Low Carbon Roadmap Technology For
Indian Cement Industry
2nd Annual Meeting of Innovation for Cool Earth Forum (ICEF)
Tokyo, Japan
October 7-8, 2015
1
Dr. S.K. Handoo Advisor(Tech.),
Cement Manufacturers’ Association
Overview of Cement Industry
Global scenario World’s total production :
• Cement production – 4,180 MTPA (2014)
• Clinker capacity- 3,570 MTPA (2014)
• Cement production accounts for ~ 5% of global CO2 emissions.
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Source: USGS, Mineral Commodity Summaries, January 2015 Source: JRC 2014 Report- Trends in global CO2 emissions- BACKGROUND STUDIES
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Source: JRC 2014 Report- Trends in global CO2 emissions- BACKGROUND STUDIES
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Source: JRC 2014 Report- Trends in global CO2 emissions- BACKGROUND STUDIES
Future Growth Projections - Global
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Source: CSI Data
2nd largest Cement producer in the world
Current installed capacity is more than 380 MTPA
Current cement production about 272 Million Tonnes/year
Average Kiln Capacity is about 4500 TPD
Approx. 7% of India’s man-made CO2 Emissions
India Scenario
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Specific Electric and Thermal Power Consumption of Selected Countries
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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 - Status paper on AFR Usage in Indian Cement Industry , May 2015
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Indian Cement Industry – Change in Pattern of Technology and Energy Efficiency
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
Proactive Cement Industry constantly improves Energy Consumption.
Some plants have become global benchmarks in energy consumption, next
to Japan.
Indian Cement Industry on High Trajectory of Growth
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(Million Tonnes)
2010* 2050
Low Demand Scenario 217 780
High Demand Scenario 217 1361
Cement Demand in various Scenario
10 * Actual Source: CSI Data
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Key Levers Expected Kg CO2 Reduction / T of Cement
1% Reduction of Clinker Factor 7.5 – 9
1% AFR TSR Increase 2 – 3
2.4 kCal/kg Cl of Thermal Energy saving < 1
1 kWh/T Electrical energy reduction ~ 1
Other Levers:
WHR Potential to be fully exploited
Development of new Cements with very low clinker factor
Carbon Capture and storage technologies Source: CSI Data
Levers of Emission Reduction
(Million Tonnes)
Scenario 2010*
2050
Anticipated CO2
emissions in
Business as
usual scenario
Targeted
Performance after
implementation of
all CO2 reduction
levers
Low Demand Scenario 137 493 275
High Demand Scenario 137 860 480
GHG Emissions - Projection
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* Actual Source: CSI Data
Roadmap 2050
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Source: Technology roadmap- Low carbon technology for Indian cement industry- WBCSD/IEA
AFR Usage
Electrical Energy
14 Source: CSI Data
Key Indicators
Clinker Factor
Thermal Energy
15 Source: CSI Data
Key Indicators
Alternative Fuel Resource
• Total Substitution Rate (TSR) of Indian cement industry is about 0.5-1.0% In comparison to some developed countries where it is about 60%.
• For year 2014 - Total Available Raw Material and Alternate Fuel- 436.68 Tonnes
• AFR through Co-processing
• Examples of AFR • Hazardous waste
• Refuse Derived Fuel from Municipal Solid Waste
• Tyre chips
• Biomass
• Industrial plastic
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•About 123 million tyres were produced in year 2013-14.
•Recycling – a small scale option
•High TSR (Upto 50%) can be achieved by co-processing tyre chips in the precalciner
•The calorific content value of tyres is between some 6450kCal/kg and 8000kCal/kg
•1 tonne of coal= .6-.95 tonne of tyre
Tyre chips
•Surplus biomass- 150 MT (2014)
•Easy availability and about 3 times the coal used in Indian cement industry
•Calorific Value Varies From 3000 -4000 KCal/Kg
Biomass
•Plastic consumption in India is about 8 MTPY, out of which, 70% i.e. 5.6 MTPY transforms to waste.
