capital cost • Recognition of Green Corporate Operation Driver • Regulatory and Social Position Market Driver Clean Technology Innovation
Advancement in Cement Industry
Advancement in Cement Industry Areas of Improvement Old Technology Clean Technology Mining & Material Handling Conventional Computer aided Conveying of Limestone -Dumpers -Ropeway -Tippers -Belt conveyors Crushing Two Stage Single stage -Pipe conveyor belt Continued…
Advancement in Cement Industry Areas of Improvement Old Technology Clean Technology -VRM's Grinding Ball mills with / without conventional classifier Blending & Storage Batch Blending Silos Continuous Blending Silos Pyro Processing Wet, Semi Dry, Dry -4 stage Preheater -Roller Press with dynamic classifiers Dry 6 stage Preheater Continued…
Advancement in Cement Industry Areas of Improvement Old Technology Clean Technology Clinker Cooler Conventional Cooler High Efficiency Cooler Burner Single channel burner Multi Channel burner Sealing Pneumatic Sealing Graphite Sealing Continued…
Advancement in Cement Industry Areas of Improvement Old Technology Clean Technology Heat Recovery Gas Cooling Tower WHRS Packing & Dispatch Bag, Bulk Plant Size, TPD 300 -1800 3000 -12000
Cleaner Technologies and Resource Conservation
Cleaner Technologies and Resource Conservation Adopted 7 ‘R’ philosophy to ensure Clean technology & resource conservation Initiatives at Shree contribute to low carbon economy leading to Total Prosperity
Cleaner Technologies and Resource Conservation Best Practices in Mines, Plant & Environment Mines Practices: 1. Blasting Techniques 2. Optimization for movement of Heavy Earth Moving Machinery (HEMM) 3. Geological Mapping and Contouring 4. New Survey techniques for Field Surveying. Plant Practices: 1. Thermal and electrical energy efficiency 2. Waste heat recovery 3. Alternative fuel and raw materials 4. Clinker substitution 5. Renewable Energy 6. Green Building Environment Practices: 1. Air 2. Water 3. Noise
Cleaner Technologies and Resource Conservation- Mines 1. Blasting Techniques Optimisation of Explosive Consumption • Use of Non - electric detonators • Implementation of recommendations of Central Institute of Mining & Fuel Research: Ø Polymer Beads are being used with Ammonium Nitrate. Ø Bottom Deck removes toe problem & save explosives. Ø Regular monitoring of vibrations by Seismograph.
Cleaner Technologies and Resource Conservation- Mines Use of Bulk Mixing Delivery Van • Uniform mixing of Ammonium Nitrate & Fuel Oil with best absorption and retention • Improved Blasting results & reduction in blasting fumes • Better productivity and safety • Facilitate to conduct big blasts to meet higher production targets. Bulk Mixing Delivery Van
Cleaner Technologies and Resource Conservation- Mines 2. Optimization of HEMM Operator Independent Truck Dispatch system (OITDS) • Mining Operation controlled by CCR. • Crew allocations through attendance recording system • Dynamic allocation of Equipment & optimization of route of dumpers • Real Time Display, Tracking & Tracing • On-line Health monitoring of HEMM • On-line Report Generation • Voice Communication
Cleaner Technologies and Resource Conservation- Mines 3. New Survey techniques for Field Surveying. New surveying techniques like surveying through ‘Total Station’ instead of conventional theodolite has been adopted. This has resulted in fast accurate survey of the Mines. Now company is exploring vast surveying through Drone Technology.
Cleaner Technologies and Resource Conservation- Plant Thermal and electrical energy efficiency Ø The best levels of specific energy consumption achieved by some Indian cement plants, at 680 kcal/ kg clinker and 66 k. Wh/t cement, are comparable with the best in the world ; Ø About 50% of Indian cement industry’s capacity today is less than ten years old. Ø While building these new cement plants, manufacturers have installed the latest, energy efficient technologies by design. As a result, recent cement plants achieve high levels of energy efficiency performance.
