waste mapping and forecasting for alternate fuel usage … mr v kannan cii... · waste mapping and...
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© Confederation of Indian Industry
Promoting Alternate Fuel and Raw material (AFR) utilisation in Indian Cement Industry
Waste Mapping and Forecasting for
Alternate Fuel Usage in Cement Plants
Confederation of Indian IndustryCII – Godrej Green Business Centre, Hyderabad
23rd March 2017, New Delhi
© Confederation of Indian Industry
Confederation of Indian Industry (CII)
Non-government, not-for-profit, industry led & industry managed apex industry association
Founded over 120 years ago
Direct membership : 8000 organizations
Indirect membership : 200,000 enterprises
Wide network
66 offices in India, 9 overseas offices, 9 centres of excellence
Institutional partnerships with 320 counterpart organizations in 106 countries
Serves as reference point for Indian industry and international business community
© Confederation of Indian Industry
CII- Sohrabji Godrej Green Business Centre Hyderabad
A unique Public – Private Partnership (CII, Govt of Andhra Pradesh, USAID and Pirojsha Godrej Foundation)
“Centre of Excellence” for Energy, Environment, Green Buildings, Renewable energy & Climate change activities in India
© Confederation of Indian Industry
Waste management in India is of paramount importance with increasing industrialization & rapid urbanization
MSW annual generation estimated to be 140 Million Tons by 2025
15, 000 tonnes of plastic waste is generated every day
7.8 Million Tons of Hazardous waste generated annually
INDC : Intended Nationally Determined Contribution
Reduce the Emissions Intensity of its GDP by 33 to 35 Per Cent by 2030 from 2005 Level
Project Background - Waste Management
© Confederation of Indian Industry
Project Background – Indian Cement Industry
Indian Cement Industry emitted 137 Mt of CO2, 7% of India’s total man made emissions
Low Carbon technology Roadmap identified AFR usage in Cement industry as one of the key levers to reduce the GHG emissions
Cement demand in India is projected to reach 500-650 MTPA by 2025 which in turn create demand for raw materials and fuels
Currently Indian Cement Industry’s average Thermal substitution rate (TSR) is around 4%, whereas the TSR in few countries are as high as 70% (Austria, Germany)
© Confederation of Indian Industry
Project Objective
Co-processing in Cement industry finds a synergy between the two and provide a sustainable solution for waste management in the country & reduces overall GHG emissions
Main objective of the project is to facilitate use of urban & industrial waste as Alternate Fuel & Raw Material (AFR) in Indian cement industry
CII in association with Cement Manufacturers’ Association (CMA) is working on this initiative
Supported by Shakti Sustainable energy foundation (SSEF)
© Confederation of Indian Industry
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Expert group
Name Designation Organisation
Mr Ulhas parlikar
Chairman – CII Intiative on increasing
AFR usage in Indian Cement industry Geocycle India
Mr A Ramchand Chief Environmental Engineer Andhra Pradesh Pollution Control Board
Mr R P Tiwari, Superintendent Engineer Chhattisgarh Pollution Control Board
Mr P K Gupta Scientist E Central Pollution Control Board
Mr V R Ghadge Senior Environmental Engineer Gujarat Pollution Control Board
Mr Venkatesh Shekar Senior Environmental Officer Karnataka State Pollution Board
Mr P S Bundela Regional Officer, Bhopal Madhya Pradesh Pollution Control Board
Mr V M Motghare Joint Director – Air Pollution Control Maharashtra Pollution Control Board
Dr Vijai kumar Singhal Chief Environmental Engineer Rajasthan Pollution Control Board
Mr S Selvan Joint Chief Environmental Engineer Tamil Nadu Pollution Control Board
© Confederation of Indian Industry
Activities carried out
Policy Advocacy Developing draft
recommendations for inclusion of Co-processing in HWM rules
Frequent meetings & discussions with various Government bodies (MoEFCC, CPCB & SPCBs)
Stake holders meetings, Expert group meetings & Industry consultation
Various submissions to MoEFCC & CPCB on promoting co-processing
Technical Research & Analysis Life Cycle approach for
AFR utilization in Cement industry