•Effectively destroys non-bio-degradable materials without any additional environmental issue
Industrial plastic
http://www.indiratrade.com/UploadResearch/635522563529111250_Sector%20Report_TYRES_.pdf http://www.cemfuels.com/articles/318-tyres-as-an-alternative-fuel (SOURCE: Action Plan for Enhancing the use of alternative fuels and raw materials in the Indian cement industry) 17
• The National Action Plan on Climate
Change was released by Prime Minister
of India in June 2008
• The Action Plan Outlines 8 Missions
including National Mission for
Enhanced Energy Efficiency (NMEEE)
• The basic objective of the NMEEE
mission is to ensure a sustainable
growth by an approximate mix of 4 E’s,
namely-Energy, Efficiency, Equity and
Environment
National Mission for Enhanced Energy Efficiency (NMEEE)
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2001 2014-2015
Energy Conservation Act enacted
National Action Plan on Climate Change released
Sector studies Commenced to identify DCs
Baseline data collection begins
Financial outlay of over US$20 million approved
National Mission for Enhanced Energy Efficiency (NMEEE) Approved by Ministry of Power
Nation wide Consultation Workshops organised; consultation continues through 2012
NMEEE approved by Prime Minister's Council on Climate Change
Energy Conservation Act amended to make provisions for issue of energy saving certificates, imposition of penalty for non compliance and trading Of ESCerts
Perform, Achieve and Trade (PAT) scheme came into effect; first compliance period begins (2012-2015)
2008 2009 2010 2011 2012
Perform, Achieve and Trade (PAT)
Overview and Elements
Covers 478 plants in 8 energy intensive industry ( Aluminium, Cement, Chlor-alkali, Fertilizer, Iron &
Steel, Paper & Pulp, Textile and Thermal Power Stations), and gate to gate boundary concept adopted.
Energy consumption of these plants was about 1/3rd of the total energy consumed in India in the
baseline year (2009-10).
Large variations in energy intensities of different units in almost every sector
Key Goal :Mandate Specific Energy Consumption improvement
Energy Intensity reduction target for each unit based on its current efficiency in base line (2009-10)
Multi- cycle process –First PAT cycle till 2014-15
Design based on extensive consultations over 2010-12
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Base line Studies completed, Draft PAT Rules prepared and feed back sought on draft targets
Assessment year of First PAT Cycle
Gaining Energy Efficiency
Successful implementation of PAT
CYCLE -1 (2012-15)
Under BEE’s PAT Scheme, Plants
with > 30,000 MTOE of Annual
Energy Consumption covered in the
First Cycle
85 Cement Plants were identified as
Designated Consumers (DCs),
to achieve the Energy Reduction Targets within a
period of 3 years.
The best thermal and electrical energy consumption presently achieved in India is 663 kcal/kg clinker and 59 kWh/t cement which are comparable to the best figures of 650 kcal/kg clinker and 65kWh/t cement in a developed country like Japan.
Overall Target for all 85 DCs is 4.8% Energy Reduction
w.r.t. the Base Level
First Cycle (2012-15) period already completed on 31
March 2015.
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Cement Sector: Baseline and Targets - An Example
Energy Transition for Industry: India and the Global Context, IEA, Jan 2011
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Although Indian
Cement Sector
being at par with
the World best
energy intensity,
but still has agreed
for energy saving
targets of 0.85
million ton of oil
equivalent energy
under PAT
Japan
India
National Target of Energy Saving among all Sectors
S.NO. Sector No. of
Identified DCs
Annual Energy
Consumption (Million
toe)
Share Consumpti
on (%)
Apportioned Energy
Reduction For PAT Cycle-1
(Million toe)
1 Power (Thermal) 144 104.56 63.38% 3.211
2 Iron & Steel 67 25.32 15.35% 1.486
3 Cement 85 15.01 9.10% 0.815
4 Aluminium 10 7.71 4.67% 0.456
5 Fertilizer 29 8.20 4.97% 0.478
6 Paper & Pulp 31 2.09 1.27% 0.119
7 Textile 90 1.20 0.73% 0.066
8 Chlor- Alkali 22 0.88 0.53% 0.054
Total 478 164.97 100.00% 6.686
Total EE Projects planned in 2012-15: 2057
Total anticipated investment : US$ 3095 million
The direct benefit for the participating industries in this period is reductions
in input costs related to energy of approximately US$ 1250 million.