Cleaner Technologies and Resource Conservation- Plant SCL Beawar plant SCL Beawar Performance • Energy reduction target = 4. 55% • Target achieved = 29. 16% 0. 25 • Target overachieved 0. 2 • ESCerts Issued Energy Consumption (MTOE) 0. 4 0. 366 0. 350 0. 35 0. 3 0. 264 = 24. 61% = 86117 Nos. 0. 15 0. 1 0. 05 0 Present Target Achieved SCL Ras Performance Energy Consumption (MTOE) 0. 5 SCL Ras plant 0. 489 0. 48 0. 465 0. 46 0. 44 0. 409 0. 42 0. 4 0. 38 0. 36 Present Target Achieved • Energy reduction target = 5. 06% • Target achieved = 20. 58% • Target overachieved • ESCerts Issued = 15. 52% = 72140 Nos.
Cleaner Technologies and Resource Conservation- Plant Methodology adopted to reduce energy consumption • Daily Monitor Energy Consumption by conducting production / power meeting • Form Energy Task Force Team with cross functional team members and discuss best energy saving initiatives and implement. • Allocation of fund by management based on the payback period less than 3 years • Award Best Energy saving initiatives during monthly safety meeting Continued…
Cleaner Technologies and Resource Conservation- Plant Encourage employees of all levels and various functions and motivate to participate in Energy Management activities through: Ø Ø Ø Ø Suggestion schemes Bench marking Quality circles Small group activities Brain storming sessions, Journals Internal and external training programs. SCL also engage various external energy professionals and experts from agencies like NCCBM, TERI, FICCI, CII, BEE accredited auditors for Energy Management activities.
Cleaner Technologies and Resource Conservation- Plant Installed High Efficiency Classifier in place of conventional classifier Shree Cement have installed High efficiency Classifier in place of conventional Classifiers there by reducing pressure drop and improving the classification efficiency of raw material.
Cleaner Technologies and Resource Conservation- Plant Installed triplet in pre heater top cyclone Shree Cement have installed additional Triplet cyclone Twin Cyclone at Preheater top resulting into pressure drop and increase in cyclone efficiency results into less return dust in Preheater exit gases. Installation of additional cyclone also result in to lower consumption of Preheater fan.
Cleaner Technologies and Resource Conservation- Plant Installation of turbo Blowers Earlier compressed air was being utilized for conveying of coal. Turbo blowers were installed to reduce power consumption Shree Cement was first in Indian Cement Industry to install turbo blower and Shree cement has now decided to install turbo blower in all units in project phase
Cleaner Technologies and Resource Conservation- Plant Thermal and electrical energy efficiency - Conditions, barriers and constraints Technical • Layout constraints/civil structural capability for stage addition in Preheater • Burnability of raw mix • Risk involved in implementation of latest technologies Policy • India’s environmental norms, necessitating installation of additional equipment, might increase future energy consumption. • Logistics/availability and quality concerns of coal, raw materials • Grid Power Quality Financial • Longer shutdown time for major modifications • Long pay back period for implementation of certain initiatives, if only energy efficiency benefits are taken into account. Uncertainty price of CER & ESCerts (PAT) • Higher investment and operating costs for oxygen enrichment
Cleaner Technologies and Resource Conservation- Plant Waste Heat Recovery Ø Adoption of WHR systems in Indian cement manufacturing facilities has been relatively slow compared to other countries. Ø Out of about 183 large cement kilns in the country, only 12 have WHR systems installed. Ø The WHR potential of the Indian cement industry is estimated at approx. 1000 MW whereas at present around 250 MW of WHR system have been installed in India. Continued…
