logging in or signing up aug3 clean pradeep Dora Download Post to : URL : Related Presentations : Share Add to Flag Embed Email Send to Blogs and Networks Add to Channel Uploaded from authorPOINTLite Insert YouTube videos in PowerPont slides with aS Desktop Copy embed code: (To copy code, click on the text box) Embed: URL: Thumbnail: WordPress Embed Customize Embed The presentation is successfully added In Your Favorites. Views: 296 Category: Entertainment License: All Rights Reserved Like it (0) Dislike it (0) Added: February 12, 2008 This Presentation is Public Favorites: 0 Presentation Description No description available. Comments Posting comment... By: csrrama (8 month(s) ago) Can you please upload some case studies on Design with energy audit and payback period,please send the presentation to my mail id rengaramanujan@yahoo.co.in Saving..... Post Reply Close Saving..... Edit Comment Close By: sanjaykaushik (13 month(s) ago) The PPT is wonderfull and informative could u pl allow me to use and may send at my email id sanjaykaushik@mail.com I shall be thankful to you Saving..... Post Reply Close Saving..... Edit Comment Close Premium member Presentation Transcript Slide1: ROUND TABLE ON CLEAN ENERGY TECHNOLOGY IN INDUSTRY DISCUSSION PAPER ON CLEAN ENERGY OPPORTUNITIES IN CEMENT INDUSTRY PRADEEP KUMAR GENERAL MANAGER NATIONAL COUNCIL FOR CEMENT AND BUILDING MATERIALS Slide2: 1. CHINA 2. INDIA 3. USA 4. JAPAN 5. KOREA MAJOR CEMENT PRODUCING COUNTRIESSlide3: INDIAN CEMENT INDUSTRY (2000-2001) MAJOR CEMENT PLANTS : 115 Nos. INSTALLED CAPACITY : 114.1 Mn.T CEMENT PRODUCTION : 93.52 Mn.T MINI CEMENT PLANTS : 300 Nos. INSTALLED CAPACITY : 9.00 Mn.T CEMENT PRODUCTION : 6.24 Mn.T TOTAL INSTALLED CAPACITY : 123.11 Mn.T TOTAL CEMENT PRODUCTION : 99.76 Mn.TSlide4: COAL CONSUMPTION : 15 MILLION TONNES / YEAR POWER CONSUMPTION : 9 BILLION UNITS / YEAR TOTAL ENERGY BILL : RS 55 BILLION / YEAR (US $ 1300 MILLION / YEAR) QUANTUM OF ENERGY INPUTS TO INDIAN CEMENT INDUSTRYSlide5: THERMAL ENERGY CONSUMPTION PROFILE OF INDIAN CEMENT INDUSTRY (DRY PROCESS PLANTS) THERMAL ENERGY KCAL/KG CL. YEARSlide7: ELECTRICAL ENERGY KWH/T CEMENT YEAR ELECTRICAL ENERGY CONSUMPTION PROFILE OF INDIAN CEMENT INDUSTRY (DRY PROCESS PLANTS)FREQUENCY DISTRIBUTION OF DRY PROCESS PLANTS FOR THERMAL ENERGY CONSUMPTION: FREQUENCY DISTRIBUTION OF DRY PROCESS PLANTS FOR THERMAL ENERGY CONSUMPTION DATA OF 44 CEMENT PLANTSFREQUENCY DISTRIBUTION OF DRY PROCESS PLANTS FOR ELECTRICAL ENERGY CONSUMPTION: FREQUENCY DISTRIBUTION OF DRY PROCESS PLANTS FOR ELECTRICAL ENERGY CONSUMPTION DATA OF 44 CEMENT PLANTSSlide11: GLOBAL WARMING AND GREENHOUSE GAS EMISSIONSlide12: SOURCES OF GREENHOUSE GAS EMISSION IN CEMENT PLANTS LIMESTONE CALCINATION USE OF FUEL FOR KILN FIRING CAPTIVE THERMAL / DG SETS OXIDATION OF ATMOSPHERIC NITROGEN AT HIGH TEMPERATURE TO FORM NOXSlide13: EVERY TONNE OF OPC PRODUCED GENERATES ONE TONNE OF CO2Slide14: REDUCING CO2 EMISSION IN CEMENT INDUSTRY THROUGH CLEAN TECHNOLOGIES USE OF INDUSTRIAL BY-PRODUCTS AS RAW MIX COMPONENT INCINERATION OF COMBUSTIBLE WASTES IN KILN PRODUCTION OF REACTIVE BELITE CLINKER INCREASING MANUFACTURE OF BLENDED CEMENTS USE OF ENERGY EFFICIENT EQUIPMENT/SYSTEMS USE OF SOLAR & WIND ENERGY RECOVERY OF WASTE HEAT FOR COGENERATION