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Provides a link between the Industry and Govt.
and also serves the cement industry and its
consumers.

Plays a pivotal role in formulation of
Government policies for cement industry
through continuous dialogues and
interactions.

Apprises industry of latest Technological
Developments and Cutting Edge Technologies.

Educates on rational use of cement including
choice of the right type of Cements for various
applications.

Creates awareness on the industry’s efforts
on Quality Assurance, Environmental
improvements, Consumer protection and
other related issues.

CMA is also a Communication partner with
Cement Sustainability Initiative (CSI) under
World Business Council for Sustainable
Development (WBCSD).

2
 40,000 Times
capacity
growth , from
0.01 to nearly
about 400
million tons
PA now
Significant
contribution to 2nd Largest in
Government the world,
Revenues after China
and Society

100 +
years

World Class
Global Quality
Production
and Green
Facilities &
Products
Technology

Best Practices
in Energy
Efficiency

Industry’s Initiatives and Achievements acknowledged and

3
appreciated world over - although, a lot still remains to be done
 Source: IMF World Economic Outlook 2013, April 2013

2nd largest cement producer, next to China, producing 7% of the global cement
production.

Indian cement plants are comparable with the best in the world in respect of
production facilities, technology, energy efficiency

Indian Cement Industry is internationally recognized as one of the most energy-
efficient and environmentally friendly industry.

9

Source: IMF World Economic Outlook 2013, April 2013

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Major thrust being given by Govt. of India for

Infrastructure Development

6

Aturning point in the life of
cement industry - ‘Partial
Decontrol’ was introduced IN
1982, which culminated to
Decontrol in 1989.

CementScenario changed
to “Buyers Market”.
Consumer is King.

Drastically
compressed time
for adding additional 100 Mt.
cement capacity mark to 11
and 3 years respectively
(Note: Production & Capacity figures are Estimated)
from 83 years taken for the
First.
Of late, subdued cement demand has significantly affected working of the
cement industry – A major cause of concern.

7
 Year


1950-60 1970 1980 1990 Post 2010

Kiln Capacity
300 - 600 600 – 1200 2400 – 3000 3300 – 6000 4500 – 12000
(Tonnes/Day)

Heat Consumption
(Kwh/Tonne 1300 - 1600 900 – 1000 800 – 900 650 – 750 650 – 750
Clinker)

P o w e r
Consumption
115 - 130 110 - 125 105 - 115 95 - 106 70 - 90
(Kwh/Tonne
Cement)


Proactive Cement Industry constantly improves Energy Consumption.


Some plants have become global benchmarks in energy consumption, next
to Japan.

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63.)64.

Source : CII Publication - Status paper on AFR Usage in Indian Cement Industry , May 2015

>

INDIAN CEMENT INDUSTRY :

Strives significantly for maintaining Ecological
balance being disturbed through Global
Warming. In first cycle of Perform, Achieve
and Trade (PAT) Scheme of BEE, ending in
2015 Energy consumption is likely to be
reduced further by 4.8%.

Continues to Take notable initiatives and
measures for Clean Development Mechanism
through increased clinker substitution and
Alternate Fuels and Raw Materials (AFRs) use
and Waste Heat Recovery (WHR) though Co-
generation.

Adopts Latest Technologies to keep it globally
competitive - Environment, Production Cost,
etc. Protection of Environment in and around cement
plants.

Still has Scope for Further Improvement with Government Support

10

Under BEE’s PAT Scheme, Plants with > 30,000 MTOE
of Annual Energy Consumption covered in the First
Cycle (2012-15).

85Cement Plants were identified as Designated
Consumers (DCs), to achieve the Energy Reduction
Targets within a period of 3 years.

Overall Target for all 85 DCs is 4.8% Energy Reduction
w.r.t. the Base Level.

FirstCycle (2012-15) period already completed on 31
March 2015. Plants made making all out efforts to
ensure smooth implementation. Measurement and
verification under process.