Cleaner Technologies and Resource Conservation- Plant Installation Waste heat recovery System In dry process cement plants, nearly 40% of the total heat input is available as waste heat from the exit gases of the preheater and cooler. Benefit: • Improved quality of power helps in smooth operation of cement plant. • Contribute to reduce global warming by way of releasing low temperature gases to atmosphere. • Reduced GHGs emissions intensity Heat Consumption 45% 55% Heat Used Heat Unused Shree Cement have installed 111 MW of Waste Heat Recovery Based Green Power Generation which is largest in the world cement industry after China. Continued…
Cleaner Technologies and Resource Conservation- Plant Before After Continued…
Cleaner Technologies and Resource Conservation- Plant Waste heat recovery - Conditions, barriers and constraints Technical • Space Constraint in the layout for close proximity of Preheater and Cooler • Waste heat availability in terms of temperature and quantity from the Preheater and Cooler • Operational problems due to dust deposition in the system Policy • Provision of renewable energy status for Waste Heat Recovery systems • Need duty incentives for import of equipment / technology Financial • Long payback periods • High CAPEX • Export to grid is not viable
Cleaner Technologies and Resource Conservation- Plant Alternative fuel and raw materials To date, AFR use is approx. 0. 6% of thermal energy across India, compared to a global average of about 4%, but the cement industry has increased its focus on AFR utilisation by using newer industrial, municipal and agricultural wastes. Alternate fuel available in India Type of waste as fuel Waste availability for Co-processing (Million tons per annum) Hazardous fuel 0. 65 Biomass 150 Used Tyre 0. 83 Industrial Plastic Waste 0. 20 RDF from MSW 6. 88 Continued…
Cleaner Technologies and Resource Conservation- Plant Use of alternate fuels & raw materials The use of waste as alternative fuels and raw materials in the cement industry has numerous environmental benefits such as: • Reduced the use of mined natural materials such as limestone, bauxite, Iron ore etc. and non-renewable fossil fuels such as coal. This also reduces the environmental impacts associated with mining of these natural materials. • Contributes towards lowering of emissions such as greenhouse gases by replacing the use of fossil fuels with materials that would otherwise have to be incinerated. • Reduced land requirement for land fill option thereby reducing the emissions and also liability associated with the landfills. • Maximizes the recovery of resources present in the waste. All the energy is used directly in the kiln for clinker production and the non-combustible part of the waste becomes part of clinker.
Cleaner Technologies and Resource Conservation- Plant Alternative fuel and raw materials
Cleaner Technologies and Resource Conservation- Plant Technical Capabilities (R&D testing facility) Shree Cement have established its own R&D centre which is approved by GOI. Following facility available at SCL: • Advance analysis through Optical microscope, Particle Size Analysis, X Ray Diffraction analysis, Spectroscopy • Standardized procedure for performance evaluation of fly ash to maximize its use. • Burnability studies to arrive at optimum raw mix level for better quality of clinker. • Refractory physical and chemical analysis. • High Performance Concrete study. • Compatibility studies of various AFR materials.
Cleaner Technologies and Resource Conservation- Plant Replacement of Laterite with Lead-Zinc Slag • Lead And Zinc is a waste from smelting industry. • Utilized around 12 Lakh tons of lead and Zinc Slag. • Cleaned up 40 hectares of land at producers site, which was being used for dumping slag. • Land now being used for plantation by producer. • Proved our industrial ecologist instinct.
Cleaner Technologies and Resource Conservation- Plant Utilization of petcoke in place of conventional fuels Ø Petroleum coke is a by-product / undesirable product of oil refining cracking process. Ø Unique Initiative of petcoke utilization in Cement and Power Plants for the first time in Indian cement industry taken by Shree Cement and achieved 100% petcoke utilization in both cement and power plants.
