Technology Gap Assessment

Transcription

1 INDIAN CEMENT INDUSTRY Technology Gap Assessment By Ashutosh Saxena Joint Director & Anil Kumar Group Manager National Council for Cement and Building Materials

2 INDIAN CEMENT INDUSTRY 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. With 99 % of installed capacity through dry process technology, Indian cement industry is at forefront of technology upgradation and modernization through adoption of state-of-the-art manufacturing technologies. Best specific energy consumption levels achieved by the Indian Cement Industry are 670 kcal/kg cl and around 68 kwh per tonne cement, which are comparable with the best achieved levels in the world. Efforts towards control of emissions and preservation of ecology are laudable.

3 INDIAN CEMENT INDUSTRY Achievement of reduction of CO2 emission to about 0.7 tonne per tonne of cement at present from a substantially high level of 1.12 in With the adoption of newer technologies and enhancement of production of blended/composite cements, Indian cement industry can achieve the targeted CO2 emissions of 0.58 t CO2 /t of cement by 2020 and 0.50 t CO2 /t of cement by 2030 from the current level of 0.7 t CO2 /t of cement. Annually recycles around 57 million tonnes of flyash and around 10 million tonnes of granulated blast furnace slag. Focus on utilization of alternate fuels. The per capita consumption of cement in India currently is 210, which is targeted to increase to 309 by the year 2020 and to 400 by the end of 2030.

4 MAJOR ISSUES BEFORE THE INDUSTRY UTILISATION OF LOW AND MARGINAL GRADE LIMESTONE DEVELOPMENT OF CEMENTS WITH LOWER CLINKER FACTORS AND IMPROVED PERFORMANCE USE OF ALTERNATE FUELS AND RAW MATERIALS FURTHER REDUCTION IN CO 2 EMISSION FROM CEMENT MANUFACTURE ASSURED AVAILABILITY OF GOOD QUALITY DRY FLYASH AND GRANULATED BLAST-FURNACE SLAG FOR PRODUCTION OF BLENDED CEMENTS RECOVERY OF WASTE HEAT FROM KILN AND COOLER EXHAUST GAS FOR SETTING-UP COST EFFECTIVE CO-GENERATION POWER UNITS CONTD

5 MAJOR ISSUES BEFORE THE INDUSTRY BENCHMARKING OF VARIOUS PERFORMANCE INDICATORS FOR ACHIEVING HIGHER ENERGY EFFICIENCY AND PRODUCTIVITY LEVELS DEVELOPMENT AND ADOPTION OF TECHNOLOGIES FOR REDUCING SO 2 AND NO X GENERATION FROM CEMENT PLANTS PROMOTION OF READY MIXED CONCRETE (RMC) AND BULK MOVEMENT OF CEMENT FOR ASSURING QUALITY AND FASTER CONSTRUCTION FASTER IMPLEMENTATION OF INFRASTRUCTURE PROJECTS AND FOCUSSED THRUST ON HOUSING TO INCREASE CEMENT DEMAND ALIGNMENT OF INDIAN STANDARDS WITH CORRESPONDING INTERNATIONAL STANDARDS TO BOOST CEMENT EXPORTS

6 Technology status of cement plants in India Modern Plants Global Technology Mining and Material Handling Computer aided Computer aided Crushing Single stage Single stage; In-pit crushing & conveying Conveying of Limestone Grinding Pyro Processing Belt conveyors VRM s, Roll Presses with dynamic classifier Dry 5/6 stage preheater High Efficiency Cooler Multi-Channel Burner Co-generation of power Pipe conveyors, Belt conveyors VRM s, Roll Presses, with dynamic classifier Dry 6 stage preheater High Efficiency Cooler Multi Channel Burner Co-processing of WDF Co-generation of power Low NO X /SO 2 emission technologies

