Many industries have limited options to decarbonise
In the light of the recent announcement by NTPC of using Carbon Clean’s CDRMax™ carbon capture technology, Prateek Bumb, Co-Founder & CTO, Carbon Clean Solutions Limited, discusses their technology and its impact on industrial decarbonisation.
Tell us about the design and carbon capture power of the NTPC Power Plant by Carbon Clean.
The carbon capture plant is designed to capture 20 tonnes of carbon dioxide (CO2) per day, from the flue gas of Unit-13 of the Vindhyachal Super Thermal Power Station. The CO2 will eventually be combined with hydrogen to produce 10 tonnes per day of methanol through a catalytic hydrogenation process.
Carbon Clean’s CDRMax™ carbon capture technology is being used for this demonstration project, which is the first step toward decarbonising the power plant. The objectives of the project are to review the economics, design optimisation and waste heat utilisation, in order to further reduce the overall cost of carbon capture and utilisation. Evidence suggests that it will be both feasible and cost-effective, by using our carbon capture technology – CDRMaxTM.
What is the key technology backing the power plant?
Carbon Clean’s CDRMax™ carbon capture technology can be used with point source gases that contain CO2 concentrations between 3 per cent and 25 per cent by volume and produces CO2 with purities greater than 99 per cent, which can then be sold, reused or sequestered.
The CDRMax™ process uses Carbon Clean’s proprietary solvent, process equipment design, and advanced heat integration to significantly reduce both capital and operating costs. Due to an extremely low rate of corrosion, smaller equipment, and other improvements, CDRMax™ has been proven to provide a 20 per cent CapEx reduction compared to other available solutions. Thanks to lower heat and energy demand, CDRMax™ reduces OpEx by 30 per cent to 40 per cent compared to other available carbon capture solutions.
Tell us about the disposal of the captured carbon.
Carbon utilisation or storage at industrial plants is determined on a case-by-case basis. For example, the carbon captured at the St Fergus Gas plant will be transported and permanently stored offshore, as part of the Acorn Project. Meanwhile, in a project with Tuticorin Alkali Chemicals & Fertilizers Limited, India, the captured carbon is converted to soda ash and sold to Unilever, which uses it to manufacture cleaning products.
What impact is Carbon Clean planning to make on industrial decarbonisation?
Heavy industry accounts for around 30 per cent of global carbon emissions. Many industries – such as cement, steel, and refineries – have limited options to decarbonise. Point source carbon capture offers these industries a means of tackling their emissions and it is available now.
Carbon Clean is leading innovation in point source carbon capture and addressing the barriers to mass deployment, which have mainly been the cost and space requirements to install the technology.
Our latest fully modular carbon capture solution, CycloneCC, overcomes these barriers. CycloneCC has a footprint that is up to 50 per cent smaller than conventional carbon capture units and it will be deployable in less than eight weeks. It also has the potential to reduce CapEx and OpEx by up to 50 per cent and drive down the cost of carbon capture to $30/tonne on average, which would make the economic case for carbon capture undeniable.
This latest innovation, alongside Carbon Clean’s recent funding round, puts the company on track to deliver industrial decarbonisation on a gigatonne scale by the mid-2030s.
How do you picture your contribution to the Indian industrial economy›s goal to reach net zero by 2070?
Outside of the project with NTCP, Carbon Clean is working with Tata Steel and Tuticorin Alkali Chemicals & Fertilizers in India. We also have a joint venture with Veolia – Veolia Carbon Clean – that is committed to reducing industrial carbon dioxide emissions and helping India achieve its climate goals through the development of a series of carbon capture and compressed biogas (CBG) projects.
Looking forward, achieving net zero in India, will require a collaborative effort between hard-to-abate sectors, government and technology providers, such as Carbon Clean.
Cement industry sees record growth amid booming construction demand
Glimpses from the 13th Cement Expo in Hyderabad.
“There’s no waste in India; everything is wealth,” was the thought-provoking idea that came from Dr Mohapatra, DG, NCCBM, as he shared his views on ‘Circular Economy and Sustainability’ at the recently concluded 8th Indian Cement Review Conference. The questions he raised and the ideas he presented were enriched with his decades of experience of working on research, development and analysis of alternative raw materials and renewable fuel for the cement industry. He highlighted the struggles in manufacturing blended cement and the opportunities that are available for its use. Finally, he suggested ways to ensure that each manufacturing plant falls within the gamut of a circular economy.
On his part Dr Sriharsha Reddy, Director, IMT Hyderabad, elaborating on ‘ESG – Green Financing: A new opportunity for the cement industry’, brought to light a number of important issues pertaining to fund procurement through traditional methods and the challenges therein.
Highlighting his views on carbon capture and its benefits for the cement manufacturers, Saurabh Palsania, Executive Director and Group Commercial Head, Dalmia Cement (Bharat), underscored the need to implement innovative technology and most importantly a proper strategy, in order to revolutionise the efforts towards net zero emissions. “Carbon capture, utilisation and storage (CCUS) is an investment-intensive process that also requires a commitment of time and labour. Keeping all these factors in mind, cement companies need to chart out an effective strategy to incorporate CCUS into their eco systems, ensure purity of the captured carbon and channel it towards predetermined activities for its optimum utility,” he said.
