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

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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 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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