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 Industry CII Godrej Green Business Centre, Hyderabad 23 rd 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
Project Background - Waste Management 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 Indian Cement Industry Indian Cement Industry emitted 137 Mt of CO 2, 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)
Expert group Name Designation Organisation Chairman CII Intiative on increasing Mr Ulhas parlikar 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 7
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 coprocessing 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 Coprocessing cement plants Technical Publications Website on Coprocessing
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 nonhomogeneous 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 Parameters Existing Anticipated Units Year 2010 2025 Cement prodution 217 600 Cement to clinker ratio 1.35 1.49 Million TPA Specific energy consumption 725 703 Total Thermal Energy Required 11.64 28.26 Quantity of coal required @ 5500 kcal/kg 21.17 51.38 Energy From Alternate fuel estimated @25% of total energy 7.07 Kcal/ kg of clinker million TOE Million TPA million TOE To achieve 25% TSR at 2025 : Indian Cement industry requires 7.07 million TOE of energy from Alternate fuels
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) 13
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 14
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 15
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 16
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 coprocessing as a preferred option 17
Summary of energy from Alternate fuels Energy from different fuels (TSR % ) 30.00 25.66 3% 7% MSW 25.00 20.00 15.00 10.00 5.00 0.00 0.20 0.87 1.83 8.49 14.27 33% 0.8% 57% Spent Pot Liner Bio mass Hazardous waste Waste tyres 18
25% TSR @ 2025 Anticipated benefits 51.38 38.53 COAL CONSUMTON (MILLION TPA) 123 92 CARBON EMISSIONS FROM FUEL (MILLIONS TONS OF CARBON DIOXIDE) BAU(Business as usual) 49.6 39.68 LANDFILLING AREA FOR MSW (1000XHECTARES) 25% TSR 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
RDF from MSW - Potential alternate fuel for Cement plants RDF Generated from MSW has a high potential to substitute conventional 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 20
MSW Mapping Cluster based approach State Urban Local Bodies Remarks Chhattisgarh Raipur, Bilaspur, Korba, Raigarh Gujarat Rajkot, Jamnagar, Ahmadabad States are Gulbarga, Bagalkot, Bellary, chosen based on Karnataka Koppal, Bangalore Cement Industry Madhya Pradesh Satna, Ratlam, Jabalpur presence Jaipur, Kota, Udaipur, Ajmer, Rajasthan Tamil Nadu 21 Telangana & AP Bhilwara Thanjavur, Tiruchirappalli, Coimbatore, Perambalur, Ariyalur, Madurai Hyderabad, Warangal, Vijayawada, Kadapa, Kurnool, Guntur ULBs based on vicinity to cement plants
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 22
Waste mapping model Tamil Nadu City Population of 2011 (Nos) MSW generated TPA in 2011 Thanjavur 2,22,943 43,800 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 No of Cement plants in Vicinity 8
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 plant 31.9 %
TSR % MSW generation Estimated growth potential of MSW & TSR Substitution in 1.5 MTPA clinker unit Estimated Quantity of MSW generated (MTPA) in six ULBs 0.817 0.915 1.024 Estimated TSR % in 1.5 MTPA Clinker production 40 36 31 2011 2021 2031 year 2011 2021 2031 year
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 Kannan Counsellor Confederation of Indian Industry CII - Godrej Green Business Centre, India Dir: +91 40 4418 5213 E-mail: Kannan.vairavan@cii.in www.greenbusinesscentre.com / www.cii.in