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28th Septeber,2016
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Dedicated Freight & Industrial Corridors
Make in India
Smart Cities
Electricity
Connectivity, Roads
Irrigation, Water Supply
High Speed Trains
Airports
Communication
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
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
(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 9
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 of 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 16
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 on/or after notification
50 50 30
# In line with European Guidelines @ Notification No.G.S.R. 612(E) dated 28.8.2014 * @10% O2
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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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