Technology Roadmap: Low-Carbon Technology for the Indian Cement Industry Mr. L Rajasekar
Proactive Indian Cement Sector Low Carbon Technology Roadmap ...
Transcript of Proactive Indian Cement Sector Low Carbon Technology Roadmap ...
Proactive Indian Cement Sector
Low Carbon Technology Roadmap and Initiatives
www.justlimateaction.org
Cement sector in India – An overview
About 50% of installed capacity based on
modern technology (<10 years old)
Continuous modernization drive in old
plants and many efficient cement plants
shifted to non-fossil fuel sources
World leader in blended cement production
65% of the installed capacity is covered
under Cement Sustainability Initiative (CSI)
Second largest cement producer in world
More than 100 years old
Nearly 400 Million Tonnes Per Annum
(MTPA) installed capacity
Plant sizes varies from 3000 to 13000 TPD
Regarded one of the most energy efficient in
world
India Low Carbon Technology RoadmapPartners and Supporters
Industry supporters
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Low Carbon Technology Roadmap (two phases)
Broad Technology papers developed
Cement demand data, scenario building
Technology
Financing
Policy
Cement
Sector
Roadma
Stakeholder outreach
Stakeholder & partner review
Data coverage in Roadmap (85%+)
Phase IPhase II
Site specific feasibility assessment at plant level for identified
technologies in phase I
Phase II outcome -Site specific technology with carbon
mitigation potential
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Low Carbon Technology Roadmap – An overview
Identification of key levers for brining down carbon footprints
Further reduction in clinker content (blended cements)
Thermal and electrical energy efficiency
Co-processing of alternative fuels (AFRs)
Electricity generation through waste heat recovery
New technology development
Further reduction in the clinker content by significant
shift from Ordinary Portland Cement (OPC) to blended
cement production by using additives and less clinker,
thereby reducing carbon emissions
Key AchievementsReducing the clinker content - Blended Cement Production
Benefits of Blended Cement :
Conservation of mineral resources such as Limestone
Reduction in electricity and fuel consumption
Usage of industrial waste i.e. fly ash and slag as a rawmaterial, thereby reducing environmental hazards
779
533
328
OPC PPC PSC
Average kg CO2/ton of cement type (estimated direct emissions)
70
4228 ~
25
30
5872 ~
75
0
20
40
60
80
100
120
FY 95 FY 05 FY 12 FY 15
Blended Cements Ordinary Portland Cement (OPC)
20 22 26
138*
FY 10 FY 12 FY 15 Cumulative FY 10 to FY15
Avoided CO2 emissions (Million Tonnes) resulting from countrywide shift from OPC to blended cement
* From FY 10 to FY 15, about 138 million tonnes of CO2 was avoided due to blended cement production. This is equivalent to 40% of annual CO2 emissions from Australia (2013).
Key AchievementsReducing the clinker content - Blended Cement Production
913 894 891 864 851 808727
NorthAmerica
Africa Europe CentralAmerica
Brazil MiddleEast
India
Source: CSI data publication 2014
747
727
2010 2013
• Consistent reduction in specific thermal energy consumption of Clinker
• Ranks one of the best in world
• Dalmia Cement’s Kadapa and Ariyalur plant annual average 700 – 704 kCal/kg Clinker
Thermal energy consumption 2013 India (kCal/kg of
Clinker)
Thermal energy consumption 2013 world comparison
(kCal/kg of Clinker)
Key AchievementsThermal energy efficiency
128 117 112 105 103 94 93
83
Electricity consumption 2013 (kWh/ton of cement)
Source: CSI data publication 2014
• 12% reduction in electricity consumption (kWh/ton of cement) during 2010-13
• Indian cement sector ranks one of the best in world
• Dalmia Cement (Bharat) Limited Ariyalur plant – 64.67kWh/ton of cement.
