Waste Mapping and Forecasting for Alternate Fuel Usage … Mr V Kannan CII... · Waste Mapping and...

© Confederation of Indian Industry

Promoting Alternate Fuel and Raw material (AFR) utilisation in Indian Cement Industry

Waste Mapping and Forecasting for

Alternate Fuel Usage in Cement Plants

Confederation of Indian IndustryCII – Godrej Green Business Centre, Hyderabad

23rd March 2017, New Delhi


Confederation of Indian Industry (CII)

Non-government, not-for-profit, industry led & industry managed apex industry association

Founded over 120 years ago

Direct membership : 8000 organizations

Indirect membership : 200,000 enterprises

Wide network

66 offices in India, 9 overseas offices, 9 centres of excellence

Institutional partnerships with 320 counterpart organizations in 106 countries

Serves as reference point for Indian industry and international business community


CII- Sohrabji Godrej Green Business Centre Hyderabad

A unique Public – Private Partnership (CII, Govt of Andhra Pradesh, USAID and Pirojsha Godrej Foundation)

“Centre of Excellence” for Energy, Environment, Green Buildings, Renewable energy & Climate change activities in India


Waste management in India is of paramount importance with increasing industrialization & rapid urbanization

MSW annual generation estimated to be 140 Million Tons by 2025

15, 000 tonnes of plastic waste is generated every day

7.8 Million Tons of Hazardous waste generated annually

INDC : Intended Nationally Determined Contribution

Reduce the Emissions Intensity of its GDP by 33 to 35 Per Cent by 2030 from 2005 Level

Project Background - Waste Management


Project Background – Indian Cement Industry

Indian Cement Industry emitted 137 Mt of CO2, 7% of India’s total man made emissions

Low Carbon technology Roadmap identified AFR usage in Cement industry as one of the key levers to reduce the GHG emissions

Cement demand in India is projected to reach 500-650 MTPA by 2025 which in turn create demand for raw materials and fuels

Currently Indian Cement Industry’s average Thermal substitution rate (TSR) is around 4%, whereas the TSR in few countries are as high as 70% (Austria, Germany)


Project Objective

Co-processing in Cement industry finds a synergy between the two and provide a sustainable solution for waste management in the country & reduces overall GHG emissions

Main objective of the project is to facilitate use of urban & industrial waste as Alternate Fuel & Raw Material (AFR) in Indian cement industry

CII in association with Cement Manufacturers’ Association (CMA) is working on this initiative

Supported by Shakti Sustainable energy foundation (SSEF)


7

Expert group

Name Designation Organisation

Mr Ulhas parlikar

Chairman – CII Intiative on increasing

AFR usage in Indian Cement industry Geocycle India

Mr A Ramchand Chief Environmental Engineer Andhra Pradesh Pollution Control Board

Mr R P Tiwari, Superintendent Engineer Chhattisgarh Pollution Control Board

Mr P K Gupta Scientist E Central Pollution Control Board

Mr V R Ghadge Senior Environmental Engineer Gujarat Pollution Control Board

Mr Venkatesh Shekar Senior Environmental Officer Karnataka State Pollution Board

Mr P S Bundela Regional Officer, Bhopal Madhya Pradesh Pollution Control Board

Mr V M Motghare Joint Director – Air Pollution Control Maharashtra Pollution Control Board

Dr Vijai kumar Singhal Chief Environmental Engineer Rajasthan Pollution Control Board

Mr S Selvan Joint Chief Environmental Engineer Tamil Nadu Pollution Control Board


Activities carried out

Policy Advocacy Developing draft

recommendations for inclusion of Co-processing in HWM rules

Frequent meetings & discussions with various Government bodies (MoEFCC, CPCB & SPCBs)