OF POWERSlide15: USE OF INDUSTRIAL BY-PRODUCTS AS RAW MIX COMPONENT PARTIALLY OR COMPLETELY CALCINED INDUSTRIAL WASTES AND BY-PRODUCTS SUCH AS FLY-ASH, BLAST FURNACE SLAG, LIMESLUDGE ETC. CAN BE EFFECTIVELY USED IN RAW MIX TO PARTIALLY SUBSTITUTE LIMESTONESlide16: INCINERATION OF COMBUSTIBLE WASTES IN KILN COMBUSTIBLE WASTES SUCH AS PET-COKE, TYRES, OIL SLUDGE, MUNICIPAL WASTES ETC, WHEN CO-FIRED AS PARTIAL REPLACEMENT OF FOSSIL FUEL, CAN REDUCE CO2 EMISSION Slide17: PRODUCTION OF REACTIVE BELITE CLINKER REDUCTION IN SPECIFIC FUEL CONSUMPTION DUE TO LOWER CLINKERING TEMPERATURE RESULTING IN LOWER CO2 EMISSION Slide18: VARIETY WISE CEMENT PRODUCED (YEAR 2000) OPC : 63% PPC : 25% PSC : 11% OTHERS : 1% PRODUCTION OF BLENDED CEMENTSSlide19: PRODUCTION OF BLENDED CEMENTSSlide20: REDUCTION IN GLOBAL WARMING GREAT POTENTIAL FOR BLENDED CEMENTS RECOMMENDATION : INCREASED USE OF INDUSTRIAL WASTES IN CEMENT MANUFACTURE BLENDED CEMENTS POZZOLANA CEMENTS SLAG CEMENTS MASONARY CEMENTS GBFS/BOFS FLY ASH SLUDGES GYPSUM WASTE RED MUD INDUSTRIAL WASTES USEDSlide21: ENERGY EFFICIENT EQUIPMENT/SYSTEMS GRINDING SYSTEMS IMPROVED BALL MILL INTERNALS HIGH EFFICIENCY SEPARATORS VERTICAL ROLLER MILL ROLLER PRESS PYRO-PROCESSING LOW PRESSURE CYCLONES HIGH EFFICIENCY COOLERS MULTI-CHANNEL BURNERS Slide22: ENERGY EFFICIENT EQUIPMENT/SYSTEMS MATERIAL HANDLING SYSTEMS BUCKET ELEVATOR IN PLACE OF PNEUMATIC CONVEYING SYSTEMS DENSE-PHASE PNEUMATIC CONVEYING PROCESS CONTROL SYSTEMS EXPERT CONTROL SYSTEM ON-LINE X-RAY ANALYSERS ELECTRICAL DRIVES/FANS HIGH EFFICIENCY FANS VARIABLE SPEED FAN DRIVES HIGH EFFICIENCY MOTORSSlide23: WIND ENERGY : 80 MW DIESEL : 1089 MW THERMAL : 433 MW TOTAL : 1602 MW PRESENT USE OF ALTERNATE ENERGY SOURCES BY INDIAN CEMENT INDUSTRY (YEAR 2000)Slide24: UPTO 25-30% OF TOTAL POWER REQUIREMENT CAN BE MET THROUGH COGENERATION OF POWER UTILISING WASTE HEAT IN A CEMENT PLANT COGENERATION OF POWER THROUGH WASTE HEAT RECOVERYSlide25: PREHEATER EXIT GAS 300 - 400oC, 180 - 250 KCAL/KG COOLER EXIT GAS 200 - 300oC, 80 - 130 KCAL/KGSlide26: OVERSEAS COGENERATION SCENARIO JAPAN 33 COGENERATION UNITS IN VARIOUS CEMENT PLANTS TOTAL COGENERATION CAPACITY ABOUT 200 MW SEPARATE BOILERS INSTALLED FOR KILN & GRATE COOLER CHINA 24 KILNS HAVING CAPACITY OF 2000 TPD & ABOVE HAVE COGENERATION UNITS WITH SUPPLEMENTARY FIRED BOILERS OUT OF TOTAL POWER REQUIREMENT ABOUT 22-36 KWH/T CLINKER IS MET THROUGH POWER COGENERATIONSlide28: COGENERATION POTENTIAL, MW : 210 CO2 REDUCTION POTENTIAL, MILLION TONNES/YEAR : 1.65 PERCENTAGE REDUCTION AS COMPARED TO EMISSIONS DUE TO ELECTRICITY CONSUMPTION (i.e. 7.4 MILLION TONNES/YEAR) : 22 CO2 REDUCTION POSSIBILITIESSlide29: HIGH COST OF IMPORTED TECHNOLOGY AND DIFFICULT ACCESS TO FUNDS HIGH COST OF CAPITAL WITHOUT ANY FISCAL INCENTIVE RELUCTANCE OF FUNDING AGENCIES TO FUND AN UNTRIED TECHNOLOGY IN INDIA CONTEMPORARY BARRIERS IN SOME STATES FOR PUTTING-UP CAPTIVE POWER GENERATION UNITS BARRIERS IN INTRODUCTION OF COGENERATION SYSTEMS IN INDIAN CEMENT INDUSTRYSlide30: EXCISE DUTY RELIEF FOR INDIGENOUS ENERGY EFFICIENT EQUIPMENT CUSTOM DUTY RELIEF FOR IMPORTED ENERGY EFFICIENT EQUIPMENT SOFT LOANS BY FINANCIAL INSTITUTIONS FOR PROCURING ENERGY EFFICIENT EQUIPMENT CONTD… SUGGESTIONS FOR ENABLING POLICY FRAMEWORKSlide31: FINANCIAL INCENTIVES BY GOVERNMENT FOR MANUFACTURING BLENDED CEMENTS ELIGIBILITY FOR CEMENT PLANTS TO SUPPLY BACK SURPLUS CAPTIVE POWER TO STATE ELECTRICITY BOARDS AT REMUNERATIVE RATESSlide32: INTERNATIONAL EXHIBITION AND SEMINAR ON ENERGY AND ENVIRONMENT IN CEMENT, CONSTRUCTION AND ALLIED SECTORS 28-31 JANUARY 2002 TAJ PALACE HOTEL, NEW DELHI ORGANISED BY NATIONAL COUNCIL FOR CEMENT AND BUILDING MATERIALS JOINTLY WITH CEMENT MANUFACTURERS’ ASSOCIATION SUPPORTED BY PLANNING COMMISSION, MINISTRY OF COMMERCE AND INDUSTRY MINISTRY OF POWER, MINISTRY OF ENVIRONMENT AND FORESTS FEDERATION OF INDIAN CHAMBERS OF COMMERCE AND INDUSTRY UNITED STATES – ASIA ENVIRONMENTAL PARTNERSHIP GERMAN TECHNICAL COOPERATIONSlide33: BACK-UPSlide34: AVAILABILITY OF FUNDS FOR INSTALLATION OF COGENERATION POWER PLANTS v GLOBAL ENVIRONMENT FACILITY (GEF) v ACTIVITIES IMPLEMENTED JOINTLY (AIJ/CDM) v OVERSEAS BANKS ASIAN DEVELOPMENT BANK (IEEP) WORLD BANK GERMAN / DEUTSCHE BANK v DISBURSING FINANCIAL INSTITUTIONS IDBI ICICI IREDASlide35: LOCATION OF NCB UNITS, CEMENT PLANT CLUSTERS AND SOURCES OF INDUSTRIAL WASTES NCB - Ahmedabad, West Zone NCB – Ballabgarh / Delhi North Zone NCB - Hyderabad, South zone NCB - Bhubneshwar, East Zone (under consideration) Fertilizer Plants Steel Plants Paper Plants 1 Cement Plants NCB Units Slide36: GLOBAL WARMING SECOND ASSESSMENT REPORT OF INTER GOVERNMENTAL PANEL ON CLIMATE CHANGE (NOVEMBER 1995) CONCLUDED THAT IF POLICIES TO REDUCE CO2 EMISSION FROM CURRENT LEVELS NOT UNDERTAKEN, THE AVERAGE GLOBAL SURFACE TEMPERATURE WOULD RISE BY ABOUT 2oC BETWEEN 1990 AND 2010 - AN AVERAGE RATE OF WARMING GREATER THAN ANY SEEN IN THE LAST 10,000 YEARS.Slide37: EVERY MWH REDUCTION IN THERMAL POWER PLANT (COAL BASED) IS EXPECTED TO REDUCE CO2 EMISSION BY ABOUT 1.12 TONNESSlide38: COGENERATION POTENTIAL IN VARIOUS PLANTS PLANT CAPACITY, PH EXIT GAS COOLER EXIT GAS COGEN. TPD FLOW TEMP FLOW TEMP POTEN. (Nm3/hr) (oC) (Nm3/hr) (oC) MW X 1000 X 1000 A 3000, 4ST* 186 415 258 250 4.6 4500, 5ST 350 320 250 250 5.5 B 3300, 4ST 289 360 129 230 4.5 C 3000, 4ST* 194 350 277 220 4.0 D 3300, 6ST 188 295 233 245 3.2 E 3300, 6ST 234 300 165 250 3.2 F 2X2800, 6ST 170 300 130 250 4.4 G 2X1700, 5ST 157 320 120 250 4.2 H 3300, 4ST* 200 390 154 290 4.2 I 2250, 5ST 148 378 149 260 3.2 J 2500, 4ST 172 365 120 230 3.0 CONTD ...Slide39: COGENERATION POTENTIAL IN VARIOUS PLANTS PLANT CAPACITY, PH EXIT GAS COOLER EXIT GAS COGEN. TPD FLOW TEMP FLOW TEMP POTEN. (Nm3/hr) (oC) (Nm3/hr) (oC) MW X 1000 X 1000 K 2225, 5ST 88 300 142 220 3.4 L 2225, 5ST 88 300 142 220 M 3250, 6ST 225 295 240 230 3.5 N 3000, 4ST 210 360 180 220 3.7 O 3700, 4ST 151 280 373 220 3.2 P 2000, 5ST 183 330 210 240 3.4 * SP PLANTS, ALL OTHERS PC PLANTSSlide40: MODIFIED RANKINE CYCLE SYSTEM ‘KALINA CYCLE’ USES BINARY FLUID OF AMMONIA AND WATER EFFICIENCY GAINS OF UPTO 50% FOR LOW TEMPERATURE (200-280oC) AND UPTO 20% FOR HIGHER TEMPERATURE HEAT SOURCES COMPARED TO RANKINE CYCLE ORMAT ENERGY CONVERTER (OEC) USES ORGANIC FLUID AS WORKING MEDIUM INSTEAD OF STEAM SUITABLE FOR MUCH LOWER TEMPERATURE HEAT SOURCES AS ORGANIC FLUID HAS A MUCH LOWER BOILING POINT THAN WATER WASTE HEAT BOILER ‘THERMOWIR’ REMOVING 60% (48-60gm/NM3) DUST FROM THE GASES REDUCING LOAD ON EXISTING ESP HIGHER