Cleaner Technologies and Resource Conservation- Plant Alternative fuel and raw materials - Conditions, barriers and constraints Technical • Variation in the quality of AFR, availability of feeding system, compatibility with raw materials. • Non availability of sorted waste and low calorific value of municipal waste Policy • Trans Boundary movement of hazardous waste • Need for legislation encouraging co-processing in the cement industry • Complicated procedural systems for co-processing • Difficulty in allotment of Government Land for installing pre-processing facility Financial • Higher investment and operating cost for waste preprocessing • No incentives available for co-processing even though it has low carbon foot print
Cleaner Technologies and Resource Conservation- Plant Clinker substitution Clinker is the main component in most types of cement. When ground and mixed with 4% to 5% gypsum, it reacts with water and hardens. Other mineral components also have these hydraulic properties when ground and mixed with clinker and gypsum: • Ground blast furnace slag (GBFS, a byproduct from the iron and steel industry) • Fly ash
Cleaner Technologies and Resource Conservation- Plant Characteristics of Clinker substitution Clinker substitute Source Characteristics of blended product compared to OPC Positive Estimated annual level of availability Limiting 2010 Fly Ash Coal- fired power plants Higher Long-term strength, increased durability, lower water consumption, better workability Relatively lower early strength, logistic barriers(distance between power plant and cement plant) 100 MTPA fly ash utilised out of 190 MTPA generated. Granulated blast furnace slag (GBFS) Iron and steel industry Improved chemical resistance, higher longterm strength Relatively lower early strength, logistic barriers (distance between iron and steel plant and cement plant) 10 MTPA of GBFS utilised out of 22 MTPA Other blending materials Non-ferrous industries, mineral processing industries Increased durability Relatively lower early strength, presence of minor constituents (e. g. magnesium oxide [Mg. O]), logistic barriers (distance between other industries and cement plant) Lead Zinc slag (1. 0 MTPA), copper slag (0. 8 MTPA), equilibrium catalyst (0. 015 MTPA), jarosite (0. 3 MTPA), Kimberlite (0. 6 MTPA), marble slurry (5. 0 MTPA). Limestone deposits Increased workability, higher long-term strength None. Relatively large deposits, but only 40 years of high grade limestone estimated to be available
Cleaner Technologies and Resource Conservation- Plant Utilization of Flyash The increased use of fly ash in Portland SCL Flyash Consumption 6. 00 Pozzolona Cement (PPC) directly impacts the reduction of clinker factor in Thereby emissions through reducing reduced CO 2 fuel combustion and reduced limestone calcination. 4. 00 MT cement. 4. 82 5. 00 3. 03 3. 29 3. 54 2. 96 3. 00 2. 00 1. 00 0. 00 2012 -13 2013 -14 2014 -15 2015 -16 (9 Months) 2016 -17 Fly ash conforming to standard IS: 3812 (1) 2003 can be used (up to 35% maximum) in the manufacture of PPC as per IS: 1489 (part 1) 1991. Shree Cement have Installed Fly ash collection and storage system at Thermal Power Plants at own cost. Continued…
Cleaner Technologies and Resource Conservation- Plant Utilization of Slag Portland Slag Cement, commonly known as PSC, is blended cement. Slag is, essentially, a non-metallic product comprising of more than 90% glass with silicates and alumino-silicates of lime. IS: 12089 standards are used for producing PSC. It is created with a combination of up to 45 - 50% slag, 45% – 50% clinker, and 3 -5% gypsum. Advantages of PSC • Ultimate compressive strength • Excellent resistance to Chloride & Sulphate attacks • Improved workability • Better compatibility with all types of admixtures • Superior finish & Minimised shrinkage cracks • Better resistance against alkali-silica reaction
Cleaner Technologies and Resource Conservation- Plant Clinker substitution - Conditions, barriers and constraints Technical • Non-availability of appropriate blending materials w. r. t. , quality & quantity • Additional CAPEX for fly ash & Slag dryers Policy • Fly ash is sold on a competitive bidding making PPC manufacturing financially unviable in many locations • New / Modification of existing standards/codes is required for higher utilization of blended materials • Lack of consumer awareness on the quality of blended products + lack of confidence of builders • Mandatory requirement of giving 20% CPP Fly ash to the brick Vendors • Need for composite cement standards Financial • Steep increase in Cost of Fly ash / Slag • Need for Tax relief for Blended Cements • Need fiscal incentives for long distance fly ash / slag transport
Cleaner Technologies and Resource Conservation- Plant Renewable Energy The government of India has set the target of renewable energy capacity to 175 GW which includes 100 GW from Solar, 60 GW from wind and 10 GW from bio-power and 5 GW from small hydro power to be achieved by 2022. Shree Cement has installed 62 k. Wp of Solar PV Plant at Beawar plant.
