Concrete

A cement plant is a high energy intensive unit

Published

1 year ago

October 19, 2023

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Pankaj Kejriwal, Managing Director, Star Cement, delves into the importance of optimising refractories to make cement manufacturing more cost efficient and eco-friendly.

Tell us about the role of energy in the manufacturing of cement? What is the volume of energy consumption?
A cement plant is a high energy intensive unit. For manufacturing of cement, both thermal energy and electrical energy is required. In the year 2022-23, thermal energy consumption was 27.50 lakh mKcal (82 per cent of total energy) and electrical energy consumption was 5.97 lakh mKcal (18 per cent of total energy). In the cement industry, about 60 kWh of electrical energy is consumed to produce one ton of cement.
The power consumption pattern is as follows:

What are the various modes of energy sources used by your organisation for its manufacturing needs?
The electrical power is taken from various sources such as IEX through open access from state electricity grid and our own captive coal/biomass fuel based thermal power plant, bamboo chips and AFR like RDF is also being used in our plants. We have recently commissioned a 12.3 MW waste heat recovery system (WHRS) plant, and another 12.5 MW WHRS plant is in the pipeline. We are also installing about 15 MW of solar power plant.
The thermal energy is produced by coal in kiln. Linkage coal is utilised in kiln along with various local or purchased coal.

Which of the said energy sources yields maximum productivity for the plant and which yields the least?
Coal, pet coke and electricity are the dominant energy sources used in cement plants, although plants will burn a variety of other fuels, including tires, biomass, RDF and other waste fuels.
As per the mentioned energy sources, WHRS with CPP is our first priority whereas grid (IEX) power is the least priority energy source. As an AFR, we are using bamboo chips, bamboo briquettes and waste plastic bags in our plant. The green energy sources have large impact on the productivity and cost of cement manufacturing. It reduces the carbon emission. As a cost impact, it reduces power cost by 12 per cent in CPP and 1.5 per cent in process plant approximately.

What are the alternative energy sources that are being adapted by the cement industry and your organisation?
The main alternative fuels used in cement industry are residue oil and solvents, contaminated garbage, process waste from food industry / pharma industry, used tires and rubber waste, plastic waste, sewage sludge and waste animal meal. Star Cement uses alternative energy sources such as biomass like municipal waste, bamboo chips and are also installing a 15 MW solar energy plant.

What is the impact of greener energy sources on the productivity and cost of cement manufacturing?
Alternative fuels utilisation in cement industry reduces the production cost and also reduces the coal requirement, coal handling/grinding etc.

How does automation and technology help in optimising the use of energy in cement plants?
By leveraging the power of automation and AI-driven analytics, the cement industry can reduce maintenance costs, enhance equipment reliability, and achieve higher energy efficiency, ultimately leading to improved productivity and profitability.
We are also focusing on automation and technology up gradation to optimise the use of energy in cement plants. To achieve this, various steps has been taken towards energy conservation and technology absorption, few are as mentioned below:
• Installed VFD in Primary Air blower by which control the rpm of blower as per process requirement and saved the energy 86,000 kWh per year.
• Optimisation of RABH purging operation. Total power saving is 2,80,000 kwh per year.
• VFD installed in VRM bag filter of 55 Kw motor, by which saving achieved 7920 kWh per year.
• Increased clinker production and optimised
the running of the different circuits, by which specific power consumption is reduced by 1.08 kwh/MT clinker.
• Optimised the coal firing system and higher clinker production reduced the specific heat consumption by 7 Kcal/kg clinker.
• Installed tertiary crusher in raw mill circuit, thereby increasing ball mill output and reducing power consumption b 2 KW / tonne of raw meal.

What are the major challenges your organisation faces in managing the energy needs of cement manufacturers?
The major challenges for our organisation in managing the energy needs for the cement manufacturing process is the less availability of alternative fuels in plant locality. The segregation of waste is yet to improve and also the Polluter Pay Principle is not being implemented effectively,
thereby increasing the cost of alternative fuel at our factory gate.
Cement industry have a long way to go as far as alternate fuel and raw material usage is concerned.
In spite of several policy, regulatory or technological barriers that industry is facing, now is the opportune time for the Indian cement industry to focus all its efforts in furthering AFR utilisation in its processes.

