Technology Roadmap: Low-Carbon Technology for the Indian Cement Industry Mr. L Rajasekar

© OECD/IEA 2013

Technology Roadmap:Low-CarbonTechnology for the Indian Cement Industry

Mr. L Rajasekar UltraTech Cement Ltd.

© OECD/IEA and WBCSD 2013

Cement Sustainability Initiative- 24 member companies

One third global cement productionTwo thirds outside of China

3

First industry-specific roadmap, with IEA

Roadmap for global CO2 emissions reductions potential up to 2050 (incl regional milestones)

Based on 38 technology-specific papers by European Cement Research Academy (ECRA)

Launched December 2009

Global Cement Technology Roadmap 2009: A world first


Emissions reduction levers:

1. Energy efficiency (thermal, electric)

2. Alternative fuels

3. Clinker substitution

4. CCS (Carbon capture and storage)Technical papers

Global Cement Technology Roadmap 2009

IEA model

Global data input


CSI in India

>60% of national production


Partnering to develop a Low-Carbon Technology Roadmap for the Indian cement industry


India Cement Production Projections


Low Carbon Technology RoadmapFor The Indian Cement Industry

Merits in evolving India Specific Roadmap

Input data to Model – Data of Indian Cement Industry

Assumptions/ options/ alternative relate to Indian Cement

Industry

Roadmap addresses issues relevant to Indian Cement

Industry

Identifying Indian cement industry-specific technology options

Based on current level of specific energy consumption &

technology absorption

Focus on identifying Gap /Barriers and specific policy

interventions


Low Carbon Technology RoadmapFor The Indian Cement Industry


Roadmap Development Process…


Data modeling and roadmap drafting

Cement demand data, data modeling

and analysis (IEA)

Stakeholder outreach – Technology, Financing, Policy

Partner and stakeholder

review

Data collected for 2009-10 by CII

CSI members Non-CSI members

Industry represented

67% ( 49%+18%)

Installed capacity

277.39 mtpa

Clinker factor 0.721 0.806

GHG emissions 644 kg CO2 / t cement

952 kg CO2 / t cement

Average GHG emissions

719 kg CO2 / t cement

Technology Papers


Low Carbon Technology Roadmap-Model


Low Carbon Growth for the Indian cement industry- Vision

Low Demand Case


Key indicators for Indian cement industry in the 2DS


Key indicators in the 2DS


Potential energy savings from implementation of the different levers


Technical Layout constraints/civil structural capability for stage addition in

Preheater High moisture limestone restricts the number of stages in the

preheater Burnability of raw mix

Policy India’s environmental norms, necessitating installation of

additional equipment, might increase future energy consumption.

Logistics/availability and quality concerns of coal, raw materials Grid Power Quality

Financial Longer shutdown time for major modifications Long pay back period for implementation of certain initiatives, if

only energy efficiency benefits are taken into account. Uncertainty price of CER & ECert (PAT)

Higher investment and operating costs for oxygen enrichment

Electrical/Thermal efficiency

Co-Processing of AFR

Clinker Substitution

Waste Heat Recovery systems



2012 2015 2020 2025 2030 2035 2040 2045 2050

Alternative fuel and raw materials

Implement appropriate policies and practices to facilitate increased use of AFR, and address public and market barriers for co-processing of AFR

Identify and classify suitable materials for AFR use

Further analysis to identify the right feed point for any specific AFR material and enforce quality control systems for AFR materials used

Disseminate information on existing AFR best practices and R&D already undertaken, including identification and mitigation of risks

Thermal and electrical energy efficiency

Ensure financial support and incentives are in place to enable major retrofits in older cement plants. Eliminate energy subsidies that can act as barriers to implementation Sustain funding to move from pilot to demonstration for fuel cell technologies, futuristic communition technologies and new types of low-carbon cement Gather reliable industry-level energy and emissions data to track performance, identify benchmarks and set targets

Clinker substitution

Develop standards and implement regulation for the clinker substitutes, composite cement and Portland Limestone cement

Update and revise standards to account for new blending sources

Continuous R&D to allow increased availability, and ensure quality of blending materials and clinker substitutesConduct R&D to allow increased availability of dump ash/pond ash, activation of granulated slag, and to prove viability of blending materials from non-ferrous industries and mineral processing industries

Waste heat recovery (WHR)

Further R&D to support the maximization of power generation from WHR systems R&D to decrease investment costs and promote the use of appropriate technology

Ensure attractive financial incentives to enable widespread implementation of WHR

Carbon use and CCS

R&D to support the use of CO2 for algal growth at cement plants Commercialisation of CO2 use for algae growthOversee a near-term approach to facilitate development and finance for demonstration of carbon capture and storage technologies

Participate in the demonstration of a full-scale post-combustion cement plant and development of a pilot oxy-fuelled cement plant

Participate in the demonstration of a full-scale oxy-fuelled cement plant Continue to accelerate commercial deployment of CCS


Cumulative investment needs in the Indian cement industry, 2010-50


Key findings

Industry achieved CO2 emission levels of 719 kg in 2010 from 1120 Kg in 1996

In absence of appropriate technological/ policy measures, CO2 emissions are projected to reach 488 Mt CO2 (LD) and 835 Mt CO2 (HD).

Technologies, policy framework and investment needs outlined in roadmap could limit the CO2 emission to 275 Mt CO2 (LD) and 468 Mt CO2 (HD)

Achieving Milestones would enhance energy security by saving 377 PJ to 485 PJ energy by 2050

Additional investment needed to reach target emission envisioned in the roadmap is between USD 29 and USD 50 billion


Roadmap Process-Learning

A workshop (1-2 days) for core roadmap team to understand IEA model structure, model inputs, and sensitivity of inputs. This will help in necessary checks, precautions during data collection/inputs to

model/Technology paper development

Active participation of National Industry Association to be ensured early in the process. This will help in moderating inputs/outcomes with wider perspective and outlook Accommodating non-CSI members, views, data

Global roadmap & Technology papers to be used as a guidance documents This helps in getting necessary inputs, verify accuracy and useful comparison

Identify National/International domain experts at early stage for their views/comments on draft Technical papers. This will expedite the activities of Technology paper development


Roadmap Process- Learning

Frequent exchanges with Global CSI/ECRA, for their views on draft documents and Inputs in areas where Country does not have domain expertise

Periodic review of Roadmap outputs by committee of CEOs for any mid course corrections

Rigorous/Persistent stakeholders dialogue with key organizations/ people jointly or individually for their Inputs on way forward to meet the objectives; participation of core team members in one-to-one dialogue with key persons is recommended.

Active involvement of Local/National policy makers and financial Institutions to be ensured at an early stage of Roadmap preparation. This will enhance acceptability/credibility of roadmap and better buying in and overcoming

barriers in Implementation and Financial constraints


Way Forward…

26

Three Pilot plants identified for feasibility assessment of implementing technical papers

Evaluate anticipated benefits, overall GHG emission reduction opportunities.

Develop an action plan for pilot plant based on GHG emission reduction opportunity and investment


For further details please contact

CSI: Roland Hunziker: [email protected]

or

IEA: Nathalie Trudeau: [email protected]

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Technology Roadmap: Low-Carbon Technology for the Indian Cement Industry Mr. L Rajasekar

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