Stake holders meetings, Expert group meetings & Industry consultation

Various submissions to MoEFCC & CPCB on promoting co-processing

Technical Research & Analysis Life Cycle approach for

AFR utilization in Cement industry

Status paper on AFR usage in Indian Cement industry

Waste forecasting for Indian Cement Industry

Variation in chemical constituents of waste streams

Capacity Building activities National & International

missions

Inventory of waste generation

Inventory of Co-processing cement plants

Technical Publications

Website on Co-processing


Publications & Website on Co-processing - www.ciiwasteexchange.org


Key milestones

AFR substitution increased from less than 1 % in 2010 to more than 4% in 2016

Recognition for Co-processing in the policy framework

> 45 Cement plants started co-processing in their production units

Few state pollution control boards like Gujarat and Tamil Nadu, developed specific action plan & implementation schedule to promote co-processing

>12 cement plants set up pre-processing facilities to convert non-homogeneous waste in to AFRs

LCA (Life Cycle approach) considered as a part of manufacturing process & extended producer responsibility


Approach Paper for achieving 25% TSR by 2025 in Indian Cement Industry

To achieve 25% TSR at 2025 : Indian Cement industry requires 7.07 million TOE of energy from Alternate fuels

Parameters Existing Anticipated Units

Year 2010 2025

Cement prodution 217 600Million TPA

Cement to clinker ratio 1.35 1.49

Specific energy consumption 725 703Kcal/ kg of clinker

Total Thermal Energy Required 11.64 28.26million TOE

Quantity of coal required @ 5500 kcal/kg 21.17 51.38

Million TPA

Energy From Alternate fuel estimated @25% of total energy 7.07

million TOE


13

Municipal Solid Waste (MSW)

MSW generation estimated to be 140 Million Tons by 2025

By effective management of MSW 22 types of diseases can be prevented/ controlled

>80% of the waste is sent to dump yards

Swachh Bharat Mission (SBM)


14

Bio mass

Domestic & widely available

32% of total primary energy derived from biomass

Used extensively in power generation

As per MNRE 120 million Tonnes/ annum of biomass available as surplus


15

Spent pot liner (SPL)

Waste from Aluminium industry

Hazardous in nature & subject to close regulatory control

Reactive with water

Co-processing in cement kiln can support SPL disposal in environmentally sustainable way


16

Tyre waste

0.83 million tons of used tyres generated annually

AF with high heat content

Better managed in Cement kiln

Many countries successfully utilising tyre waste in cement kiln


17

Hazardous waste(HW)

0.6 million tons of incinerable hazardous waste generated annually

41,523 HW generating units in India

HW disposed through TSDF

New HWM 2016 considers co-processing as a preferred option


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Summary of energy from Alternate fuels

0.20 0.87 1.83

8.49

14.27

25.66

0.00

5.00

10.00

15.00

20.00

25.00

30.00

Energy from different fuels (TSR % )

57%

0.8%

33%

3%7%

MSW

Spent PotLinerBio mass

HazardouswasteWaste tyres


51.38

123

49.638.53

92

39.68

COAL CONSUMTON (MILLION TPA)

CARBON EMISSIONS FROM FUEL (MILLIONS

TONS OF CARBON DIOXIDE)

LANDFILLING AREA FOR MSW

(1000XHECTARES)

BAU(Business as usual) 25% TSR

25% TSR @ 2025 – Anticipated benefits

Coal consumption reduces by 25%

Land filling area requirement in the country will reduce by 20%

GHG emissions from fuel reduces by 25%

Reduce imports & increase economic activity of the country


20

RDF from MSW - Potential alternate fuel for Cement plants

RDF Generated from MSW has a high potential to substituteconventional fuels in cement plants RDF will have a better calorific value

Homogeneous physical & chemical properties

Reduces Environmental & health impacts

Further growth potential

Scientific & Sustainable solution with no residual left over

Developing Municipal solid waste mapping for selected Municipalities in

different states


21

MSW Mapping – Cluster based approach

State Urban Local Bodies RemarksChhattisgarh Raipur, Bilaspur, Korba, Raigarh

States are chosen based on Cement Industrypresence

ULBs based on vicinity to cement plants

Gujarat Rajkot, Jamnagar, Ahmadabad

KarnatakaGulbarga, Bagalkot, Bellary, Koppal, Bangalore

Madhya Pradesh Satna, Ratlam, Jabalpur

RajasthanJaipur, Kota, Udaipur, Ajmer, Bhilwara

Tamil Nadu

Thanjavur, Tiruchirappalli, Coimbatore, Perambalur, Ariyalur, Madurai

Telangana & AP

Hyderabad, Warangal, Vijayawada, Kadapa, Kurnool, Guntur


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MSW mapping in Selected Municipalities