Tell us about the compliance and standards followed by you to maintain energy use and efficiency in the organisation?
Our organisation is a designated consumer under PAT cycle 2 and 3. We are following all the compliance and standards as per BEE guidelines to achieve our Specific Energy Consumption targets as directed by Bureau of Energy Efficiency, Ministry of Power, Government of India.
As per BEE guidelines Mandatory Energy Audit, monitoring and verification audits are conducted to ensure optimum use of energy after every three years. We have also conducted detailed energy audit by CII, Hyderabad, in May 2023 as an additional exercise.

What kind of innovations in the area of energy consumption do you wish to see in the cement industry?
Use of solar power, hydrogen fuel and maximising the use of AFR are the areas of innovations, we wish to see in the cement industry in near future. Also increasing the efficiency of WHR boilers will help in better recovering the waste heat.
Along with cheaper and greener fuel sources, we would like technology to further reduce the
energy consumption in the grinding process.
Usage of alternative materials, which reduce the overall clinker component in blended cement like LC3 will also go a long way in reducing the
energy requirements.

-Kanika Mathur

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Concrete

Indian Steel Ministry Seeks $1.7 Bn for Low-Carbon Steel Production

India is actively working on a green steel policy

Published

13 hours ago

January 20, 2025

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India’s Ministry of Steel has requested 150 billion rupees (approximately $1.74 billion) from the federal budget to incentivise mills to produce low-carbon steel, according to two government sources familiar with the matter.

As the world’s second-largest steel producer after China, India is actively working on a green steel policy aimed at reducing emissions in steel production. This initiative forms part of the country’s broader efforts to meet its net-zero target by 2070, as outlined by Prime Minister Narendra Modi.

The steel ministry plans to use the funds to offer incentives that encourage emissions reduction, improve research and development, increase raw material efficiency, and incentivise banks to offer lower interest rates on renewable energy loans. These details were shared by the sources, who requested anonymity as the discussions are private.

The steel ministry did not respond to an email seeking comment.

Once the funds are allocated, the ministry will submit the proposal for the cabinet’s approval. In December, the government defined ‘green steel’ as steel produced with emissions lower than 2.2 metric tons of CO2 per tonne of finished steel.

The proposed incentives would remain in place until 2030, with green steel potentially being used in government projects.

India’s steel production generates 2.55 metric tons of carbon dioxide per tonne of crude steel, 38% higher than the global average of 1.85 tons, according to Global Energy Monitor.

Concrete

Cement Industry Needs 35-45% Emissions Cut for Net-zero by 2070

This need was highlighted at a workshop organised by NITI Aayog at Vigyan Bhawan.

Published

13 hours ago

January 20, 2025

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The Indian cement sector, responsible for 5.8 per cent of the country’s total CO? emissions, requires the adoption of carbon capture, utilisation, and storage (CCUS) technologies to achieve a 35-45 per cent reduction in emissions and meet the net-zero target by 2070. This need was highlighted at a workshop organized by NITI Aayog at Vigyan Bhawan.

Titled “Carbon Capture, Utilization, and Storage (CCUS) in the Indian Cement Sector,” the workshop brought together government officials, industry leaders, researchers, and academicians to discuss decarbonisation strategies. The Indian cement industry, with an installed capacity of 600 million tonnes and an annual production of 391 million tonnes, plays a critical role in the country’s infrastructure development and economy.

Prof Ajay Kumar Sood, Principal Scientific Adviser to the Prime Minister, stated that CCUS is an essential tool for addressing emissions in the cement sector, which is crucial for meeting India’s long-term climate goals. He stressed the need to balance economic growth with environmental targets and advance research and development to overcome challenges in decarbonizing this hard-to-abate sector.