EFFICIENCY COMPARED TO CONVENTIONAL HEAT EXCHANGERS RECENT DEVELOPMENTSSlide41: AREAS OF ENERGY WASTAGE HIGH EXIT FLUE GAS TEMPERATURE FOR PREHEATER AND COOLER EXHAUST. HIGH CLINKER TEMPERATURE FROM COOLER. FALSE AIR INFILTRATION IN KILN, PREHEATER AND ESP CIRCUITS. IMPROPER COMBUSTION. HIGH RADIATION LOSSES FROM KILNS AND PREHEATER.Slide42: ESTIMATED COGENERATION POTENTIAL, CAPITAL COST AND PAYBACK PERIOD PLANT A PLANT B (3000 TPD) (3300 TPD) COGENERATION POTENTIAL, MW 5.5 (8*) 4.0 INVESTMENT, Rs MILLION 275 (400*) 270 PAYBACK PERIOD, YEARS 2.6 (3.1*) 3.0 * WITH SUPPLEMENTARY FIRINGSlide43: TOTAL POWER AND CAPTIVE POWER REQUIREMENT FOR VARIOUS PLANT CAPACITIES PLANT TOTAL POWER CAPTIVE POWER* CAPACITY, REQUIREMENT, REQUIREMENT, TPD MW MW 1200 9.5 3 3000 23.5 7 4500 29.0 9 * TAKING CAPTIVE POWER REQUIREMENT @30% OF TOTAL POWER FOR MAINTAINING CONTINUOUS PRODUCTION FROM KILNSlide44: INSTALLATION COSTS OF VARIOUS TYPES OF POWER SYSTEMS THERMAL STATIONS : Rs 5-5.5 CRORES/MW DG SETS : Rs 1.8-2.5 CRORES/MW COGENERATION SYSTEMS : Rs 5-6 CRORES/MWSlide45: COST OF POWER GRID SUPPLY : Rs 3.35 - 5.24 PER KWH (DIFFERENT STATES) DIESEL CAPTIVE GENERATION : Rs 2.20 - 3.45 PER KWH COGENERATED POWER : Rs 2.10 - 3.00 PER KWHSlide46: FINANCIAL EVALUATION CASE STUDY OF 3300 TPD PLANT PROJECT COST : Rs 2700 LAKHS DEBT - EQUITY RATIO : 1.5 : 1 AVERAGE DSCR : 2.38 IRR : 31.64% BREAK EVEN POINT - PROJECT : 43.94% - CASH : 31.94%Slide47: AVERAGE ENERGY CONSUMPTION IN A 1 MTPA CEMENT PLANT THERMAL ENERGY : 0.80 MILLION KCAL/TONNE CLINKER ELECTRICAL ENERGY : 100 KWH/TONNE CEMENT COAL REQUIREMENT : 2,00,000 TONNES/YEAR POWER REQUIREMENT : 20 MW (AT 70% LOAD FACTOR)Slide48: ITEM KCAL/KG CLINKER TOTAL HEAT INPUT BY HEAT BALANCE 797.5 AVAILABILITY OF WASTE HEAT (i) SENSIBLE HEAT IN PH GASES 224 (ii) SENSIBLE HEAT IN COOLER EXHAUST 122.9 TOTAL 346.9 CASE STUDY IN A 1.2 MTPA, 4-STAGE PREHEATER CEMENT PLANTSlide49: ESTIMATED COGENERATION POTENTIAL IN A 1.2 MTPA PLANT LOCATION QTY OF GASES WASTE HEAT BOILER GROSS POWER Nm3/hr WORKING TEMP. GENERATION INLET OUTLET MW I PREHEATER EXHAUST 195427 390 260 4.0 II COOLER EXHAUST 182588 300 230 Slide50: COGENERATION POTENTIAL, MW : 4.0 ESTIMATED COST, Rs MILLION : 260 DEBT/EQUITY RATIO : 75:25 REPAYMENT OF LOAN, YEARS : 10 INTEREST RATE, PER ANNUM : 13% COST OF PURCHASED POWER, RS/KWH : 4 PAYBACK PERIOD, YEARS : 3.5 ECONOMIC EVALUATIONSlide51: INDIAN CEMENT INDUSTRY - 2000 TOTAL No. OF PLANTS WITH MORE : 54 THAN 1.0 MILLION TONNE CAPACITY MANPOWER EMPLOYED APPROX. : 1,35,000 PER CAPITA CONSUMPTION, Kg INDIA : 98 SOUTH KOREA : 1343 TAIWAN : 964 CHINA : 404 RUSSIA : 179 GERMANY : 419 UK : 216 FRANCE : 319 USA : 359 WORLD : 256Slide52: EXPORT OF CEMENT : 2.72 Mn.T EXPORT OF CLINKER : 1.85 Mn.T COUNTRIES : NEPAL, BANGLADESH, SRI LANKA, MAURITIUS AND COUNTRIES IN AFRICA & WEST ASIA INDIAN CEMENT INDUSTRY - 2000Slide53: CO2 EMISSIONS FROM CEMENT PLANTS YEAR 2000 (MILLION TONNES/YEAR) PROCESS (THERMAL) CALCINATION : 50 COAL COMBUSTION : 40 90 ELECTRICITY GRID POWER (THERMAL) : 3.8 CAPTIVE POWER (DIESEL & THERMAL) : 3.6 7.4 TOTAL CO2 EMISSIONS, MILLION TONNES/YEAR : 97.4 CO2 EMISSION IN CEMENT MANUFACTURESlide54: ROUND TABLE ON CLEAN ENERGY TECHNOLOGIES IN CEMENT MANUFACTURE You do not have the permission to view this presentation. 