BEST PRACTICES & TECHNOLOGIES FOR ENERGY EFFICIENCY IN INDIAN CEMENT INDUSTRY By Ashutosh Saxena

1. BEST PRACTICES & TECHNOLOGIES FOR ENERGY EFFICIENCY IN INDIAN CEMENT INDUSTRY By Ashutosh Saxena General Manager National Council for Cement and Building Materials

2. Indian Cement Industry –An Overview

3. GROWTH OF INDIAN CEMENT INDUSTRY

4. CHANGING PROCESS PROFILE OF INDIAN CEMENT INDUSTRY

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

6. ENERGY INPUTS TO INDIAN CEMENT INDUSTRY COAL CONSUMPTION : 22 Mn TONNES/YEAR POWER CONSUMPTION : 14 BILLION UNITS/YEAR TOTAL ENERGY BILL : RS 95 BILLION/YEAR

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

8. 181 128 910 79 726 42

9. 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.

10. 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

11. Energy Efficient Cement Manufacturing Technologies

12. 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

13. ELECTRICAL ENERGY CONSUMPTION VRM Vs BALL MILL (RAW MILL)

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

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

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

17. OTHER EFFICIENT EQUIPMENT/SYSTEMS • HIGH EFFICIENCY POLLUTION CONTROL EQUIPMENT (LESS THAN 50 mg/NM3 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

18. PRESENT STATUS OF TECHNOLOGY

19. PRESENT STATUS OF TECHNOLOGY Contd….. 4

20. Contd….. 5

21. 6

22. BLENDED CEMENTS

23. CEMENT VARIETIES – PRODUCTION IN 2008 • Ordinary Portland Cement (OPC) : 25 % • Portland Pozzolana Cement (PPC) : 66.50 % • Portland Slag Cement (PSC) : 8 % • Other Cements : 0.50 %

24. SHIFT IN TYPE OF CEMENT

25. CO2 EMISSION FROM CEMENT MANUFACTURE

26. ALTERNATE FUELS AND ENVIRONMENT

27. 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 actas substitute raw material in the cement

28. Alternate Fuels : Problems and Prospects Deciding Factors for utilization of Alternate Fuels are :- • Proximity of the cement plant to the source • Extent of availability on sustainable basis • Compositional compatibility of raw materials and the Alternate Fuels. • Type of cement manufacturing process employed and production capacity. • Infrastructural facilities for handling and storage.

29. COGENERATION OF POWER UTILISING WASTE HEAT IN CEMENT MANUFACTURE

30. WHR SYSTEM FOR POWER GENERATION

31. CONCLUSIONMAJOR AREAS FOR ENERGY EFFICIENCY IN INDIAN CEMENT INDUSTRY

32. 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./-

33. MAJOR AREAS FOR ENERGY EFFICIENCY IN INDIAN CEMENT INDUSTRY • ADOPTION OF TECHNOLOGIES FOR REDUCING EMISSION OF SO2 & NOX • BULK TRANSPORTATION OF CEMENT • FUTURE R & D EFFORTS: • MAXIMISING UTILIZATION OF ALTERNATE FUELS, FLY ASH, SLAG AND OTHER RAW MATERIALS • ALGAL FARMS FOR CO2 ABSORPTION • NANO TECHNOLOGY IN CEMENT MANUFACTURE AND USE • BETTER COMBUSTION EFFICIENCY TECHNOLOGIES

34. Thank you