BEST PRACTICES & TECHNOLOGIES FOR ENERGY EFFICIENCY IN INDIAN CEMENT INDUSTRY

Indian Cement Industry – An Overview

GROWTH OF INDIAN CEMENT INDUSTRY

CHANGING PROCESS PROFILE OF INDIAN CEMENT INDUSTRY

PLANTS WITH CAPACITY OF ONE MILLION TONNES AND ABOVE Total : 146 Large Cement Plants

ENERGY INPUTS TO INDIAN CEMENT INDUSTRY ITEM% OF COST OF PACKED CEMENT RAW MATERIAL10-15 COAL20-25 POWER17-20 MANPOWER5-8 COAL CONSUMPTION:22 Mn TONNES/YEAR POWER CONSUMPTION:14 BILLION UNITS/YEAR TOTAL ENERGY BILL:RS 95 BILLION/YEAR

ENERGY CONSUMPTION PROFILE (DRY PROCESS PLANTS - WTD. AVG.) THERMAL ENERGY KCAL/KG CL. ELECTRICAL ENERGY KWH/T CEMENT BEST IN INDIA BEST IN WORLD DATA OF 40 DRY PLANTS

TOOLS OF ENERGY EFFICIENCY IMPROVEMENT  EXISTING PLANTS  TECHNOLOGY UPGRADATION  RETROFITTING OF ENERGY EFFICIENT EQUIPMENT  NEW PLANTS  IDENTIFICATION AND SELECTION OF STATE-OF-THE-ART TECHNOLOGIES  FUEL QUALITY  BLENDING WITH IMPORTED COAL FOR IMPROVING AVERAGE QUALITY  USE OF PET-COKE & OTHER COMBUSTIBLE WASTES  BLENDED CEMENT  GREATER USE OF INDUSTRIAL WASTES LIKE FLYASH AND SLAG FOR MAKING BLENDED CEMENTS Contd.

 MANAGEMENT SYSTEMS  ENERGY MANAGEMENT  TOTAL PRODUCTIVE MAINTENANCE (TPM), COMPUTERIZED MAINTENANCE SYSTEM AND INVENTORY CONTROL  TOTAL QUALITY MANAGEMENT (TQM)  REFRACTORY MANAGEMENT SYSTEM  POWER SUPPLY  IMPROVING QUALITY OF POWER THROUGH CAPTIVE GENERATION (DIESEL, THERMAL AND WIND POWER)  PERFORMANCE MONITORING  INTER-FIRM COMPARISON AND BENCHMARKING  TARGET SETTING AND MONITORING

Energy Efficient Cement Manufacturing Technologies

HIGH EFFICIENCY SIZE REDUCTION TECHNIQUES  VERTICAL ROLLER MILL  BALL MILL OPERATION IN CLOSED CIRCUIT  BOLTLESS & CLASSIFYING LINERS IN BALL MILLS  ROLLER PRESS  V - SEPARATOR  SEPARATOR  HIGH EFFICIENCY  TWO-STAGE MODULAR SEPARATOR SYSTEM

ELECTRICAL ENERGY CONSUMPTION VRM Vs BALL MILL (RAW MILL)

ELECTRICAL ENERGY CONSUMPTION VRM Vs ROLLER PRESS Vs BALL MILL (CEMENT MILL)

HIGH EFFICIENCY PYRO-PROCESSING SYSTEMS  LATEST GENERATION PRECALCINER  5/6 STAGE PREHEATER WITH LOW PRESSURE CYCLONES  HIGH EFFICIENCY GRATE COOLER  MULTI-CHANNEL BURNER

THERMAL ENERGY CONSUMPTION 6-ST PC Vs 5-ST PC

OTHER EFFICIENT EQUIPMENT/SYSTEMS  HIGH EFFICIENCY POLLUTION CONTROL EQUIPMENT (LESS THAN 50 mg/NM 3 EMISSION)  ELECTRO-STATIC PRECIPITATOR (ESP)  FIBRE GLASS BAG FILTER  HIGH EFFICIENCY FAN (75-82% EFFICIENCY)  ENERGY EFFICIENT MOTOR (93-95% EFFICIENCY)  VARIABLE SPEED AC DRIVES  EFFICIENT ILLUMINATION SYSTEMS  MECHANICAL MATERIAL CONVEYORS (IN PLACE OF PNEUMATIC CONVEYING SYSTEMS)  HIGH SPEED HIGH CAPACITY BUCKET ELEVATOR  PIPE CONVEYOR

PRESENT STATUS OF TECHNOLOGY

Low Technology Plants Modern PlantsGlobal Technology Mining and Material Handling ConventionalComputer aided CrushingTwo stageSingle stageIn-pit crushing & conveying Conveying of Limestone Dumpers/Ropeway/ Tippers Belt conveyorsPipe conveyors, Belt conveyors GrindingBall Mills with / without conventional classifier VRM’s, Roller Presses with dynamic classifier Contd….. 4

