The cement industry in India is expected to significantly increase production capacity between 2010 and 2027. This will require large amounts of coal which may be difficult to obtain due to limited coal linkages. Using waste as an alternative fuel in cement kilns provides benefits over direct waste disposal and coal usage. UltraTech Cement utilizes various industrial and municipal wastes as alternative fuels, amounting to over 40% of its fuel usage. Proper storage, processing, and feeding systems are required to safely co-process wastes in cement kilns. Further policy and regulatory support is needed to encourage greater waste diversion from disposal to cement production.
The cement industry in India is expected to significantly increase production capacity between 2010 and 2027. This will require large amounts of coal which may be difficult to obtain due to limited coal linkages. Using waste as an alternative fuel in cement kilns provides benefits over direct waste disposal and coal usage. UltraTech Cement utilizes various industrial and municipal wastes as alternative fuels, amounting to over 40% of its fuel usage. Proper storage, processing, and feeding systems are required to safely co-process wastes in cement kilns. Further policy and regulatory support is needed to encourage greater waste diversion from disposal to cement production.
The cement industry in India is expected to significantly increase production capacity between 2010 and 2027. This will require large amounts of coal which may be difficult to obtain due to limited coal linkages. Using waste as an alternative fuel in cement kilns provides benefits over direct waste disposal and coal usage. UltraTech Cement utilizes various industrial and municipal wastes as alternative fuels, amounting to over 40% of its fuel usage. Proper storage, processing, and feeding systems are required to safely co-process wastes in cement kilns. Further policy and regulatory support is needed to encourage greater waste diversion from disposal to cement production.
The cement industry in India is expected to significantly increase production capacity between 2010 and 2027. This will require large amounts of coal which may be difficult to obtain due to limited coal linkages. Using waste as an alternative fuel in cement kilns provides benefits over direct waste disposal and coal usage. UltraTech Cement utilizes various industrial and municipal wastes as alternative fuels, amounting to over 40% of its fuel usage. Proper storage, processing, and feeding systems are required to safely co-process wastes in cement kilns. Further policy and regulatory support is needed to encourage greater waste diversion from disposal to cement production.
year Capacity Mn T 2010 228.3 2022 605.8 2027 975.6
Coal requirement for cement plant -2030- 150 Mn T
The availability of linkage coal a major concern for the cement industry. Even importing coal is not the best option . Will have to compete with power plants . The industry has no choice but to use waste derived fuels Linkage coal for Cement sector
No new Coal allotment to Cement industry . Coal materialization thru
linkage has come down from 14. 8 mill T in FY 06 to 11.9 in FY 11
Data based on CMA member companies
Alternate fuel use in Cement kilns
Country % TSR by AFR Country % TSR by AFR
Netherlands 83 Sweden 29 Switzerland 48 Luxemburg 25
Austria 46 Czech Republic 24
Norway 35 Japan 10 France 34 United states 25
Belgium 30 India Less than 1
Germany 42
Source: CEMBUREAU Waste generation in India
Type of waste Quantity Mil T Quantity Mil T
Municipal waste 58. 4
Hazardous waste A+B+C 6.21
A recyclable 3.08 3.08
B Land fillable 2.72 2.72
C Incinerable 0.41 0.41
Total 64.61
National Inventory of Hazardous Wastes Generating Industries &
Hazardous Waste Management in India February 2009, CPCB
Municipal waste alone can generate 9 mil T of RDF to replace 4. 5 Mil T of coal Equivalent to 22 % of current coal requirement for cement plant operation . Does not include other non hazardous waste
Incinerable waste generation in India
State Hazardous waste incinerable Maharashtra 36.75% Gujarat 26.12% AP 7.61% Rajasthan 5.54% U.P 3.78% Punjab 3.57% WB 3.03% TN 2.68%
Total Incinerable waste generation 0.41MTA
Total Incinerable waste capacity 0.32 MTA Deficit of Incineration capacities 0.09MTA UltraTech - Leading Indian Cement Manufacturer has taken this Challenge as Technology Mission.