Cleaner Technologies and Resource Conservation- Plant Green Building A ‘green’ building is a building that, in its design, construction or operation, reduces or eliminates negative impacts, and can create positive impacts, on our climate and natural environment. Green buildings preserve precious natural resources and improve our quality of life. The building has the following features: • High Performance solar controlled glasses • Eco-friendly building material • Adequate day lighting • Energy Efficiency Building Envelope • Rain water tank and STP Provision • Solar reflective paint on terrace Continued…
Cleaner Technologies and Resource Conservation- Plant Shree Cement CCR Building Suratgarh
Cleaner Technologies and Resource Conservation- Environment EMISSION STANDARD FOR NON CO- PROCESSING KILN Parameter Unit Plant Commissioned Before 25/08/2014 Plant Commissioned after 25/08/2014 Dust Emissions mg/Nm 3 30 30 NOx for SLC Kilns mg/Nm 3 1000 600 NOx for ILC kilns mg/Nm 3 800 600 SO 2 Emission mg/Nm 3 Time for Compliance 100, Pyritic sulphur in the limestone is <0. 25% 700, Pyritic sulphur in the limestone is 0. 25 -0. 5 % 1000, Pyritic sulphur in the limestone is >0. 5 % 31 st March 2017 All monitored values for SO 2 and NOx shall be corrected to 10% Oxygen, on dry basis. The norms for SO 2 and NOx shall be applicable to stacks attached to Kiln
Cleaner Technologies and Resource Conservation- Environment EMISSION STANDARD FOR CO- PROCESSING IN KILN Parameter Unit Plant Commissioned Before 25/08/2014 Plant Commissioned after 25/08/2014 Dust Emissions mg/Nm 3 30 30 NOx for SLC Kilns mg/Nm 3 1000 600 NOx for ILC kilns mg/Nm 3 800 600 NOx for combined kilns mg/Nm 3 1000 600 SO 2 Emission mg/Nm 3 Time for Compliance 100, Pyritic sulphur in the limestone is <0. 25% 700, Pyritic sulphur in the limestone is 0. 25 -0. 5 % 1000, Pyritic sulphur in the limestone is >0. 5% 31 st March 2017 HCl mg/Nm 3 10 HF mg/Nm 3 1 TOC mg/Nm 3 10 Hg and its compounds mg/Nm 3 0. 05 Cd, TI and its compounds 0. 05 Heavy Metals 0. 5 Dioxins and Furans Ng TEQ/Nm 3 0. 1 All monitored values for SO 2 and NOx shall be corrected to 10% Oxygen, on dry basis. The norms for SO 2 and NOx shall be applicable to stacks attached to Kiln
Cleaner Technologies and Resource Conservation- Environment Baghouse in place of ESPs Earlier Electrostatic Precipitator (ESP) were installed to reduce emissions from raw mill. These ESPs are converted into Pulse jet type Baghouse. The major advantage of upgrading to this filter is that bags in this assembly can be cleaned online without disrupting setup and played a significant role in reducing our emissions. Continued…
Cleaner Technologies and Resource Conservation- Environment Installation of IGBT in place of SCR in Cooler ESP field A high frequency power supply system using insulated gate bipolar transistors (IGBTs) was installed to produce power at a higher frequency other than a standard line frequency of 50/60 Hz, where conventional Silicon- Controlled Rectifier (SCRs) were being used.
Cleaner Technologies and Resource Conservation- Environment Installation of Continuous Emissions Monitoring System The Continuous Emission Monitoring (CEMS) System measures concentration of gaseous emissions ie. SO 2 and NOx. PM emissions are monitored using Opacity Meters. Data are recorded/observed through analog outputs to a recording system and send directly to a DAS (Data Acquisition System) for storage and onward transmission. SCL installed & connected Online monitoring system for PM, SO 2, NOx Continued…
Cleaner Technologies and Resource Conservation- Environment Installation of Continuous Emissions Monitoring System
Cleaner Technologies and Resource Conservation- Environment Air Cooled Condensors in place of water cooled condensors In ACCs system, ambient air is used as cooling media instead of water for cooling the exhaust steam. Before the installation of ACC’s water consumption for power generation was approx. 1088 m 3/MW per year, this reduced to 99. 73 m 3/MW per year with installation of ACCs, resulting into net saving of about 90. 8%.