Scheme provides opportunity to earn Escerts, which
can be traded.

11

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INDIAN CEMENT INDUSTRY -

Consumes around 39% of Fly Ash generated from Thermal Power Plants.

Consumes almost 100% Slag generated by Steel Plants.

PBFS; Others; PBFS; Others;

6.86 0.33 6.98 0.35 OPC;
OPC;
32.15
31.66

PPC; PPC;
61.16 


 

60.52
2013-14*





 
 
2010-11

PBFS; Others; Others;

PBFS;
11.05 0.75 0.51
10.4
PPC;
19.41

PPC;
26.18 OPC; OPC;
62.02 69.68
2000-01 1990-91

15
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Consumes the entire quantity of granulated BF Slag
generated – more than 10 Mt. annually.

Increased use of Blended Cements (PPC & PSC) over the
years.

From 18% of Total Production in 1989 to 70% in 2011-12

Consumes 90% fluoro and phospho-gypsum waste from
fertilizer industry exceeding 3.5 Mt.

Uses waste materials as fuel including those from other
industry – e.g., Pet Coke, Rice Husk, Bagasse, Cut Tyres and
MSW.

17
 Alternate Fuels and Raw Material Availability in 2014 (Mt./year)
Surplus Biomass 150.00 Industrial Plastic Waste 0.20

Municipal Solid Wastes 75.00 Fly ash 200

Used Tyres 0.83 Blast Furnace Slag 10.00

Hazardous waste 0.65 Total 436.68

Source : CPCB, Holtec & India Infrastructure Research


These wastes pose threat to

environment as adequate
infrastructure to properly
deal with them, in an
ecologically sustaining
manner, is missing.

Co-processing of these wastes in cement kiln as
alternative fuel and raw materials can mitigate the
waste management issues to a large extent.

AFR use offers a high potential of reducing coal
consumption, and consequent reduction in equivalent
carbon dioxide emissions.

By adopting best available Technologies and Environmental practices in
cement plants viz. Waste Heat Recovery Power Projects and Uses of
Alternate Fuels - Pet coke, Lignite, Husk, Municipal Wastes, Biomass, etc.

CO2 emission level reduced from 1.12 per tonne cement produced in
1996 to 0.719 per tonne CO2 emission in 2010.

Is on the top in Certified Emission Reductions Projects registered with the
Clean Development Mechanism (CDM) of Kyoto Protocol.

Indian roadmap now outlines a low-carbon growth pathway for the Indian
cement industry that could lead to further carbon intensity reductions.

These reductions could result
from increased clinker
substitution and alternative fuel
usage; futher Improvements to
energy efficiency, and
development and widespread
implementation of newer
technologies.

19

To meet the targets set


Increase Thermal Substitution Rate (TSR %)


To Further Reduce Clinker Factor


Further increase in Blended Cements


Increasing Co-generation through Waste Heat Recovery (WHR)


Increasing Use of Renewable Energy

75

LIKELY CEMENT DEMAND IN 2024 AT 10% GROWTH TO MEET GOVT’S
FUTURE PLANS AND INPUTS REQUIREMENTS

(Mt.)
Particular 2014-15 2023-24 (est.)
Cement Production 270.00 665.00

Cement Cap. 360.00 750.00

(at 90% utilization)

156.00
Coal for Kilns and CPP 60.00
(at 23.5% requirement)

Limestone (1.5 times of production) 380.00 998.00

Gypsum ( 5% of production) 12.00 33.00
Power (MW)
(worked on 20 mw requirement for one MT 5100 13300
production)

21
 Country % TSR Country % TSR
by AFR by AFR
Netherlands 83 Germany 42
Switzerland 48 Sweden 29
Austria 46 Japan 10
Norway 35 United states 25
France 34 India Less than 1
Source: CEMBUREAU

•
Increasing industrialization and urbanization would generate alarmingly industrial and

agricultural wastes and fly ash.
•
A commercial and viable usage of wastes would supplement energy requirements of
Cement Industry. This would enhance significantly TSR in Cement Industry.