Pratap Padode, Founder & President, FIRST Construction Council, summarised the challenges faced by the Indian cement industry as well as the growth opportunities it presented for manufacturers in terms of technological innovation and capacity building. He supported his opinions with statistical findings and his in-depth knowledge about the Indian cement and construction industries.
Several discussions from the event highlighted several critical aspects of the cement industry.
ESG – Green Financing: A new opportunity for the cement industry
The cement industry has made progress in reducing energy consumption and power usage, but the challenge now lies in reducing carbon emissions. With breakthrough carbon capture technologies and solar calcination of limestone, the industry can work towards achieving zero CO2 emissions. However, the economic value of carbon capture needs to be explored, with government support through carbon labelling, trading, and green funds. Other solutions such as non-contact grinding and heat recovery from kilns can also be explored to bring emissions to zero. The industry can achieve sustainability and low carbon footprint with digital transformation and well-planned processes. To finance green initiatives, traditional lending institutions such as banks are now considering the economic value of eco-friendly practices. However, long-term loans remain a challenge, and other lending institutions such as venture capitalists and government grants need to be explored.
Demystifying digitalisation and maximising the value chain impact
Digitalisation is crucial in optimising all stages of cement production. Industry 4.0 has provided tools that help determine the desired product quality, which is vital in meeting customer demands. As the importance of ESG continues to grow, digitalisation can help improve processes and reduce environmental impact. Transparency is also key, and a cloud-based platform can facilitate this. Automation at the plant level is vital for both efficiency and safety. However, it is important to remember that profitability is also essential for sustainability. Therefore, implementing digital tools and automation must be done with a focus on achieving profitability without compromising on sustainability.
Innovative supply chain strategies in the cement industry
Innovative supply chain strategies are crucial for the cement industry to remain competitive, with logistics and transportation being at the forefront. Industry experts discussed that the key to cost efficiency lies in innovation in first and last mile connectivity. However, logistics should not be viewed as merely a commercial function, but rather as a technology function. By investing in technology, cement manufacturers can drive the supply chain in a much better way, enabling them to evaluate processes from a revenue angle rather than just cost.
Industry experts also agreed that logistics is the only differentiator a cement company can have today, rather than cost or quality. As such, it is essential for cement manufacturers to explore non-renewable sources of energy to address the energy demand for distribution. Automation is also considered a key element for future logistics solutions. With these innovative strategies in place, the cement industry can increase efficiency and sustainability, which in turn can positively impact the bottom line.
On his part, Gaurav Gautam, Head of Sales, Beumer Group, highlighted the innovations in material handling systems that the is undertaking in order to make the movement of finished products smoother along the supply chain. The company specialises in tailor-made intralogistics solutions that help maximise productivity of cement companies.
Truly, the 8th Indian Cement Review Conference brought the industry together in a informative discussion on thought-provoking ideas and suggestions. The presentation weremade by Jayesh Patil, Assistant Manager, Flow Aids, Martin Engineering; Nischal Basavaraj, Regional Head – South, Liugong India; Sasi M Kumar, Business Development Manager – Cement, ExxonMobil; and S Chakravarti, Managing Director, Ecodea Projects and Control.
The conference was held alongside the 13th Cement Expo and Indian Cement Review Awards 2023. Partners supporting the event included: Presenting Partner: ExxonMobil Lubricants; Gold Sponsor: JK Cement and PhillipCapital India; Silver Sponsor: LiuGong India; Associate Sponsor: Humboldt Wedag India; Presentation Partners: Martin Engineering Company India, Beumer India, and Ecodea Projects & Control; Logo Sponsor: Stotz Gears; and Exhibiting Partners: Toshniwal Industries; TIDC (Murugappa Group), and Ringfeder Power Transmission India.
Solutions to protect concrete against monsoon
Concrete patching compounds for repairing concrete window ledges.
As the monsoon season rapidly approaches in India, the urgency to address potential damage to the commonly used building material – concrete –intensifies. Weathering and loading can cause cracks and deterioration, impacting both the structure’s integrity and aesthetics and leading to water penetration and reinforcement corrosion. To ensure durability and prevent further damage, it is essential to promptly repair any concrete cracks.
Several structures face a common problem during monsoon season – holes created by water penetration or impact in concrete window sills. These not only affect the window’s appearance and functionality but also pose a safety hazard. Fortunately, various concrete repair compounds are available in India to fill such holes and restore the window sill. Don’t wait until it’s too late –CW researches some of the concrete repair compounds that could help protect concrete structures from monsoon damage:
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Heidelberg Materials secures SBTi validation
The Science-Based Targets Initiative (SBTi) has validated Heidelberg Materials’ new 2030 CO2 reduction targets. The targets have a base year of 2020 and conform to a 1.5°C climate change framework. Per tonne of cementitious material, the producer is now committed to reducing its Scope 1 CO2 emissions by 24 per cent, its Scope 2 CO2 emissions by 65 per cent and its Scope 3 emissions by 25 per cent.
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