7 Technology status of cement plants in India Modern Plants Global Technology Blending & Storage Packing & Despatch Process Control Energy consumption level Continuous Blending silos Bag Bulk DDC Fuzzy Logic expert system kwh/t cem kcal/kg cl. Continuous Blending Multi-chamber Silos Dome silos Bulk Palletizing & Shrink Wrapping DDC ( Direct Digital Control) Fuzzy Logic expert system kwh/t cem kcal/kg cl. Plant Size (TPD)

8 Technology Gap Assessment

9 Blended Cements Present production of blended cements in the country has been around 72% as against only 36% in consuming about 28% of the total fly ash generated and the entire quantity of granulated blast furnace slag, the waste generated by steel plants exceeding 10 million tonnes annually. Accordingly, the current clinker factor, a major technology lever to reduce carbon footprints, is 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.

10 Newer Materials Considering the availability of cement grade limestone in the country, there is an immediate need to develop newer techniques, technologies and materials such as multi-blend composite cements, high volume fly ash cements and geo-polymeric cements besides others to achieve greater sustainability of cement manufacture as well as for performance enhancement, cost reduction and durable constructions. Other ways of reducing clinker factor are by increasing usage of different waste materials like lead zinc slag, copper slag, jarosite, marble slurry etc.

11 DEVELOPMENT OF CEMENTS AND CONCRETE WITH LOWER CLINKER FACTORS Development of Indian standard specifications for newer cements such as composite cements and Portland limestone cements Maximizing fly ash content in PPC and modification of existing standards for enhancing fly ash content Availability of fly ash as per Indian standard specifications Investigations on applications of nanotechnology for improving cement performance and lowering clinker factor Optimizing concrete composition and performance for lowering the clinker content in concrete

12 Alternate Fuel Utilization Indian Cement Industry s present overall Thermal Substitution Rate (TSR) by alternate fuels is less than 1%, while in some developed countries, this figure is as high as around 40%. In individual cases, however, as high as 11% TSR is reported by plants in India. The industry needs to work towards achieving international best practices for alternate fuels utilization. The targeted overall TSR in India cement industry is 5 % by the end of 2020 and further increased to 19% by the end of 2030.

13 Co-processing of Hazardous Wastes The coal quality available for the cement industry is poor and quantity is inadequate, the industry therefore, is importing coal or utilizing petcoke and other alternate fuels to compensate the shortcoming. Co-processing in cement kiln is an eco-friendly alternative to disposal of industrial and hazardous wastes in comparison to incineration method It is helpful in reducing the impact of increasing costs of conventional fuels and also in conservation of non-renewable fossil fuels The utilization of alternate fuels/wdf by the cement industry is expected to reduce green house gas emissions

14 Types of Alternate Fuels used in Cement Industry Pet coke Pet coke from petroleum refineries Waste Derived Fuels used for Co-processing in Cement Kilns are Scrapped tyres Common Effluent Treatment Plant (CETP) Sludge Municipal Solid Waste (MSW) Spent wash Plastic waste Paint sludge

15 Energy Efficiency The current average thermal energy consumption in the Indian cement industry is 725 kcal/kg of clinker and the average electrical energy consumption level is 85 kwh/t of cement. The average thermal energy consumption is targeted to be 709 by 2020 and further reduced to 694 kcal/kg of clinker by The electrical energy consumption is further targeted to reduce to 76 by 2020 and to 73 kwh/t of cement by the end of 2030.

16 Progressive Reduction in Energy Consumption by Indian Cement Industry Year Dry 90% Post 2000 (Dry 99%) Predominant Technology/ Process Wet 96% Semi-Dry Dry-4 Stage Preheater (PH) Precalciner (PC) 85% Dry-5/6 Stage PH/PC, Vertical Roller Mill (VRM) & Pre-Grinders, Advanced Coolers Double-Stream PH, Efficient Coolers, High Pressure Grinding Rolls, Advanced Kiln Control System, IT based Plant Operation Capacity (Tonnes/ Day) Heat Consumption (kcal/kg. Clinker) (670/725) * Power Consumption (kwh/tonne Cement Source: NCB and CMA Database (68/85) * * (Best/Average)

17 Co-generation of Power through Waste Heat Recovery Cogeneration of power, a relatively recent initiative in the Indian cement industry, is expected to find wider application across the industry in future. About 19 cement plants have successfully implemented it and have installed ~200 MW of cogeneration capacity. The industry potential of co-generated power is estimated to be more than 600 MW. The cogeneration of power will be increased to estimated 300 MW by the end of 2020 and to 500 MW by the end of 2030.