Sectoral Share in Energy Saving Target (%)
(2012-15)
Reduction in India's CO2
emissions by 24 million tons /
year in 2014-15.
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Concept of Target, Compliance, ESCerts & Penalty
If any DC fails to achieve targets, it shall be liable to a
penalty which shall not exceed U$ $ 16000 ( INR 1.0
Million) and, in the case of continuing failure, with an
additional penalty which shall not be less than the price
for every metric ton of oil equivalent of energy ( Appx.
US $ 160) ,that is in excess of the prescribed norms.
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Conclusion
• Energy Savings Potential :
Introduction of Perform, Achieve and Trade (PAT) Scheme for Energy Intensive Industries – improves energy efficiency
– facilitates cost effectiveness by certifying energy saving that could be traded due to its market based mechanism
• Benefits : At the end of first phase of PAT Cycle (2012- 2015) – Energy saving potential of 6.686 million toe for 478 Designated
Consumers
– Reduction in India’s CO2 emissions
» 24 million tons per year in 2014-15
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Waste Heat Recovery
OVERVIEW
Explored potential of WHR in Indian Cement Industry is around 500MW
Approx. Present installed capacity of WHR is around 300 MW.
More than 20 plants have installed WHR , rapid installation by other plants in progress
Up to 22 kWh/t clinker or about 20% of the power consumption of a cement plant can be met by using currently available waste heat recovery technologies without significant changes in kiln operation.
ADVANTAGES
Effective utilization of waste heat, that is otherwise lost in atmosphere.
Saves fuel (coal) & reduces CO2 emissions to significant levels.
Should be credited under Renewable Energy Sector.
Source: Technology Compendium on Energy Saving Opportunities -Cement
Sector report by Shakti foundation, CII and BEE- 2013
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Key Policy Issues
• Energy Efficiency − Incentivizing Super Energy Efficient products
• Alternate Fuel Utilization − Landfill of wastes still prevalent (MSW, Haz and non Haz waste)
− Preprocessing of waste needs encouragement
− Surplus Biomass burnt in the Fields to be used as AF
• Newer types of cement − Composite Cement, Increased substitution in PPC / PSC
• Waste Heat Recovery − High capital cost and no policy support
− According RE status for faster adoption
• Carbon Capture and Storage R&D − Soft financing, innovative financing models, GCF funds
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Key messages
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• Roadmap outlines possible transition path for Indian cement industry to support global goal of halving CO2 emissions by 2050
• BAU: 488 Million tonnes (Mt) CO2 and 835 MtCO2 by 2050 [represents 255% (low demand case) to 510% (high demand case) increase compared to 2010 emissions]
• Roadmap projections: Reduction of direct CO2 emissions intensity to 0.35 tonnes (t) of CO2/t cement in 2050 - about 45% lower than 2010 levels, a saving of between 212 MtCO2 (100% growth) and 367 MtCO2 (240% growth) compared to BAU scenario
• Attainable only with supportive policy framework, technology development and appropriate financial resources invested over long term
• Key levers: Energy efficiency, clinker substitution, alternative fuels and raw materials, Waste Heat Recovery, new technologies (including CCS)
Contact:
Cement Manufacturers’ Association
E-mail: [email protected], [email protected]
Website: www.cmaindia.org
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