Dr GVK Prasad, Executive President – Operations, KCP Limited.
KCP has designed the road map with milestones to achieve the CO2 emissions reductions required for future. We are also putting all efforts for shifting from OPC to blended cements. It was targeted to increase blended cement percentage from the present 35-55 per cent by this year-end and 100 per cent by 2015, says Dr GVK Prasad, Executive President – Operations, KCP Limited. Excerpts from the interview.
What is KCP stated goal of reducing your carbon footprint in the next three years?
KCP has designed the road map with milestones to achieve the CO2 emissions reductions required for the future. The following are key reduction levers identified to reduce CO2 emissions:
a)Thermal and electrical efficiency;
b) Alternative fuel use;
c) Clinker substitution;
d) Installation of waste heat recovery power plant;
e) Installation of captive solar power units;
f) Realising the full potential of each lever requires potential and economic support and technology development within the KCP itself.
Highlight the strategies put in place to conserve the fossil fuel through AFR?
Alternate fuels use entails replacing conventional fuels mainly coal. KCP has already taken action for usage of waste-oil and solvents, plastic, textiles and paper residues in the kiln. In addition, arrangements are underway for feeding discarded tyres and pre-treated industrial waste in the cement kiln. Feeding arrangements are also in progress for feeding biomass material in calciners.
Also tell us on the thrust you give for renewable energy sources.
We believe that power generation from renewable energy sources are increasingly important to meet KCP’s power demands. We at KCP believe that enhanced use of natural and renewable energy sources is needed to help take the burden off our current dependency on fossil fuels.
Power generation from renewable energy sources is increasingly becoming important all over the world as we strive to mitigate green house gases and climate change issues important for our survival on planet earth. We have a diversified portfolio of power projects in which green energy generation has an important share. We have successfully commissioned a 8.25 mw of hydroelectric power projects in Nekarikallu, Guntur, Andhra Pradesh and it is presently generating 340 lacs Kwh/year.
We have also set up wind power of 3.25 mw capacity in Tamil Nadu. We have also installed 2.30 mw capacity fuel less power unit using waste hot gases generated in our one of the cement units located in Macherla, Guntur, AP. Recently, we have successfully commissioned 1.15 mw solar photovoltaic project, India’s first captive such project in Muktyala, Krishna District, Andhra Pradesh. We have finalised plans to develop 4,60 mw of solar power project which is in various stages of development.
We have also in the process of identified locations for setting up of wind and solar based capacities. We expect that, of our total energy portfolio, as much as ten percent will come from renewable energy capacities. India’s potential for generating renewable energy is huge, especially solar power.
KCP’s strategy for its renewable renewable energy: Becoming one of the largest green portfolio company in the industrial sector; A company with a diversified portfolio consisting of wind, solar and hydel projects; Striving for a portfolio which provides attractive returns; Earning additional revenues through carbon credits and renewable energy certificates.
Could you throw some light on the initiative of reducing your carbon footprint through WHR systems?
At KCP, we currently generate about 30 per cent of our electrical energy needs from waste heat recovery in our Cement Unit-I located at Macherla. Since our Cement Unit-II located at Muktyala has designed most thermal efficiency plant, it is not possible to put-up waste recovery plant because of low exit temperatures. We are planning to utilise this low temperature cooler exit gases for pre-heating the boiler blow down water by which we are able to save 350 kgs/hr coal in our captive power plant.
Brief us on high efficiency pollution control equipment used for cement kilns, raw mills, coal
KCP designed and operating all their pollution control equipments with emission levels less than 25 mg/Nm3 as against PCB norm of 50 mg/Nm3. KCP is the first cement company installed bag filter for de-dusting of cooler gases in their cement unit-I and working successfully for last 15 years. In our cement unit-II, all bag filters are provided stand by chambers where in we can attend maintenance job during operation without affecting the performance. In addition, one additional chamber provided in cooler ESP to take care of emission level whenever problem in one of the chambers. In our CPP, KCP is first time in installing hybrid bag filter consist of ESP and bag filter to ensure the emission levels less than 25 mgs/Nm3 even change in fuel properties.
What are steps initiated to reduce water consumption in your plants? KCP has taken several steps for reduction of water consumption in their both cement units. Our major water conservation efforts are installation of air cooled condenser in captive power plant; recycling in green belt area, And adoption of dry technologies for dust control, implementation of water conservation measures in the plant and colony. By taking above initiatives, the specific water consumption has come down from 92 lit/mt clinker to 72 lit/mt clinker in our unit – II and from 125 lit/mt clinker to 85 lit/mt clinker in our unit-I.
How green is KCP’s operation, from mining to production and despatch of cement?
Our focus is on energy conservation and we developed cleaner and energy efficient technology in our plants and mines. We have initiated several energy efficient steps and few are presented below: Installation/replacement of high efficiency motors; Installation/replacement of high efficiency motors; Optimisation of belt conveyor speed and capacity utilisation; Installation/retrofit of > 82 per cent efficiency fans; Installation of VFDs for all fans including Aux bag filter fans; Installation of level sensors in crusher dump hopper to avoid ideal running; Increase the stack height of cooler ESP for reduce the load on the fan; Installation of solar water heaters and solar lighting system in the colony; Usage of LED lighting system.
How do you view the advantages of the PAT scheme?
PAT is a very good scheme which will help cement industry for implementation of best available practices and technologies, economically viable energy efficient projects and faster adoption of low carbon technology.
Will KCP be opting for the Greenco rating?
Yes. We are in the process of obtaining Greenco rating for our Cement Unit-II.
How do you assess the challenges on the logistics front?
KCP has taken several initiatives for making the supply chain efficient by increase transport of product and other raw materials through rail, having dedicated trucks for movement of raw material and cement.
Where does the company see itself five years down the line?
KCP has already developed a road map for achieving the deep emission reduction and we are moving towards the year 2020 with 30 per cent reduction on current CO2 emission.
Will there be a shift towards production of more blended cements than OPC?
KCP is putting all efforts for shifting OPC to blended cements. It was targeted to increase blended cement percentage from the present 35 to 55 per cent by this year end and a hundred per cent by 2015.