This mapping will further elaborate on various parameters like Current inventory & MSW management practices

Area & Population

Growth potential

Location of cement plants with capacity

Developing different models of MSW management in Clusters

PPP Model

Common Pre - processing facility model

Business Model

Capacity Building requirements


Waste mapping model – Tamil Nadu

CityPopulation of

2011 (Nos)

MSW

generated TPA

in 2011No of Cement plants in

Vicinity

Thanjavur 2,22,943 43,800

8

Tiruchirappalli 8,47,387 2,27,679

Coimbatore 10,50,721 2,94,202

Ariyalur 28,902 4,928

Madurai 10,17,865 2,37,250

Perambalur 49,000 8,760

Total 8,16, 619


Estimated Thermal substitution from MSW of 6 cities in 1.5 MTPA Clinker unit

MSW generated from 6 cities 0.817 Million TPA

8 Cement plants are in nearby clusters

In a 1.5 Million TPA clinker unit - RDF generated from this MSW can substitute

31.9% of fuel on TSR basis

60,000 Tonnes of Coal can be substituted annually

MSW growth potential :25% by 2031

Corresponding TSR substitution can be as high as 40%


Estimated Thermal substitution from MSW of 6 cities in 1.5 MTPA Clinker unit

Parameter Values Unit

Total MSW generated from 6 cities 0.81 Million TPA

MSW for RDF generation 0.57 Million TPA

RDF generation 0.11 Million TPA

Energy from RDF 0.034 Million TOE

Generated RDF used as Alternate fuel in 1.5 Million TPA clinker unit

Clinker production 1.50 MTPA

Thermal Energy required 0.107 Million TOE

Estimated % Energy from RDF of 6 Municipalities as TSR

% in 1.5 MTPA cement plant31.9 %


Estimated growth potential of MSW & TSR Substitution in 1.5 MTPA clinker unit

0.8170.915

1.024

2011 2021 2031

MSW

ge

ne

rati

on

year

Estimated Quantity of MSW generated (MTPA) in six ULBs

31

3640

2011 2021 2031TS

R %

year

Estimated TSR % in 1.5 MTPA Clinker production


MSW Cluster mapping study

Develop cluster level engagement with stake holders on improving co-processing initiatives

To understand opportunities & barriers

To understand current inventory & growth potential

Estimate RDF generation Potential from MSW

Estimate substitution possibilities in cement plants


Way Forward

Facilitate Cement Industry to achieve TSR levels of 25% by 2025 with focus on MSW as fuel

Awareness creation on New Waste Management Rules & Guidelines

Regional level workshops

Sharing of best practices

Publications


Way Forward

Working with different stake holders like Cement Industry, Municipalities, Government bodies (CPCB, MoEFCC, MoUD, DIPP, NEERI etc), Technology providers towards

Large scale management of MSW through Co-processing

Roadmap for MSW management through cement kiln co-processing

Cluster level engagements

Capacity building activities & Developing Business models


Way Forward

Co-processing in cement plants : Pillar to support India’s journey towards Low Carbon economy Swachh Bharat Mission

INDC

CII will work closely with industry & other stake holders in promoting AFR Utilization & further accelerate the TSR levels


Thank you

V KannanCounsellorConfederation of Indian IndustryCII - Godrej Green Business Centre, IndiaDir: +91 40 4418 5213E-mail: [email protected] / www.cii.in

Waste Mapping and Forecasting for Alternate Fuel Usage … Mr V Kannan CII... · Waste Mapping and...

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