Displaying items by tag: Waste Heat Recovery

India: UltraTech Cement aims to increase contribution of so-called ‘green energy’ to 25% of its total power consumption by 2021 from 10% at present. It also intends to raise its contribution of renewable energy to its total power consumption by five times in the next two years to 2021 to over 10%. By building capacity for renewable power the cement producer intends to become one of the largest users of renewable energy in the Indian cement sector.

In addition to renewable energy, the green energy contribution includes energy generated through waste heat recovery systems (WHR). During its 2019 financial year UltraTech commissioned 28MW of WHR systems to take its total generation from WHR to 8% of total power consumption. Further upgrades are expected to be completed in a phased manner by 2021, taking its WHR share to 15% of its total power requirement.

“To bring the cement sector in line with the Paris Agreement on climate change, UltraTech Cement’s annual emissions will need to fall by at least 16% by 2030. There are a number of solutions for reducing emissions associated with cement production as identified by the latest Low Carbon Technology Roadmap published by International Energy Agency (IEA) in partnership with Cement Sustainability Initiative (CSI). These solutions need to be deployed at scale to meet the decarbonisation challenge,” said K K Maheshwari, the managing director of UltraTech Cement.

UltraTech Cement has set a target to reduce its CO₂ emissions by 25% from its 2005 – 2006 level by 2021. The company is also working on CO₂ reduction strategies including energy efficiency, alternative fuels, WHR, renewable energy and reducing its clinker ratio.

India: UltraTech Cement’s net sales rose by 20% year-on-year to US$5.24bn in its 2019 financial year from US$4.35bn in the 2018 reporting period. Its profit after tax grew by 10% to US$347m from US$317m. Its power and fuel costs increased by 33% to US$1.20bn from US$903m.

The cement producer said that production stabilised at its integrated plant in Manavar, Madhya Pradesh, reaching a clinker production capacity utilisation rate of 100% in the quarter that ended on 31 March 2019. It worked on the plants of its UltraTech Nathdwara Cement subsidiary to reach a production utilisation rate of 72% in March 2019. Both plants were acquired from Binani Cement in late 2018.

The plants it acquired from Jaypee Associates in 2017 are running at a capacity utilisation rate of 82%. A planned shutdown was undertaken at its Bela plant in Madhya Pradesh plant for cost improvements. The company intends to install waste heat recovery (WHR) units at these plants. Work on the 4Mt/yr Bara grinding unit is on track and the first phase of the expansion is expected to be commissioned during the first quarter of its 2020 financial year.

India: Birla Corporation’s earnings before interest, taxation, depreciation and amortisation (EBITDA) rose due to increased sales of blended cement in the last quarter of 2018. Blended cements represented 89% of its total sales volumes compared to 85% in the same period in 2017.

The company’s net sales grew by 14.6% to US$653m in the nine months to the end of 2018 from US$569m in the same period in 2017. Its EBITDA rose by 17.1% to US$96.8m from US$82.7m. Its cement production increased by 10.5% to 9.86Mt from 8.92Mt and its cement sales increased by 9.9% to 9.79Mt from 8.92Mt. It said that better sales in key markets had offset raw material price rises such as petcoke, coal and diesel. It noted that the price of diesel had risen by over 20% in the reporting period although it had started to soften in the most recent quarter.

The cement producer held a ground breaking ceremony in late January 2019 for a new plant being built by its RCCPL subsidiary at Yavatmai district in Maharashtra. The 3.9Mt/yr unit has an investment of US$342m and it includes a 40MW captive power plant and a 10.6MW waste heat recovery (WHR) system. Commissioning is scheduled for the 2021 – 2022 financial year. The company is also planning to upgrade RCCPL’s plant at Kundanganj with 1.2Mt/yr of additional production capacity. Other new projects include a 12.25MW WHR system at Maihar that is expected to be commissioned in mid-2019. It is building solar power plants at Maihar, Chanderia and Satna with 11MW, 3.6MW and 1.2MW capacity respectively. Birla Corporation also said that restrictions on using explosives placed on limestone mining at Chanderia in Rajasthan had increased its costs.

Kenya: Devki Group has ordered a waste heat recovery (WHR) unit from China’s Sinoma Energy for its Athi River plant as part of a US$250m package. The deal also includes supplying a power plant for the company’s steel plant in Kilifi, according to the Daily Nation newspaper. Both projects will be completed by late 2020.

India: Chandrababu Naidu, the chief minister of Andhra Pradesh, has laid the foundation stone for Ramco Cements’ new 3.15Mt/yr integrated plant at Kalavatala, Kolimigundla Mandal in Kurnool District. The project has an investment of nearly US$210m. The plant will include a waste heat recovery (WHR) unit and a captive power plant. A 25km railway line from Samjamala has also been proposed to support the plant. Once the required statuary clearances are obtained the plant is expected to take 15 months to build.