18 Co-generation of Power through Waste Heat Recovery Large-scale adoption of Cogeneration of Power through Waste Heat Recovery technology will require suitable government schemes of incentives including capital subsidy and tax exemption. Moreover, this technology should be granted Renewable Energy status for issuance of RE certificates.

19 CO 2 reduction by Indian Cement Industry The CO 2 emission levels have been brought down from 1.12 tonne of CO 2 /tonne of cement in 1996 to ~0.7 tonne of CO 2 /tonne of cement in 2015 by adopting various measures including the following: Manufacture of blended cements Improving energy efficiency through retrofits and adoption of energy efficient equipment Co-generation of power through waste heat recovery system Use of non-conventional fuels including waste derived fuels

20 Pollution Control The use of latest state-of-the-art high efficiency pollution control equipment like ESP s and bag filters has made it possible for the cement industry to be well within the particulate emission norms. The recently prescribed norms for PM, SO2 and NOx are at par with the stringent EU norms. However, Indian cement plants need adequate time to implement measures in order to comply with the norms (particularly with SO2 and NOx) in a gradual phased manner, given the fact that there is a need for availability of good quality coal, ammonia, equipment design modifications and concerns on health hazards associated with use of ammonia in NOx reduction technologies.

21 NOx Control On the technological front, Indian cement industry has largely adopted state-of-the-art manufacturing technologies. However, technologies for low nitrogen oxide (NOx) emissions have not penetrated significantly, though a few installations have been put up in the country. There is an urgent need to identify 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, both for primary and secondary measures.

22 NOx Control Primary Control Measures for NOx Reduction Process Optimization Control of Combustion Zone Temperature and Excess Air Optimizing fuel and feed mix High Thermal efficiency Staged Combustion Low NOx Burner Low NOx Calciner Secondary Control Measures for NOx Reduction SNCR Selective Non-Catalytic Reduction SCR Selective Catalytic Reduction

23 SO 2 Control Technologies for low sulphur dioxide (SO 2 ) emissions have also not penetrated significantly. 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.

24 SO 2 Control Primary Control Measures for SO2 Reduction Control of Sulphur in fuel and feed Inline Raw Mill Secondary Control Measures for SO2 Reduction Slaked Lime Injection De-SOx Cyclone Wet Scrubber Gas Suspension Absorber

25 Renewable Energy Introduction of renewable energy resources such as wind mills & solar plants are among major technology challenges towards energy efficiency. However, this calls for larger investment, which can be neutralized with strong support in the form of subsidies/ incentives. Presently around 8 plants have gone for installation of wind power with rated capacity of around 256 MW. Replication potential exists for other plants for around 30% renewable energy substitutions. Few cement plants have installed solar plants with an overall generation potential of around 16.5 MW. All these will contribute their bit to achieve the national targets of 175 GW of energy through Renewable Energy route.

26 Other Challenges & Avenues For old and energy inefficient plants, process optimization; installation of latest generation clinker coolers; energy efficient grinding systems; multichannel burners etc. shall remain the other energy efficient technological avenues. 70% of the plants have adopted Multi-Channel burners resulting in efficient combustion. But still the scope is there for rest 30% cement plants particularly those plants which are planning to use alternate fuels for coprocessing purpose.

27 Other Challenges & Avenues To reduce electrical energy consumption, energy efficient transformers; light pipes; automation; latest intelligent MCCs; Light emitting Plasma (LEP s); induction lights; installation of static synchronous compensator & static reactive power compensator to improve power factor can play a crucial role.