Cleaner Technologies and Resource Conservation- Environment Water Conservation – Best Practices Ø Installation of water meters for regular monitoring and study of daily water consumption Ø Use of recycle water from STP for horticulture Ø Installation of PVC Pipelines in place of MS pipelines to avoid water leakages Ø Use of RO reject water in mill spray and synthetic gypsum manufacturing Ø Recycling of cooling water and utilization for dust suppression.
Cleaner Technologies and Resource Conservation- Environment Noise Control - Best Practices • In mining of lime stone Non-Electric Detonators and Top Line Detonators are used to reduce noise, vibration and flying of rocks. • HEMM fitted with closed cabins & Silencers. • Use of PPE’s in high noise area. • Use of Rock Breaker for secondary blasting. • Green belt development as sound barrier.
Technologies Need Way To India
Technologies Need Way To India Several newer technologies that could significantly improve the CO 2 emissions reduction profile of the Indian cement industry are at various stages of development: 1. Utilization of advanced automation systems in cement manufacture 2. Use of Nano-Technology in cement production 3. Alternative binding cement materials for reducing CO 2 emissions 4. Fluidized bed Advance Cement Kiln System 5. Improving the burnability of raw mix by use of mineralizer 6. Fuel Cell 7. Developing national standards on composite cements Continued…
Technologies Need Way To India Newer technologies: Conditions, barriers and constraints Technical • Many of these technologies are in conceptual, R&D and pilot plant stage. Some of these technologies are to be scaled up to industrial level • Some of these technologies are patented and not available in open domain • Complicacy in technology transfer • Increase the number and skills level of scientific researchers with cement industry expertise by creating teaching and research positions on materials science Policy • Need for Government policy for technology transfer • Need financial/infrastructural support for domestic R&D activities • Need of building adequate R&D and infrastructure in the country Financial • High cost of R&D and Infrastructural development • Uncertainty in project scaling and profitability • Need incentives to support R&D activities from Government
Technologies Need Way To India 1. Utilization of advanced automation systems in cement manufacture The control and operation of kiln systems today is extremely complex, with properties of input fuel and feed materials varying greatly and with product standards becoming increasingly stringent. Cement kiln operators today encounter such sudden variations that dynamic control of the kiln is vital to achieve optimum results and lower manufacturing costs. An effective advanced automation and control system can bring substantial improvements in overall performance of Cement Plant. Continued…
Technologies Need Way To India Utilization of advanced automation systems in cement manufacture Anticipated benefits • Thermal savings: 6 – 8 kcal/kg clinker • Electrical savings: 3 – 6 k. Wh/mt clinker • CO₂ reduction: 4 – 8 kg CO₂/mt cement Primary influencing parameters • Expert control systems simulate the best operator by using information, hence the expertise level of operators is vital • Present levels of operation efficiency and energy efficiency • Existing plant configuration determines additional equipment requirement • Uptime of control systems could be a concern Continued…
Technologies Need Way To India Utilization of advanced automation systems in cement manufacture Conditions, barriers and constraints Technical • Uptime of control system is a concern. Typical uptime varies from 70 - 80%, thereby affecting kiln control, energy efficiency and overall return on investment Policy • None to date Financial • Return on investment could be long (about 4 -6 years) in a few cases (with low energy tariff)
Technologies Need Way To India 2. Use of Nano-Technology in cement production Nanotechnology can be defined as the study and manipulation of the properties and structure of matter at nanoscale. Applications of nanosciences and nanotechnology in the study and further development of cement, alternative cementitious binders and concrete are being made for achieving cement and concrete with improved performance as well as greater sustainability. Continued…
Technologies Need Way To India Use of Nano-Technology in cement production The efforts are currently directed towards: • Development of nano-cement and eco-friendly, high performance cements/binders manufactured with lower clinker content • Improvement in cement and concrete performance through incorporation of nanoparticles and chemical admixture • Better understanding of cementitious materials through nanoscale investigations of cement hydration reactions and hydration products to achieve cement and concrete with tailor-made performance • Development of activators/catalysts for low temperature clinkerization • Use of nanoparticles for the reinforcement of the cementitious matrix for improved flexibility and toughness • Application of photocatalytic Ti. O 2 nanoparticles for self-cleaning concrete surfaces • Cement based nano-composites for various applications Continued…