Low Technology PlantsModern PlantsGlobal Technology Pyro Processing Wet Semi Dry Dry - 4 stage preheater - Conventional cooler -Single channel burner Dry -5/6 stage preheater -High Efficiency Cooler -Multi Channel Burner 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 Blending & Storage Batch-Blending SilosContinuous Blending silos -Continuous Blending -Multi-chamber Silos -Dome silos Contd….. 5

Low Technology Plants Modern PlantsGlobal Technology Packing & Dispatch Bag- Bag - Bulk -Palletizing & Shrink Wrapping Process ControlRelay Logic / Hard Wired / PLC -DDC -Fuzzy Logic expert system -DDC -Neurofuzzy expert system Energy consumption level kWh/t cem kcal/kg cl kWh/t cem kcal/kg cl kWh/t cem kcal/kg cl. Plant Size (TPD) 300 – – –

BLENDED CEMENTS

CEMENT VARIETIES – PRODUCTION IN 2008  Ordinary Portland Cement (OPC): 25 %  Portland Pozzolana Cement (PPC): %  Portland Slag Cement (PSC): 8 %  Other Cements: 0.50 %

SHIFT IN TYPE OF CEMENT YEAROPC (%) PPC+PSC (%)

CO 2 EMISSION FROM CEMENT MANUFACTURE SOURCES OF CO 2 EMISSION OPCPPC Tonne /t% % CALCINATION COMBUSTION OF FUEL USE OF POWER TOTAL

ALTERNATE FUELS AND ENVIRONMENT

Benefits of Utilization of Alternate Fuels in Cement Kiln Prevents resource depletion of non-renewable fossil fuels Lowers the emissions of gases such as GHG’s by replacing the use of fossil fuels Maximises energy recovery. All the available energy is used directly in the kiln for clinker production Eliminates the need for disposal of inorganic ashes and slags as they act as substitute raw material in the cement

Alternate Fuels : Problems and Prospects Deciding Factors for utilization of Alternate Fuels are :- èProximity of the cement plant to the source èExtent of availability on sustainable basis èCompositional compatibility of raw materials and the Alternate Fuels. èType of cement manufacturing process employed and production capacity. èInfrastructural facilities for handling and storage.

COGENERATION OF POWER UTILISING WASTE HEAT IN CEMENT MANUFACTURE

WHR SYSTEM FOR POWER GENERATION ITEMUNITPHAQC 1VOLUMETRIC FLOW RATENM3/H BOILER INLET TEMPERATUREDEG. C BOILER OUTLET TEMPERATUREDEG. C GROSS POWER GENERATIONKW 7700 (30%) 5ANNUAL REDUCTION IN POWER PURCHASED MILLION KWH ANNUAL SAVING OF POWER COSTRS MILLION ANNUAL REDUCTION IN FOSSIL FUEL EQUIVALENT TONNES (OIL BASIS) ANNUAL REDUCTION IN CO 2 TONNES45000 (5% of Total)

CONCLUSION MAJOR AREAS FOR ENERGY EFFICIENCY IN INDIAN CEMENT INDUSTRY

MAJOR AREAS FOR ENERGY EFFICIENCY IN INDIAN CEMENT INDUSTRY  TECHNOLOGY UPGRADATION & USE OF ENERGY EFFICIENT TECHNOLOGY FOR PRE-1990 PLANTS  WASTE HEAT RECOVERY FOR COGENERATION OF POWER  AUTOMATION, ON-LINE QUALITY CONTROL & EXPERT CONTROL SYSTEM  USE OF ALTERNATE FUELS INCLUDING RUBBER TYRES, AGRICULTURAL, INDUSTRIAL & MUNICIPAL WASTES  EFFICIENT COLLECTION, PROCESSING & TRANSPORTATION SYSTEMS FOR ALTERNATE FUELS  USE OF RENEWABLE ENERGY SOURCES  USE OF NATURAL GAS AS FUEL IN CEMENT PLANT CLUSTERS Contd./-

 ADOPTION OF TECHNOLOGIES FOR REDUCING EMISSION OF SO 2 & NO X  BULK TRANSPORTATION OF CEMENT  FUTURE R & D EFFORTS:  MAXIMISING UTILIZATION OF ALTERNATE FUELS, FLY ASH, SLAG AND OTHER RAW MATERIALS  ALGAL FARMS FOR CO 2 ABSORPTION  NANO TECHNOLOGY IN CEMENT MANUFACTURE AND USE  BETTER COMBUSTION EFFICIENCY TECHNOLOGIES MAJOR AREAS FOR ENERGY EFFICIENCY IN INDIAN CEMENT INDUSTRY