94
83
2010 2013
Electricity consumption India (kWh/ton of cement)
Key AchievementsElectrical energy efficiency
Carbon Footprint in Cement Sector
Current scenario
Source: Global Average and India average figures have been taken form the low carbon technology roadmap for cement sector developed by WBCSD, CSI and IEA
Our Eastern India operations
• 395 kg/ton of cement for FY 15.
Dalmia Cement (Bharat) Limited (group average)
• 531 kg/ton of cement for FY 15
• An aspiration of 1.4% per annum reduction is estimated in the India roadmap
Low Carbon Technology Roadmap 2050 and beyond
Low Carbon Technology Partnership initiative (LCTPi)
• Cement LCTPi India ambition is up to 20% reduction of CO2 emissions by 2030
compared to Business As Usual scenario
• The aspirations can be met through:
• Increasing clinker substitution (blended cements)
• Enhancing energy efficiency (thermal and electrical energy)
• Increasing use of alternative fuels and raw materials (non-fossil fuel use)
• Development of new products, technologies (research and development)
• In order to achieve this level of ambition in cement sector, availability of concessional
financing, policy reform and removal of barriers in technology transfer is required
Additional technological interventions for low carbon
growth
Electrical energy efficiency
• Installation of high efficiency
fans, blowers and compressors
• Use of latest generation high
efficiency electrical motors and
variable speed drives
• Generating electrical energy
from waste heat recovery system
• Installation of energy efficient
grinding systems such as VRM
and Roll Press
• Use of Renewable energy from
wind, solar, Hydro, etc.
Thermal energy efficiency
• Additional preheater cyclone stage
installation wherever feasible
• Installation of higher efficiency latest
generation clinker cooler
• Improved insulation for reducing
radiation losses from kiln, preheater
and cooler
• Reduction of false air in kiln by
installing new design sealing systems
• Installation of low primary air kiln
burner systems and reduction in fuel
conveying air
• Improvement in plant heat rate of CPP
by improving boiler and turbine
efficiency
New developments
• Geopolymer cement
• Composite cements
• Carbon Capture Storage
and Use (CCS - U)
• Reducing carbon
emissions from inbound
and outbound logistics
through optimisation
Structured visits to other
plants to understand the
new technology initiatives
Alternative Fuel Utilisation
Current practice
• The alternative fuel utilisation in India is increasing gradually
but still very low compared to Europe
• Current usage of alternative fuel in India is about 1% (heat
basis) compared to 30-40% (heat basis) in Europe.
Potential and recommendations
• Significant thermal substitution potential from waste streams
• Viable business model through policy intervention such as
polluter to pay principle needs to be developed as it is the
case in developed world
• Government is supporting by development of new standards
to facilitate co-processing in cement kilns.
• With supportive policy in alternative fuel
utilisation, the average thermal
substitution rate in India can reach 19%
in 2030 and 25% in 2050 as compared
to 1% in current scenario
• This will result into saving of fossil fuels
and significant mitigation in CO2
emissions.
Source: India Low Carbon technology Roadmap
External support needed to meet our low carbon
growth aspirations
• New low carbon technologies are capital intensive
• Need low cost finance through Green Climate Fund for further reduction of carbon footprint in
developing countries
• Co-generation through waste heat recovery system
• High potential for electricity generation from waste heat recovery
• Needs new capital intensive technologies to utilise low temperature waste heat
• Waste heat recovery to be treated as renewable energy to get priority low cost finance
• Cement sector needs incentives for encouraging waste utilization
• Need to bring in developed country policies on ‘Polluter to Pay’ in developing countries to enhance
usage of waste materials in cement sector
• Making technologies available for developing countries
• Developed countries should remove the barriers in their technology transfer
• More research on CO2 sequestration and it’s conversion into new product
• Addressing the gap from 2016 to 2020
• Need for revamping the international carbon trading market to incentivize low carbon technologies
Dalmia Cement - Partnerships for Sustainable
Development
Best Wishes for Clean, Green and Happy Globe.
Thank You.
Mahendra SinghiGroup CEO and Whole Time Director – Dalmia Cement (Bharat) Group