Need of the Hour - To encourage AFR

22
Type of waste Quantity Quantity
Mt. Mt.
Municipal waste 58. 4
Hazardous waste A+B+C 6.72
A recyclable 3.37
B Land fillable 2.82
C Incenerable 0.49
Total 65.12

23
 
Plastic consumption in India is
about 8 MTPY, out of which, 70%
i.e. 5.6 MTPY transforms to waste.
Sixty per cent of this waste is
recycled and rest forty per cent
is littered around.

Indiscriminate dumping of plastic waste 
IndustrialPlastic Waste can be

advantageously utilized by the
Cement Industry.
Potential Benefits

Co-processing plastic waste effectively destroys non-bio-
degradable materials without any additional environmental issue.

Plastic Waste Co-processing in Cement plants to be encouraged

24
•
Use of Hazardous Waste (HW) in
Cement Kilns an economical
option compared to destruction
in incinerators.

•
About 0.65 MTPY of incinerable

HW is available in India. Out of
this more than 50% can be co-
processed in Cement Kilns.

•
Use of HW will reduce the need

of Capital Investment for setting A Section of Municipal Solid Waste Plant of an Indian Manufacturers

up Incinerators.
•  Co-processing in cement industry, which is higher in the waste
management hierarchy - above land fill and incineration - needs to be
included in the policy framework through amendment of the Hazardous
Waste Management Rule, 2008 under Environment Protection Act, 1986.

25
Used tyres can be effectively
fired either at cement kiln inlet
or in pre-calciner.

Potential Benefits

Co-processing of tyres is environmentally safe and sustainable.

It has GHG mitigation potential apart from saving of coal.

26

Burning biomass in the fields
causes high local pollution and
using it in small boilers and
furnaces generates fly ash and
bottom ash which is usually y
dumped in open, causing local
environment nuisance.


Biomass can be efficiently utilized in cement kilns, as they have a

much better thermal efficiency without leaving any ash residue or
gaseous emissions.

Surplus Biomass is about 150 MTPY (2014), which could replace a large
amount of fossil fuel and mitigate CO2 emissions.

27

Municipal, Industrial and Agricultural
wastes are reported to be over 435 Mn.T.
at present and are going to scale up
substantially in the near future.

Cement Industry can effectively utilize
these wastes as fuel.
Potential Benefits
Rag picker at a waste dump site in Delhi


Greatly reduces local Waste

Management Problems and saves on
land area and other costs required for
MSW sanitary landfills.


Reduces Green House Gas emission from land fills (methane avoidance).

Replaces considerable quantity of coal usage in cement industry.

28
 INDIAN CEMENT INDUSTRY’S MISSION : 2020
ENHANCING TSR WITH THE INCREASED USAGE OF AFR


In August 2012, CMA signed Consulting Agreement with Institute of Industrial

Productivity (IIP), Washington DC.

The First Phase of the Project identified the five most promising alternate fuels for
co-processing in cement kilns and the two most promising blending materials. An
Implementable Action Plan was chalked out to increase the TSR with the increased
usage of AFR in the cement industry from less than 1% to 15% by 2020. Action Plan
discussed at the First International Conference organised by CMA and IIP in August
2013.

Second phase of the Project came out with a set of 5 White Papers/Guidelines to
address some major regulatory barriers. These were deliberated at the Second
International Conference on “Enhanced Usage of Alternate Fuels & Raw Materials
(AFR) in Cement Industry“ organised in February 2015.

Recommendations to help enhancing the use of AFR, cutting across the Regulatory
Financial and other Bottlenecks coming in the way submitted to the Government.

Technical, Policy and Regulatory and Financial barriers to be removed to encourage

increased usage of AFR, including free movement of all types of wastes.

29