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aug3 clean pradeep Dora Download Post to : URL : Related Presentations : Share Add to Flag Embed Email Send to Blogs and Networks Add to Channel Uploaded from authorPOINTLite Insert YouTube videos in PowerPont slides with aS Desktop Copy embed code: (To copy code, click on the text box) Embed: URL: Thumbnail: WordPress Embed Customize Embed The presentation is successfully added In Your Favorites. Views: 296 Category: Entertainment License: All Rights Reserved Like it (0) Dislike it (0) Added: February 12, 2008 This Presentation is Public Favorites: 0 Presentation Description No description available. Comments Posting comment... By: csrrama (8 month(s) ago) Can you please upload some case studies on Design with energy audit and payback period,please send the presentation to my mail id rengaramanujan@yahoo.co.in Saving..... Post Reply Close Saving..... Edit Comment Close By: sanjaykaushik (13 month(s) ago) The PPT is wonderfull and informative could u pl allow me to use and may send at my email id sanjaykaushik@mail.com I shall be thankful to you Saving..... Post Reply Close Saving..... Edit Comment Close Premium member Presentation Transcript Slide1: ROUND TABLE ON CLEAN ENERGY TECHNOLOGY IN INDUSTRY DISCUSSION PAPER ON CLEAN ENERGY OPPORTUNITIES IN CEMENT INDUSTRY PRADEEP KUMAR GENERAL MANAGER NATIONAL COUNCIL FOR CEMENT AND BUILDING MATERIALS Slide2: 1. CHINA 2. INDIA 3. USA 4. JAPAN 5. KOREA MAJOR CEMENT PRODUCING COUNTRIESSlide3: INDIAN CEMENT INDUSTRY (2000-2001) MAJOR CEMENT PLANTS : 115 Nos. INSTALLED CAPACITY : 114.1 Mn.T CEMENT PRODUCTION : 93.52 Mn.T MINI CEMENT PLANTS : 300 Nos. INSTALLED CAPACITY : 9.00 Mn.T CEMENT PRODUCTION : 6.24 Mn.T TOTAL INSTALLED CAPACITY : 123.11 Mn.T TOTAL CEMENT PRODUCTION : 99.76 Mn.TSlide4: COAL CONSUMPTION : 15 MILLION TONNES / YEAR POWER CONSUMPTION : 9 BILLION UNITS / YEAR TOTAL ENERGY BILL : RS 55 BILLION / YEAR (US $ 1300 MILLION / YEAR) QUANTUM OF ENERGY INPUTS TO INDIAN CEMENT INDUSTRYSlide5: THERMAL ENERGY CONSUMPTION PROFILE OF INDIAN CEMENT INDUSTRY (DRY PROCESS PLANTS) THERMAL ENERGY KCAL/KG CL. YEARSlide7: ELECTRICAL ENERGY KWH/T CEMENT YEAR ELECTRICAL ENERGY CONSUMPTION PROFILE OF INDIAN CEMENT INDUSTRY (DRY PROCESS PLANTS)FREQUENCY DISTRIBUTION OF DRY PROCESS PLANTS FOR THERMAL ENERGY CONSUMPTION: FREQUENCY DISTRIBUTION OF DRY PROCESS PLANTS FOR THERMAL ENERGY CONSUMPTION DATA OF 44 CEMENT PLANTSFREQUENCY DISTRIBUTION OF DRY PROCESS PLANTS FOR ELECTRICAL ENERGY CONSUMPTION: FREQUENCY DISTRIBUTION OF DRY PROCESS PLANTS FOR ELECTRICAL ENERGY CONSUMPTION DATA OF 44 CEMENT PLANTSSlide11: GLOBAL WARMING AND GREENHOUSE GAS EMISSIONSlide12: SOURCES OF GREENHOUSE GAS EMISSION IN CEMENT PLANTS LIMESTONE CALCINATION USE OF FUEL FOR KILN FIRING CAPTIVE THERMAL / DG SETS OXIDATION OF ATMOSPHERIC NITROGEN AT HIGH TEMPERATURE TO FORM NOXSlide13: EVERY TONNE OF OPC PRODUCED GENERATES ONE TONNE OF CO2Slide14: REDUCING CO2 EMISSION IN CEMENT INDUSTRY THROUGH CLEAN TECHNOLOGIES USE OF INDUSTRIAL BY-PRODUCTS AS RAW MIX COMPONENT INCINERATION OF COMBUSTIBLE WASTES IN KILN PRODUCTION OF REACTIVE BELITE CLINKER INCREASING MANUFACTURE OF BLENDED CEMENTS USE OF ENERGY EFFICIENT EQUIPMENT/SYSTEMS USE OF SOLAR & WIND