Technologies Need Way To India Use of Nano-Technology in cement production Conditions, barriers and constraints Technical • The health hazards associated with handling and use of nanoparticles need to be studied Policy • None to date Financial • Present cost of production of nanoparticles is very high and needs to be brought down for economic utilization
Technologies Need Way To India Alternative binding cement materials Belite clinker: Contains no alite or small amounts, and up to 90% belite leading to about a 6% reduction of the process CO 2 intensity of clinker. Calcium sulphoaluminate clinker (CSA): Contains ye’elimite as the main constituent, which directly reduces CO 2 emissions, commercial CSA clinker yields 44% reduction in process CO 2 intensity of clinker compared to Portland Clinker. Alkali‐activated binders (geo-polymers): Produced by the reaction of an alumino-silicate (the precursor) with an alkali activator; and, as an alternative to traditional cement products, can reduce CO 2 emissions depending on the carbon emissions associated with the production of alkali activators. Continued…
Technologies Need Way To India Alternative binding cement materials Conditions, barriers and constraints Technical • Current market deployment of belite cements is very limited (and confined to a small number of countries) due to their much lower early strength characteristics Policy • Global commercial use remains limited and to date they have been primarily used in non‐structural applications Utilisation • Rely on materials similar to those used in blended Portland cements to reduce the clinker-to-cement ratio
Technologies Need Way To India Fluidized bed Advance Cement Kiln System FAKS, the fluidized bed advanced cement kiln system, has been researched and developed to burn low grade coals efficiently, reducing NOx emissions significantly and increasing thermal efficiency by resourcefull recovering in-process heat from solids and gases. Continued…
Technologies Need Way To India Continued…
Technologies Need Way To India Fluidized bed Advance Cement Kiln System Anticipated benefits CO 2 reduction (direct): 20 - 25 kg/tonne clinker Other benefits • Reduced NOx emissions • Low capital cost per ton of cement production while fulfilling the stringent NOx emission standards • Suitable for locations where limestone deposits are limited (less than 20 million tonnes) • It is of modular design, so capacity can be increased by multiple units • Plant is relatively easier to relocate due to smaller foot print Primary influencing parameters • Reduced environmental emissions level in terms of NOx • Low cost technology Continued…
Technologies Need Way To India Fluidized bed Advance Cement Kiln System Conditions, barriers and constraints Technical • Technology currently only applicable for low capacity kiln (up to 1, 000 tpd): yet to be established for higher capacity • Technology assessment is to be carried out to know whether CO 2 reduction potential is available for higher capacity plants • Increased electrical energy consumption by 9 k. Wh/t clinker (8. 5 k. Wh/t OPC) based on reported data of cement kilns (rotary kiln vs FAKS) in Japan Policy • None to date Financial • None to date
Technologies Need Way To India Improving the burnability of raw mix by use of mineralizer The mineralizers, in general, have been found to reduce the clinkerization temperature by about 50 o. C or even higher without compromising clinker quality. Such reduction in clinkering temperature has a direct bearing of the reduction of fuel consumption, besides improvement in clinker morphology. The selection and use of the mineralizers are generally governed by the following considerations: • • • Reaction effects desired Compatibility with a given kiln feed Process adopted Physical form of mineralizers Economic viability of using mineralizers Continued…
Technologies Need Way To India Improving the burnability of raw mix by use of mineralizer Anticipated benefits • Thermal savings (direct): reduction in clinkering temperature by around 50 o. C, reduction in heat consumption by about 13 kcal/kg clinker • Electrical savings: reduction in power consumption up to 1 k. Wh/tonne cement • CO 2 reduction (direct): 5 - 15 kg/tonne clinker Indirect benefits: • Scope for using sub grade/low carbonate raw materials • Increased lifetime of refractories • Clinker quality improvement • Scope for using more pozollanic materials Continued…
