REGIONAL

1
BEST PRACTICES TECHNOLOGIES FOR ENERGY
EFFICIENCY IN INDIAN CEMENT INDUSTRY
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
ITEM OF COST OF PACKED CEMENT
RAW MATERIAL 10-15
COAL 20-25
POWER 17-20
MANPOWER 5-8
COAL CONSUMPTION 22 Mn TONNES/YEAR POWER
CONSUMPTION 14 BILLION UNITS/YEAR TOTAL ENERGY
BILL RS 95 BILLION/YEAR
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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
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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.
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• 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

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Energy Efficient Cement Manufacturing
Technologies
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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

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ELECTRICAL ENERGY CONSUMPTION VRM Vs BALL MILL
(RAW MILL)
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ELECTRICAL ENERGY CONSUMPTION VRM Vs ROLLER PRESS
Vs BALL MILL (CEMENT MILL)
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HIGH EFFICIENCY PYRO-PROCESSING SYSTEMS

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

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

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PRESENT STATUS OF TECHNOLOGY
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PRESENT STATUS OF TECHNOLOGY
Low Technology Plants Modern Plants Global Technology
Mining and Material Handling Conventional Computer aided Computer aided
Crushing Two stage Single stage In-pit crushing conveying
Conveying of Limestone Dumpers/Ropeway/ Tippers Belt conveyors Pipe conveyors, Belt conveyors
Grinding Ball Mills with / without conventional classifier VRMs, Roller Presses with dynamic classifier VRMs, Roller Presses with dynamic classifier
Contd..
4
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Low Technology Plants Modern Plants Global 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 NOX/SO2 emission technologies
Blending Storage Batch-Blending Silos Continuous Blending silos Continuous Blending Multi-chamber Silos - Dome silos
Contd..
5
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Low Technology Plants Modern Plants Global Technology
Packing Dispatch Bag - Bag - Bulk Bulk - Palletizing Shrink Wrapping
Process Control Relay Logic / Hard Wired / PLC DDC - Fuzzy Logic expert system DDC - Neurofuzzy expert system
Energy consumption level 90-100 kWh/t cem. 900-1000 kcal/kg cl. 75-85 kWh/t cem. 700-800 kcal/kg cl. 70-80 kWh/t cem. 675-740 kcal/kg cl.
Plant Size (TPD) 300 1800 3000 6000 6000 12000
6
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BLENDED CEMENTS
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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

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SHIFT IN TYPE OF CEMENT
YEAR OPC () PPCPSC ()
1999 67 32
2004 45 54
2008 25 74
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CO2 EMISSION FROM CEMENT MANUFACTURE
SOURCES OF CO2 EMISSION OPC OPC PPC PPC
SOURCES OF CO2 EMISSION Tonne /t Tonne /t
CALCINATION 0.50 60 0.37 58
COMBUSTION OF FUEL 0.24 29 0.176 28
USE OF POWER 0.09 11 0.09 14
TOTAL 0.83 100 0.636 100
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ALTERNATE FUELS AND ENVIRONMENT
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Benefits of Utilization of Alternate Fuels in
Cement Kiln

• Prevents resource depletion of non-renewable
  fossil fuels
• Lowers the emissions of gases such as GHGs 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

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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.

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COGENERATION OF POWER UTILISING WASTE HEAT IN
CEMENT MANUFACTURE
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WHR SYSTEM FOR POWER GENERATION
ITEM UNIT PH AQC
1 VOLUMETRIC FLOW RATE NM3/H 360750 191600
2 BOILER INLET TEMPERATURE DEG. C 340 360
3 BOILER OUTLET TEMPERATURE DEG. C 230 90
4 GROSS POWER GENERATION KW 7700 (30) 7700 (30)
5 ANNUAL REDUCTION IN POWER PURCHASED MILLION KWH 56.07 56.07
6 ANNUAL SAVING OF POWER COST RS MILLION 232.70 232.70
7 ANNUAL REDUCTION IN FOSSIL FUEL EQUIVALENT TONNES (OIL BASIS) 14517 14517
8 ANNUAL REDUCTION IN CO2 TONNES 45000 (5 of Total) 45000 (5 of Total)
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CONCLUSIONMAJOR AREAS FOR ENERGY EFFICIENCY IN
INDIAN CEMENT INDUSTRY
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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./-
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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

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Thank you