ENERGY RECOVERY OF WASTE HEAT FOR COGENERATION OF POWERSlide15: USE OF INDUSTRIAL BY-PRODUCTS AS RAW MIX COMPONENT PARTIALLY OR COMPLETELY CALCINED INDUSTRIAL WASTES AND BY-PRODUCTS SUCH AS FLY-ASH, BLAST FURNACE SLAG, LIMESLUDGE ETC. CAN BE EFFECTIVELY USED IN RAW MIX TO PARTIALLY SUBSTITUTE LIMESTONESlide16: INCINERATION OF COMBUSTIBLE WASTES IN KILN COMBUSTIBLE WASTES SUCH AS PET-COKE, TYRES, OIL SLUDGE, MUNICIPAL WASTES ETC, WHEN CO-FIRED AS PARTIAL REPLACEMENT OF FOSSIL FUEL, CAN REDUCE CO2 EMISSION Slide17: PRODUCTION OF REACTIVE BELITE CLINKER REDUCTION IN SPECIFIC FUEL CONSUMPTION DUE TO LOWER CLINKERING TEMPERATURE RESULTING IN LOWER CO2 EMISSION Slide18: VARIETY WISE CEMENT PRODUCED (YEAR 2000) OPC : 63% PPC : 25% PSC : 11% OTHERS : 1% PRODUCTION OF BLENDED CEMENTSSlide19: PRODUCTION OF BLENDED CEMENTSSlide20: REDUCTION IN GLOBAL WARMING GREAT POTENTIAL FOR BLENDED CEMENTS RECOMMENDATION : INCREASED USE OF INDUSTRIAL WASTES IN CEMENT MANUFACTURE BLENDED CEMENTS POZZOLANA CEMENTS SLAG CEMENTS MASONARY CEMENTS GBFS/BOFS FLY ASH SLUDGES GYPSUM WASTE RED MUD INDUSTRIAL WASTES USEDSlide21: ENERGY EFFICIENT EQUIPMENT/SYSTEMS GRINDING SYSTEMS IMPROVED BALL MILL INTERNALS HIGH EFFICIENCY SEPARATORS VERTICAL ROLLER MILL ROLLER PRESS PYRO-PROCESSING LOW PRESSURE CYCLONES HIGH EFFICIENCY COOLERS MULTI-CHANNEL BURNERS Slide22: ENERGY EFFICIENT EQUIPMENT/SYSTEMS MATERIAL HANDLING SYSTEMS BUCKET ELEVATOR IN PLACE OF PNEUMATIC CONVEYING SYSTEMS DENSE-PHASE PNEUMATIC CONVEYING PROCESS CONTROL SYSTEMS EXPERT CONTROL SYSTEM ON-LINE X-RAY ANALYSERS ELECTRICAL DRIVES/FANS HIGH EFFICIENCY FANS VARIABLE SPEED FAN DRIVES HIGH EFFICIENCY MOTORSSlide23: WIND ENERGY : 80 MW DIESEL : 1089 MW THERMAL : 433 MW TOTAL : 1602 MW PRESENT USE OF ALTERNATE ENERGY SOURCES BY INDIAN CEMENT INDUSTRY (YEAR 2000)Slide24: UPTO 25-30% OF TOTAL POWER REQUIREMENT CAN BE MET THROUGH COGENERATION OF POWER UTILISING WASTE HEAT IN A CEMENT PLANT COGENERATION OF POWER THROUGH WASTE HEAT RECOVERYSlide25: PREHEATER EXIT GAS 300 - 400oC, 180 - 250 KCAL/KG COOLER EXIT GAS 200 - 300oC, 80 - 130 KCAL/KGSlide26: OVERSEAS COGENERATION SCENARIO JAPAN 33 COGENERATION UNITS IN VARIOUS CEMENT PLANTS TOTAL COGENERATION CAPACITY ABOUT 200 MW SEPARATE BOILERS INSTALLED FOR KILN & GRATE COOLER CHINA 24 KILNS HAVING CAPACITY OF 2000 TPD & ABOVE HAVE COGENERATION UNITS WITH SUPPLEMENTARY FIRED BOILERS OUT OF TOTAL POWER REQUIREMENT ABOUT 22-36 KWH/T CLINKER IS MET THROUGH POWER COGENERATIONSlide28: COGENERATION POTENTIAL, MW : 210 CO2 REDUCTION POTENTIAL, MILLION TONNES/YEAR : 1.65 PERCENTAGE REDUCTION AS COMPARED TO EMISSIONS DUE TO ELECTRICITY CONSUMPTION (i.e. 7.4 MILLION TONNES/YEAR) : 22 CO2 REDUCTION POSSIBILITIESSlide29: HIGH COST OF IMPORTED TECHNOLOGY AND DIFFICULT ACCESS TO FUNDS HIGH COST OF CAPITAL WITHOUT ANY FISCAL INCENTIVE RELUCTANCE OF FUNDING AGENCIES TO FUND AN UNTRIED TECHNOLOGY IN INDIA CONTEMPORARY BARRIERS IN SOME STATES FOR PUTTING-UP CAPTIVE POWER GENERATION UNITS BARRIERS IN INTRODUCTION OF COGENERATION SYSTEMS IN INDIAN CEMENT INDUSTRYSlide30: EXCISE DUTY RELIEF FOR INDIGENOUS ENERGY EFFICIENT EQUIPMENT CUSTOM DUTY RELIEF FOR IMPORTED ENERGY EFFICIENT EQUIPMENT SOFT LOANS BY FINANCIAL INSTITUTIONS FOR PROCURING ENERGY EFFICIENT EQUIPMENT