Status paper on AFR usage in Indian Cement industry
Waste forecasting for Indian Cement Industry
Variation in chemical constituents of waste streams
Capacity Building activities National & International
missions
Inventory of waste generation
Inventory of Co-processing cement plants
Technical Publications
Website on Co-processing
© Confederation of Indian Industry
© Confederation of Indian Industry
Publications & Website on Co-processing - www.ciiwasteexchange.org
© Confederation of Indian Industry
Key milestones
AFR substitution increased from less than 1 % in 2010 to more than 4% in 2016
Recognition for Co-processing in the policy framework
> 45 Cement plants started co-processing in their production units
Few state pollution control boards like Gujarat and Tamil Nadu, developed specific action plan & implementation schedule to promote co-processing
>12 cement plants set up pre-processing facilities to convert non-homogeneous waste in to AFRs
LCA (Life Cycle approach) considered as a part of manufacturing process & extended producer responsibility
© Confederation of Indian Industry
Approach Paper for achieving 25% TSR by 2025 in Indian Cement Industry
To achieve 25% TSR at 2025 : Indian Cement industry requires 7.07 million TOE of energy from Alternate fuels
Parameters Existing Anticipated Units
Year 2010 2025
Cement prodution 217 600Million TPA
Cement to clinker ratio 1.35 1.49
Specific energy consumption 725 703Kcal/ kg of clinker
Total Thermal Energy Required 11.64 28.26million TOE
Quantity of coal required @ 5500 kcal/kg 21.17 51.38
Million TPA
Energy From Alternate fuel estimated @25% of total energy 7.07
million TOE
© Confederation of Indian Industry
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Municipal Solid Waste (MSW)
MSW generation estimated to be 140 Million Tons by 2025
By effective management of MSW 22 types of diseases can be prevented/ controlled
>80% of the waste is sent to dump yards
Swachh Bharat Mission (SBM)
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Bio mass
Domestic & widely available
32% of total primary energy derived from biomass
Used extensively in power generation
As per MNRE 120 million Tonnes/ annum of biomass available as surplus
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Spent pot liner (SPL)
Waste from Aluminium industry
Hazardous in nature & subject to close regulatory control
Reactive with water
Co-processing in cement kiln can support SPL disposal in environmentally sustainable way
© Confederation of Indian Industry
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Tyre waste
0.83 million tons of used tyres generated annually
AF with high heat content
Better managed in Cement kiln
Many countries successfully utilising tyre waste in cement kiln
© Confederation of Indian Industry
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Hazardous waste(HW)
0.6 million tons of incinerable hazardous waste generated annually
41,523 HW generating units in India
HW disposed through TSDF
New HWM 2016 considers co-processing as a preferred option
© Confederation of Indian Industry
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Summary of energy from Alternate fuels
0.20 0.87 1.83
8.49
14.27
25.66
0.00
5.00
10.00
15.00
20.00
25.00
30.00
Energy from different fuels (TSR % )
57%
0.8%
33%
3%7%
MSW
Spent PotLinerBio mass
HazardouswasteWaste tyres
© Confederation of Indian Industry
51.38
123
49.638.53
92
39.68
COAL CONSUMTON (MILLION TPA)
CARBON EMISSIONS FROM FUEL (MILLIONS
TONS OF CARBON DIOXIDE)
LANDFILLING AREA FOR MSW
(1000XHECTARES)
BAU(Business as usual) 25% TSR
25% TSR @ 2025 – Anticipated benefits
Coal consumption reduces by 25%
Land filling area requirement in the country will reduce by 20%
GHG emissions from fuel reduces by 25%
Reduce imports & increase economic activity of the country
© Confederation of Indian Industry
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RDF from MSW - Potential alternate fuel for Cement plants
RDF Generated from MSW has a high potential to substituteconventional fuels in cement plants RDF will have a better calorific value
Homogeneous physical & chemical properties
Reduces Environmental & health impacts
Further growth potential
Scientific & Sustainable solution with no residual left over