Technologies Need Way To India Improving the burnability of raw mix by use of mineralizer Conditions, barriers and constraints Technical Though the use of a mineralizer is a technically attractive option to further economize the cement manufacturing process, there are certain barriers, for example: • Additional cost of mineralizer(s) • Inconsistent availability or non-availability • Problems during pyro-processing • Uniform dispersion in raw mix Policy • None to date Financial • Capital cost due to requirement of extra storage facility for mineralizer(s) • Infrastructure required for mineralizer handling system
Technologies Need Way To India Fuel cell technology A fuel cell is a device that converts the chemical energy from a fuel into electricity through a chemical reaction with oxygen or another oxidizing agent. Hydrogen is the most common fuel, but hydrocarbons, such as natural gas and alcohols like methanol are sometimes used. Hydrogen fuel cell power may find a place as a green power generation technology in the future after a few successful commercial installations at different capacities. Currently, fuel cell technology in smaller capacity is under commercial trials in different parts of the world. In these, technology suppliers are willing to supply the power with a Power Purchase Agreement at a price comparable to prevailing conventional power cost. Continued…
Technologies Need Way To India Fuel cell technology Anticipated benefits • Thermal savings: Unknown • Electrical savings: Unknown • CO 2 reduction (direct): 1. 2 tonne of CO 2 per 1, 000 k. Wh if it is replacing the CPP power, and 0. 9 tonne of CO 2 per 1, 000 k. Wh if it is replacing grid power • CO 2 reduction (indirect): Unknown Primary influencing parameters • The technology is yet to be fully commercialized Continued…
Technologies Need Way To India Fuel cell technology Conditions, barriers and constraints Technical • Technology is patented Policy • Fiscal incentives like concessional import duty structure etc. should support this green and patented technology Financial • None to date
Technologies Need Way To India Developing national standards on composite cements Blended cements, which are produced using more than one mineral addition, are known as 'composite cement‘. At present, the Bureau of Indian Standards (Go. I) has no specific standard for composite cements. European standards identify composite cements (CEM V), where both granulated blast furnace slag (GBFS) and siliceous fly ash/pozzolanic material are used together as cement replacement materials. To facilitate the manufacture and use of composite cement in India it is required to formulate the standards for composite cements. Continued…
Technologies Need Way To India Developing national standards on composite cements Anticipated benefits Thermal and electrical savings: Apart from thermal energy, there will be a specific electrical energy reduction per tonne of cement, which will indirectly reduce the Scope II CO 2 emissions if the plant does not have CPP. If the plant has CPP, it will reduce Scope I CO 2 emissions. Thermal savings reduction potential depends on clinker substitution level achieved: Clinker Substitution 25% 35% 45% 55% 70% Thermal Saving (k. Cal/kg cement) 170 235 305 375 475 CO 2 Reduction Potential (kg CO 2 / tonne cement) 205 285 370 450 575 Continued…
Technologies Need Way To India Developing national standards on composite cements Conditions, barriers and constraints Technical • Further experimental investigations using indigenous materials and Indian test procedures would be required to generate enough data to enable formulation of national standard Policy • Government funding for R&D of composite cement is required. Based on the results, Indian Standards must be developed using European standards as guidelines Financial • Possibility of high capital expenditure (CAPEX)
Indian Cement Industry CO 2 Emissions reduction The Indian cement CO 2 Emissions industry has made strong 1. 2 1 adopting available footprint the by best technologies (BAT) and environmental CO 2 Emissions t. CO 2/t Cement efforts to reduce its carbon 1. 12 0. 7190000001 0. 8 0. 6 0. 4 0. 2 0 1996 2010 practices. 86 Source: International Energy Agency
Key indicators in the 2 DS Low-Demand Case High-Demand Case 2010 2020 2030 2050 Production (Mt) 217 416 598 780 492 848 1361 Per-capita consumption (kg/capita) 188 309 400 467 364 565 812 Clinker-to-cement ratio 0. 74 0. 70 0. 64 0. 58 Electric intensity of cement production (k. Wh/t cement) 80 76 73 71 75 72 70 Thermal intensity of clinker production (kcal/kg clinker) 725 709 694 680 703 690 678 Alternative fuel use (as a share of thermal energy consumption) (%) 0. 6 5 19 25 87 Notes: Data for 2010 is for financial year 2009/10 ending 31 March 2010. The electric intensity of cement production does not include the reductions that may come from the use of WHR.
Key indicators in the 2 DS
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