© 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
© OECD/IEA and WBCSD 2013
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
© OECD/IEA and WBCSD 2013
Partnering to develop a Low-Carbon Technology Roadmap for the Indian cement industry
© OECD/IEA and WBCSD 2013
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
© OECD/IEA and WBCSD 2013
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
© OECD/IEA and WBCSD 2013
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
© OECD/IEA and WBCSD 2013
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
© OECD/IEA and WBCSD 2013
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
© OECD/IEA and WBCSD 2013
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
© OECD/IEA and WBCSD 2013
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
© OECD/IEA and WBCSD 2013
Way Forward…
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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
© OECD/IEA and WBCSD 2013
For further details please contact
CSI: Roland Hunziker: [email protected]
or
IEA: Nathalie Trudeau: [email protected]