In view of the environmental hazards of dumping and the ever-increasing solid and semi-solid waste, especially in urban centres, we look at the role the cement sector plays in sustainable waste disposal.
In September 2019, I visited the site where the world’s biggest cement kiln was being built on the banks of the Yangtze river, just 40 km from Wuhan, China. For a cement plant to be built that close to a city it would have meant a great deal of network optimisation principles to be rejigged, but this was hardly the case for this unit. It was the municipal waste of Wuhan, which drove the rationale of location to its logical conclusion. Wuhan had an excess 3000 tonnes of municipal waste per day that was to be consumed by this cement kiln, thus the rationale was driven more by the city’s concern for sustainability and environment than anything else. But it had economics in-built in the operating cost structure of making cement – the proximity to market on the one hand and the replacement cost of coal on the other got the better of many known disadvantages of using municipal wastes, the processing cost included.
Logistics rule The backbone of the economics of using municipal waste as alternate fuel in this unit was driven by logistics cost, as the Yangtze river provided the perfect ground for moving the entire waste by barges after drying and then through pipeline from the jetty to the pre-calciner section. This was a fraction of the cost of moving coal and the difference of heat value was more than compensated. One of the major drawbacks of municipal waste is the heat value when compared with coal or pet coke. The energy density is low—approximately 10-13 MMBTU/ton—well below sub-bituminous coal at roughly 17-21 MMBTU/ton. The second is the moisture content, which in most MSW (Municipal Waste) is above 50 per cent. The partial drying facilities in this case provided the additional fillip. The rest of the deterrents are more related to sulphur and chlorine, where there are technologies available for mitigation. The real win-win is brought about by the proximity of the city to the unit that solves the problem of distributed availability of wastes that deters setting up of single location processing units of wastes and consumption, which also reduces the logistics cost. For this facility near Wuhan, the incineration of processed waste in a single kiln provided the best cost alternative to coal as both sides of the market- waste generation and disposal side balancing with the consumption side as alternate fuel economics was weighed, the true cost of externalities included. As the true cost of externalities get built-in the cost of coal or pet coke, this balancing act will only get simpler and easier to implement.
Working hand in hand To replicate such an act in many other locations, similar partnerships need to be reviewed – between waste handlers, the municipalities and the incinerating agencies that generate power, including cement makers, who can directly use it as heat input for producing clinker. The partnerships will include co-processing centres in between, logistics service providers and the broader public who can hardly be ignored from the equation. Think of the colossal waste that municipal waste creates, in terms of open dumps, which form 75 per cent of all waste disposal in India, and the bulk of this is adjacent to prime land in the cities. If only the city dwellers and municipalities come together to enact new laws that restrict such dumping, the situation can start to improve. The enactment of new laws across the world over, starting with the landfill acts, paved the way for municipal waste recycling to move into a new gear. Poland and Germany have shown how these could transform the waste to wealth landscape. No wonder then that Germany and Poland do not use any coal or pet coke in their cement kilns today but only process municipal processed waste instead. When the projected municipal waste is escalating at a frenetic pace (currently at 500 kg per capita), thanks to urbanisation, the focus must shift to reorganising how the waste could be stopped from simply becoming somebody else’s problem. While technical solutions in processing diverse wastes and solving pollution problems is at the top of the agenda, logistical issues cannot be lost sight of either. It is in this logistics of waste where several constituencies must come together; if the externalities are accounted for and the principle of ‘polluter pays’ is enacted, the public must come forth as the most important constituent of this jigsaw puzzle. This is where the role of the government also steps up as a positive mediator.
Steel Authority of India Limited (SAIL) has entered into a strategic partnership with John Cockerill India Limited (JCIL) to advance green steel production and technology within the steel industry.
The Memorandum of Understanding (MoU) was signed in Mumbai between SAIL Director (Finance) Anil Kumar Tulsiani and JCIL Managing Director Michael Kotas. This collaboration will focus on improving technologies in cold rolling, carbon steel production, green steel, and specialized silicon steels.
The partnership also aims to integrate green technologies into traditional iron and steelmaking processes to reduce carbon emissions and enhance resource efficiency. This move aligns with SAIL’s sustainability goals and its commitment to reducing the environmental impact of steel production.
SAIL is focused on transforming its operations and adopting advanced technologies to contribute to a greener future in the steel industry. The MoU marks a significant step towards the company’s vision of sustainable growth.
India is exploring the implementation of safeguard duties to curb the influx of steel at low or zero tariffs under the free trade agreement (FTA) with the ASEAN region. This move comes as Chinese companies expand their steel manufacturing capacities in ASEAN countries.
Discussions are underway between the steel and commerce ministries, ahead of the next India-ASEAN FTA review talks scheduled for February. Industry experts report that Chinese firms are adding approximately 97 million tonnes (mt) of blast furnace-basic oxygen furnace (BF-BOF) capacity in ASEAN, expected to be operational within the next 5-6 years.
With annual steel consumption in ASEAN at around 75 mt, there are concerns that the surplus production could be redirected to India due to the tariff advantages under the India-ASEAN FTA. “Discussions are ongoing, and measures like imposing a safeguard duty are being considered,” a senior government official said.
Alok Sahay, Secretary General of the Indian Steel Association, noted that the influx of 97 mt of new BF-BOF capacity in ASEAN countries poses a threat to Indian steel producers. “Given the current FTA and the limited growth in ASEAN’s consumption, these new capacities are mainly for export. India’s low-to-zero tariffs make it an attractive market compared to the EU or the US,” Sahay added.
The South East Asia Iron and Steel Institute (SEASI) projects that the region’s steel production capacity will reach 145 mt by 2026. Praful Venugopal, CEO of Mittal Steel Indonesia, mentioned that Chinese producers have signed agreements with Indonesia to set up plants that will contribute an additional 20 mt of capacity. Indonesia’s steel consumption is around 17 mt, and these new plants are designed to supply exports.
The anticipated oversupply from ASEAN could lead to depressed domestic steel prices in India, where production in FY24 was 139 mt, just slightly above consumption of 136 mt.
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The central government has identified instances of substandard steel imports and has taken measures to prevent their entry into the country. The Ministry of Steel stated that cheaper imports tend to lower domestic steel prices and negatively impact both large and small steel producers.
According to the ministry, numerous traders and manufacturers have been attempting to bypass the Bureau of Indian Standards (BIS) requirements by making minor alterations to steel grades. Official reports indicate that this appears to be an effort to import inexpensive steel under the guise of different grades.
The BIS has established 151 standards encompassing 1376 steel grades under the Steel Ministry’s Quality Control Orders (QCO). The ministry emphasized that this framework ensures compliance with BIS standards for both domestically produced and imported steel. The statement further highlighted that these measures are aimed at restricting the import of low-quality steel.
While steel imports require a BIS license, certain grades not yet covered by BIS standards may be imported with a No Objection Certificate (NOC) from the Steel Ministry. However, the ministry noted instances of misuse of this provision. Officials observed that many traders and manufacturers have been modifying steel grades slightly to circumvent BIS requirements.
Official data revealed that import applications for 1136 additional grades have been submitted to the Steel Ministry. Most of these grades are reportedly neither internationally recognized nor covered by BIS standards. They often involve minor variations in chemical composition or product dimensions and appear to facilitate the import of cheaper steel under the pretext of alternative grades. Furthermore, many of these shipments were ordered without obtaining the requisite NOC from the ministry.
Addressing concerns regarding restrictions on Japanese steel imports, the ministry clarified that 735 applications for importing Japanese steel had been received. Of these, 594 were approved, while 141 were denied due to non-compliance with established norms.