Developing Municipal solid waste mapping for selected Municipalities in
different states
© Confederation of Indian Industry
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MSW Mapping – Cluster based approach
State Urban Local Bodies RemarksChhattisgarh Raipur, Bilaspur, Korba, Raigarh
States are chosen based on Cement Industrypresence
ULBs based on vicinity to cement plants
Gujarat Rajkot, Jamnagar, Ahmadabad
KarnatakaGulbarga, Bagalkot, Bellary, Koppal, Bangalore
Madhya Pradesh Satna, Ratlam, Jabalpur
RajasthanJaipur, Kota, Udaipur, Ajmer, Bhilwara
Tamil Nadu
Thanjavur, Tiruchirappalli, Coimbatore, Perambalur, Ariyalur, Madurai
Telangana & AP
Hyderabad, Warangal, Vijayawada, Kadapa, Kurnool, Guntur
© Confederation of Indian Industry
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MSW mapping in Selected Municipalities
This mapping will further elaborate on various parameters like Current inventory & MSW management practices
Area & Population
Growth potential
Location of cement plants with capacity
Developing different models of MSW management in Clusters
PPP Model
Common Pre - processing facility model
Business Model
Capacity Building requirements
© Confederation of Indian Industry
Waste mapping model – Tamil Nadu
CityPopulation of
2011 (Nos)
MSW
generated TPA
in 2011No of Cement plants in
Vicinity
Thanjavur 2,22,943 43,800
8
Tiruchirappalli 8,47,387 2,27,679
Coimbatore 10,50,721 2,94,202
Ariyalur 28,902 4,928
Madurai 10,17,865 2,37,250
Perambalur 49,000 8,760
Total 8,16, 619
© Confederation of Indian Industry
Estimated Thermal substitution from MSW of 6 cities in 1.5 MTPA Clinker unit
MSW generated from 6 cities 0.817 Million TPA
8 Cement plants are in nearby clusters
In a 1.5 Million TPA clinker unit - RDF generated from this MSW can substitute
31.9% of fuel on TSR basis
60,000 Tonnes of Coal can be substituted annually
MSW growth potential :25% by 2031
Corresponding TSR substitution can be as high as 40%
© Confederation of Indian Industry
Estimated Thermal substitution from MSW of 6 cities in 1.5 MTPA Clinker unit
Parameter Values Unit
Total MSW generated from 6 cities 0.81 Million TPA
MSW for RDF generation 0.57 Million TPA
RDF generation 0.11 Million TPA
Energy from RDF 0.034 Million TOE
Generated RDF used as Alternate fuel in 1.5 Million TPA clinker unit
Clinker production 1.50 MTPA
Thermal Energy required 0.107 Million TOE
Estimated % Energy from RDF of 6 Municipalities as TSR
% in 1.5 MTPA cement plant31.9 %
© Confederation of Indian Industry
Estimated growth potential of MSW & TSR Substitution in 1.5 MTPA clinker unit
0.8170.915
1.024
2011 2021 2031
MSW
ge
ne
rati
on
year
Estimated Quantity of MSW generated (MTPA) in six ULBs
31
3640
2011 2021 2031TS
R %
year
Estimated TSR % in 1.5 MTPA Clinker production
© Confederation of Indian Industry
MSW Cluster mapping study
Develop cluster level engagement with stake holders on improving co-processing initiatives
To understand opportunities & barriers
To understand current inventory & growth potential
Estimate RDF generation Potential from MSW
Estimate substitution possibilities in cement plants
© Confederation of Indian Industry
Way Forward
Facilitate Cement Industry to achieve TSR levels of 25% by 2025 with focus on MSW as fuel
Awareness creation on New Waste Management Rules & Guidelines
Regional level workshops
Sharing of best practices
Publications
© Confederation of Indian Industry
Way Forward
Working with different stake holders like Cement Industry, Municipalities, Government bodies (CPCB, MoEFCC, MoUD, DIPP, NEERI etc), Technology providers towards
Large scale management of MSW through Co-processing
Roadmap for MSW management through cement kiln co-processing
Cluster level engagements
Capacity building activities & Developing Business models
© Confederation of Indian Industry
Way Forward
Co-processing in cement plants : Pillar to support India’s journey towards Low Carbon economy Swachh Bharat Mission
INDC
CII will work closely with industry & other stake holders in promoting AFR Utilization & further accelerate the TSR levels
© Confederation of Indian Industry
Thank you
V KannanCounsellorConfederation of Indian IndustryCII - Godrej Green Business Centre, IndiaDir: +91 40 4418 5213E-mail: [email protected] / www.cii.in