CONTD… SUGGESTIONS FOR ENABLING POLICY FRAMEWORKSlide31: FINANCIAL INCENTIVES BY GOVERNMENT FOR MANUFACTURING BLENDED CEMENTS ELIGIBILITY FOR CEMENT PLANTS TO SUPPLY BACK SURPLUS CAPTIVE POWER TO STATE ELECTRICITY BOARDS AT REMUNERATIVE RATESSlide32: INTERNATIONAL EXHIBITION AND SEMINAR ON ENERGY AND ENVIRONMENT IN CEMENT, CONSTRUCTION AND ALLIED SECTORS 28-31 JANUARY 2002 TAJ PALACE HOTEL, NEW DELHI ORGANISED BY NATIONAL COUNCIL FOR CEMENT AND BUILDING MATERIALS JOINTLY WITH CEMENT MANUFACTURERS’ ASSOCIATION SUPPORTED BY PLANNING COMMISSION, MINISTRY OF COMMERCE AND INDUSTRY MINISTRY OF POWER, MINISTRY OF ENVIRONMENT AND FORESTS FEDERATION OF INDIAN CHAMBERS OF COMMERCE AND INDUSTRY UNITED STATES – ASIA ENVIRONMENTAL PARTNERSHIP GERMAN TECHNICAL COOPERATIONSlide33: BACK-UPSlide34: AVAILABILITY OF FUNDS FOR INSTALLATION OF COGENERATION POWER PLANTS v GLOBAL ENVIRONMENT FACILITY (GEF) v ACTIVITIES IMPLEMENTED JOINTLY (AIJ/CDM) v OVERSEAS BANKS ASIAN DEVELOPMENT BANK (IEEP) WORLD BANK GERMAN / DEUTSCHE BANK v DISBURSING FINANCIAL INSTITUTIONS IDBI ICICI IREDASlide35: LOCATION OF NCB UNITS, CEMENT PLANT CLUSTERS AND SOURCES OF INDUSTRIAL WASTES NCB - Ahmedabad, West Zone NCB – Ballabgarh / Delhi North Zone NCB - Hyderabad, South zone NCB - Bhubneshwar, East Zone (under consideration) Fertilizer Plants Steel Plants Paper Plants 1 Cement Plants NCB Units Slide36: GLOBAL WARMING SECOND ASSESSMENT REPORT OF INTER GOVERNMENTAL PANEL ON CLIMATE CHANGE (NOVEMBER 1995) CONCLUDED THAT IF POLICIES TO REDUCE CO2 EMISSION FROM CURRENT LEVELS NOT UNDERTAKEN, THE AVERAGE GLOBAL SURFACE TEMPERATURE WOULD RISE BY ABOUT 2oC BETWEEN 1990 AND 2010 - AN AVERAGE RATE OF WARMING GREATER THAN ANY SEEN IN THE LAST 10,000 YEARS.Slide37: EVERY MWH REDUCTION IN THERMAL POWER PLANT (COAL BASED) IS EXPECTED TO REDUCE CO2 EMISSION BY ABOUT 1.12 TONNESSlide38: COGENERATION POTENTIAL IN VARIOUS PLANTS PLANT CAPACITY, PH EXIT GAS COOLER EXIT GAS COGEN. TPD FLOW TEMP FLOW TEMP POTEN. (Nm3/hr) (oC) (Nm3/hr) (oC) MW X 1000 X 1000 A 3000, 4ST* 186 415 258 250 4.6 4500, 5ST 350 320 250 250 5.5 B 3300, 4ST 289 360 129 230 4.5 C 3000, 4ST* 194 350 277 220 4.0 D 3300, 6ST 188 295 233 245 3.2 E 3300, 6ST 234 300 165 250 3.2 F 2X2800, 6ST 170 300 130 250 4.4 G 2X1700, 5ST 157 320 120 250 4.2 H 3300, 4ST* 200 390 154 290 4.2 I 2250, 5ST 148 378 149 260 3.2 J 2500, 4ST 172 365 120 230 3.0 CONTD ...Slide39: COGENERATION POTENTIAL IN VARIOUS PLANTS PLANT CAPACITY, PH EXIT GAS COOLER EXIT GAS COGEN. TPD FLOW TEMP FLOW TEMP POTEN. (Nm3/hr) (oC) (Nm3/hr) (oC) MW X 1000 X 1000 K 2225, 5ST 88 300 142 220 3.4 L 2225, 5ST 88 300 142 220 M 3250, 6ST 225 295 240 230 3.5 N 3000, 4ST 210 360 180 220 3.7 O 3700, 4ST 151 280 373 220 3.2 P 2000, 5ST 183 330 210 240 3.4 * SP PLANTS, ALL OTHERS PC PLANTSSlide40: MODIFIED RANKINE CYCLE SYSTEM ‘KALINA CYCLE’ USES BINARY FLUID OF AMMONIA AND WATER EFFICIENCY GAINS OF UPTO 50% FOR LOW TEMPERATURE (200-280oC) AND UPTO 20% FOR HIGHER TEMPERATURE HEAT SOURCES COMPARED TO RANKINE CYCLE ORMAT ENERGY CONVERTER (OEC) USES ORGANIC FLUID AS WORKING MEDIUM INSTEAD OF STEAM SUITABLE FOR MUCH LOWER TEMPERATURE HEAT SOURCES AS ORGANIC FLUID HAS A MUCH LOWER BOILING POINT THAN WATER WASTE HEAT BOILER ‘THERMOWIR’ REMOVING 60% (48-60gm/NM3) DUST FROM THE GASES