The advantages of co processing of
alternate fuel in cement plant • Co processing ranks higher in the waste processing hierarchy . • High flame temperature (2000°C) – ensures complete destruction of harmful pollutants • Residence time of combustion gases above 1000°C in excess of 3-4 seconds – ensures complete destruction of pollutants. • Complete destruction of organic compounds. • Total neutralization of acid gases, sulphur oxides and hydrogen chloride, by the active lime in the kiln load, in large excess to the stoichiometry. • Embedding of the traces of heavy metals in the clinker structure with very stable links (metallic silicates formation). • No production of by-products such as ash or liquid residue from gas cleaning.
8 The advantages of co processing of alternate fuel in cement plant • Produces overall environmental benefits by reducing releases to air, water and land. • Maximizes the recovery of energy while ensuring their safe disposal • Saving of non renewable fossil fuels. Substitution of coal with waste. Savings are made through resource conservation and associated CO2 emissions. • Reduced burden on TSDF • Immobilization of toxic and heavy material • Reduced NOx emissions when using certain types of waste
India UAE- Integrated Units-12 Clinkerisation Units-1 Grinding Units -11 Grinding Units -3 Bulk terminal -4 Grinding Units Bangladesh -1 Bulk terminal Sri lanka -1 Industrial Wastes We Co-Process Automobile Industry ( Paint Sludge, Phosphate Sludge, ETP Sludge, Spent Catalyst, Waste Oil) Textile Industry ( ETP Sludge, Waste Oil) Pharmaceutical & Bulk Drug Industry (Spent Carbon, ETP Sludge, Spent Catalyst, Mother Liquor, Waste Oil, Still Bottom Residue, Spent and distillation Residue) Soft Drink Industry ( ETP Sludge, Spent Carbon) Petroleum Refinery Pesticide Industry Paint and Dyes Industries Agro Waste and Biomass ( Rice Husk, Soya Husk, Mustard Husk, Ground Nut Husk, Saw Dust etc) Tyre Chips, Rubbers, Plastics and polythene MSW/RDF
Overall AF Consumption 2.50 2.28 2010-11 2011-12 2012-13…
2.00 Targeted % TSR for FY 2012-13
2.00 1.80 1.84
1.57 1.50 1.26 1.13
1.00
0.68 0.71
0.50
0.15
0.00 % AF Weight % TSR Qty (in Lac MT) Overview of AF Usage in UltraTech (Based on Material)
Hazardous waste 43% ,Non Hazardous waste 15%
Biomass fuel 42%
Alternative Raw Material
Utilization of Fly ash, Slag as Substitute materials for Cement Production . Potential to use LD slag , spent pot liners , lime sludge . 16.81 million tonnes of recycled material used during Fy-10-11 and Fy-11-12. Alternative Raw Materials Rate (% total raw materials for cement production) 14.10 and 13.75 during Fy-10-11 and Fy-11-12. Storage Yard & Feeding System at RDCW We have a well covered storage yard with good ventilation, concrete floor and leachate collection drainage system. A special and fully mechanized feeding system with hopper, belt conveyor, weigh feeder etc. Fully dedicated handling vehicle like dozer. Special manpower for pre-processing, handling and monitoring of waste fuel feeding. Pump for feeding liquid/semi solid material like sludge. Plastic and wood shredding machine for size reduction.
15
Alternate Fuel Feeding System at RDCW
BUCKET ELEVATOR
TRANSFER UNLOADING TOWER AREA
16 Alternate Fuel Feeding System at RDCW
17
Storage Yard at RDCW With Different Wastes
18 Municipal Solid Waste Plant at Jaipur ( Rajasthan)
(Future plan and Support required )
• Policy to encourage waste generators to divert incinerable waste to cement plant. • To include “co processing ”in Hazardous wastes (Management, Handling, and Trans boundary Movement ) Rules,2008 and place it above incineration . • To Create a class of Waste processing facilities for fuel homogenization and preparation for Industry . • Polluters pay principle to be enforced . • Need for better coordination between regulatory authority, TSDF operators and cement industry. • Inter States movement permission. • Permit import of non hazardous waste such as Tyres and RDF . 21