Dr VK Saraswat, Member of NITI Aayog, noted that the cement industry is a key player in the Asia-Pacific region, which is witnessing rapid growth in the global cement market. He emphasised that carbon capture and utilization technologies, along with clean energy initiatives, are vital for reducing emissions in the cement sector. He also highlighted the role of carbon pricing and climate finance in supporting decarbonisation efforts.

India holds significant potential for CCUS, with regions like the Krishna-Godavari Basin, Deccan Traps, and mature oil and gas fields offering substantial CO? storage capacity. Innovative utilisation pathways, such as producing methanol, biodegradable plastics, and value-added chemicals, were discussed as potential solutions for creating a low-carbon future.

Pankaj Agarwal, Secretary of the Ministry of Power, shared that the government is preparing a comprehensive CCUS Mission to support these efforts. Ranjith Rath, CMD of Oil India, emphasised the need for innovative solutions and geo-sequestration techniques to mitigate emissions effectively.

Concrete

15th Cement EXPO: A Step Forward in Cement Innovation

Published

4 days ago

January 17, 2025

admin

Mumbai

Following the immense success of the 14th Cement EXPO, held on December 14-15, 2023, at the Manekshaw Centre, New Delhi, the next edition of this premier event is set to take place in March 2025. The 15th Cement EXPO will be hosted at Yashobhoomi, Delhi, on 12th and 13th November 2025.

Meanwhile, the Cement Expo Forum 2025 is scheduled for 5th and 6th March 2025 at Taj Krishna in Hyderabad. This exciting 3-in-1 event, organised by FIRST Construction Council (FCC) and Indian Cement Review (ICR), will bring together industry leaders, innovators, and stakeholders to discuss the future of the cement sector.

Building on the Success of the 14th Cement EXPO

The 14th Cement EXPO was widely praised for its strong participation, attracting over 1,500 senior managers and decision-makers from across the cement industry. The event was inaugurated by Dr. Vibha Dhawan, Director General of TERI, and Ali Emir Adiguzel, Founder and Director of the World Cement Association, alongside Pratap Padode, Founder of FIRST Construction Council (FCC). The two-tiered exhibition space featured cutting-edge products and innovations from top companies within the cement industry’s supply chain.

The event also garnered significant support from key government bodies, including the Ministry of Road Transport and Highways, Government e-Marketplace (GeM), and the Department for Promotion of Industry and Internal Trade (DPIIT), Ministry of Commerce and Industry, Government of India (GoI).

Recognition and Excellence in the Cement Industry

The 7th Indian Cement Review Awards celebrated excellence by presenting awards to 11 companies in various categories, recognising their contributions to growth and innovation within the industry. Notably, Parth Jindal, Managing Director of JSW Cement, was honoured with the prestigious Indian Cement Review – Person of the Year Award 2023. Meanwhile, Vinita Singhania, Vice Chairman and Managing Director of JK Lakshmi Cement Ltd, received the Lifetime Achievement Award for her outstanding leadership and contributions to the sector.

A Vision for Sustainability

With the theme of “Driving Sustainability Through Technology,” the 9th Indian Cement Review Conference hosted thought-provoking discussions and presentations, highlighting the industry’s commitment to adopting innovative, sustainable practices. The conference served as a platform for dialogue on the latest technological advancements aimed at transforming the cement sector, addressing key challenges, and fostering growth.

What to Expect from Cement EXPO 2025

The 15th Cement EXPO, along with the 10th Indian Cement Review Conference and the 8th Indian Cement Review Awards, is set to be even bigger and more impactful than the 2023 edition. With an expanded exhibition space, greater participation, and more in-depth discussions, the 2025 event will continue to drive the industry forward. This 3-in-1 event promises to be a pivotal moment in the ongoing transformation of the cement sector.

As the industry evolves, the 15th Cement EXPO 2025 will serve as a crucial platform for showcasing innovations, discussing emerging trends, and forging new partnerships to shape the future of cement and construction.

For more details:

Cement Expo Forum 2025: https://cementexpo.in/forum

15^th Cement Expo 2025: https://cementexpo.in/

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