REDUCING LOAD ON EXISTING ESP HIGHER EFFICIENCY COMPARED TO CONVENTIONAL HEAT EXCHANGERS RECENT DEVELOPMENTSSlide41: AREAS OF ENERGY WASTAGE HIGH EXIT FLUE GAS TEMPERATURE FOR PREHEATER AND COOLER EXHAUST. HIGH CLINKER TEMPERATURE FROM COOLER. FALSE AIR INFILTRATION IN KILN, PREHEATER AND ESP CIRCUITS. IMPROPER COMBUSTION. HIGH RADIATION LOSSES FROM KILNS AND PREHEATER.Slide42: ESTIMATED COGENERATION POTENTIAL, CAPITAL COST AND PAYBACK PERIOD PLANT A PLANT B (3000 TPD) (3300 TPD) COGENERATION POTENTIAL, MW 5.5 (8*) 4.0 INVESTMENT, Rs MILLION 275 (400*) 270 PAYBACK PERIOD, YEARS 2.6 (3.1*) 3.0 * WITH SUPPLEMENTARY FIRINGSlide43: TOTAL POWER AND CAPTIVE POWER REQUIREMENT FOR VARIOUS PLANT CAPACITIES PLANT TOTAL POWER CAPTIVE POWER* CAPACITY, REQUIREMENT, REQUIREMENT, TPD MW MW 1200 9.5 3 3000 23.5 7 4500 29.0 9 * TAKING CAPTIVE POWER REQUIREMENT @30% OF TOTAL POWER FOR MAINTAINING CONTINUOUS PRODUCTION FROM KILNSlide44: INSTALLATION COSTS OF VARIOUS TYPES OF POWER SYSTEMS THERMAL STATIONS : Rs 5-5.5 CRORES/MW DG SETS : Rs 1.8-2.5 CRORES/MW COGENERATION SYSTEMS : Rs 5-6 CRORES/MWSlide45: COST OF POWER GRID SUPPLY : Rs 3.35 - 5.24 PER KWH (DIFFERENT STATES) DIESEL CAPTIVE GENERATION : Rs 2.20 - 3.45 PER KWH COGENERATED POWER : Rs 2.10 - 3.00 PER KWHSlide46: FINANCIAL EVALUATION CASE STUDY OF 3300 TPD PLANT PROJECT COST : Rs 2700 LAKHS DEBT - EQUITY RATIO : 1.5 : 1 AVERAGE DSCR : 2.38 IRR : 31.64% BREAK EVEN POINT - PROJECT : 43.94% - CASH : 31.94%Slide47: AVERAGE ENERGY CONSUMPTION IN A 1 MTPA CEMENT PLANT THERMAL ENERGY : 0.80 MILLION KCAL/TONNE CLINKER ELECTRICAL ENERGY : 100 KWH/TONNE CEMENT COAL REQUIREMENT : 2,00,000 TONNES/YEAR POWER REQUIREMENT : 20 MW (AT 70% LOAD FACTOR)Slide48: ITEM KCAL/KG CLINKER TOTAL HEAT INPUT BY HEAT BALANCE 797.5 AVAILABILITY OF WASTE HEAT (i) SENSIBLE HEAT IN PH GASES 224 (ii) SENSIBLE HEAT IN COOLER EXHAUST 122.9 TOTAL 346.9 CASE STUDY IN A 1.2 MTPA, 4-STAGE PREHEATER CEMENT PLANTSlide49: ESTIMATED COGENERATION POTENTIAL IN A 1.2 MTPA PLANT LOCATION QTY OF GASES WASTE HEAT BOILER GROSS POWER Nm3/hr WORKING TEMP. GENERATION INLET OUTLET MW I PREHEATER EXHAUST 195427 390 260 4.0 II COOLER EXHAUST 182588 300 230 Slide50: COGENERATION POTENTIAL, MW : 4.0 ESTIMATED COST, Rs MILLION : 260 DEBT/EQUITY RATIO : 75:25 REPAYMENT OF LOAN, YEARS : 10 INTEREST RATE, PER ANNUM : 13% COST OF PURCHASED POWER, RS/KWH : 4 PAYBACK PERIOD, YEARS : 3.5 ECONOMIC EVALUATIONSlide51: INDIAN CEMENT INDUSTRY - 2000 TOTAL No. OF PLANTS WITH MORE : 54 THAN 1.0 MILLION TONNE CAPACITY MANPOWER EMPLOYED APPROX. : 1,35,000 PER CAPITA CONSUMPTION, Kg INDIA : 98 SOUTH KOREA : 1343 TAIWAN : 964 CHINA : 404 RUSSIA : 179 GERMANY : 419 UK : 216 FRANCE : 319 USA : 359 WORLD : 256Slide52: EXPORT OF CEMENT : 2.72 Mn.T EXPORT OF CLINKER : 1.85 Mn.T COUNTRIES : NEPAL, BANGLADESH, SRI LANKA, MAURITIUS AND COUNTRIES IN AFRICA & WEST ASIA INDIAN CEMENT INDUSTRY - 2000Slide53: CO2 EMISSIONS FROM CEMENT PLANTS YEAR 2000 (MILLION TONNES/YEAR) PROCESS (THERMAL) CALCINATION : 50 COAL COMBUSTION : 40 90 ELECTRICITY GRID POWER (THERMAL) : 3.8 CAPTIVE POWER (DIESEL & THERMAL) : 3.6 7.4 TOTAL CO2 EMISSIONS, MILLION TONNES/YEAR : 97.4 CO2 EMISSION IN CEMENT MANUFACTURESlide54: ROUND TABLE ON CLEAN ENERGY TECHNOLOGIES IN CEMENT MANUFACTURE