Other new projects the cement producer has scheduled include an upgrade at its Jayanthipuram plant in Krishna District to 4.6Mt/yr from 3.1Mt/yr with a 27MW WHR unit. The project has a cost of just over US$100m and it is expected to be commissioned in March 2020. The company is also upgrading the grinding capacity of its Vizag plant to 2Mt/yr from 0.9Mt/yr. This project has an investment of around US$25m and is also expected to be commissioned in March 2020. Once these three projects are completed Ramco Cements says that it will become the largest producer in Andhra Pradesh with a production capacity of nearly 10Mt/yr.

In the east of the country Ramco Cements us building a new 0.9Mt/yr grinding plant in Odisha with a railway terminal for around US$70. This is expected to be commissioned by September 2019. In West Bengal the company is upgrading the grinding capacity at its Kolaghat plant in East Midnapore district to 2Mt/yr from 0.9Mt/yr for around US$60m. This project also includes a railway terminal and it is scheduled for commissioning in April 2019. Altogether the company plans to reach a cement production capacity of 20Mt/yr by 2020 across the country.

India: The board of Ambuja Cements has approved an extension to its Marwar Mundwa integrated plant project in Rajasthan. The clinker production capacity of the plant has been increased to 3.1Mt/yr and an additional 1.8Mt/yr cement grinding capacity has been added. The total investment of the project has been increased to around US$326m. A waste heat recovery (WHR) unit has also been added to the project. Once completed the plant will increase the subsidiary of LafargeHolcim’s production capacity of 31.5Mt/yr.

Pakistan: Bestway Cement has promoted its environmental credentials following the Supreme Court’s mandated investigation into water usage by cement companies near the Katas Raj Temples in 2018. The cement producer says that all of its cement plants are ISO 14001:2004 Environment Management Systems certified. Specifically on the issue of water conservation, it has installed air-cooled condenser systems at two of its plants at Chakwal and Kallar Kahar respectively and it has built rain-harvesting ponds. In total the company has spent around US$14m on water conservation measures. Altogether it says that it has achieved 80% and 88% reductions in consumption of ground water for industrial use, respectively, at the two plants.

Other environmental measures the company has made include installing waste heat recovery (WHR) units at all four of its cement plants. Its total WHR capacity is 45.5MW giving it 28% of its total power needs. The company is recognised by the United Nations Framework Convention on Climate Change (UNFCCC) under its Clean Development Mechanism (CDM) Program for its initiative to reduce carbon emissions/footprint. It has also implemented tree plantation at its plants and surrounding areas, it uses drip irrigation and sewerage waste management and its head office in Islamabad has been certified as a Green Office by the World Wide Fund for Nature (WWF).

Oman: Raysut Cement Company has ordered a waste heat recovery unit from China’s Sinoma. No cost for the deal or an expected timescale has been disclosed. The company says it is the first of its kind in the country. Once completed it is expected to reduce the company’s power costs at its plant by up to 30%.

India: A report by the Cement Sustainability Initiative (CSI) shows that the local cement sector is on track to meet its 2030 targets from the low carbon technology roadmap (LCTR). Direct CO₂ emission intensity fell by 5% in 2017 in the Indian cement sector compared to the 2010 baseline. CO₂ emission intensity, including onsite or captive power plant (CPP) power generation, was reduced by 6.8% compared to the 2010 baseline. The alternative fuels thermal substitution rate (TSR) increased by 5 times from 2010 to 2017. The sector consumed more than 1.2Mt of alternative fuels in 2017.

“Sustainability is a journey, not a destination. In our globalised and interconnected world, no one can solve alone the challenges ahead of us and the only opportunity to succeed is through collaborative partnerships, where the common interests of all are considered as more important than the sum of individual interests. This is exactly the spirit that has animated the CSI’s low carbon journey since 1999. This flagship project - with its members - has developed, implemented and shared collective solutions for measuring, reporting and improving its greenhouse gas reduction performance, year after year,” said Philippe Fonta, managing director CSI.

The CSI and the International Energy Agency (IEA) worked with nine local CSI member companies - ACC, Ambuja Cements, CRH, Dalmia Cement (Bharat), HeidelbergCement, Orient Cement, Shree Cement, UltraTech and Votorantim Cimentos - to carry out the status review on the sector’s performance trends, continuous implementation measures and notable achievements based on the milestones set in the 2013 LCTR. The Status Review Report was developed in consultation with Confederation of Indian Industry (CII), with support from International Finance Corporation (IFC) and the Cement Manufacturers Association (CMA).

The findings of the report show that the direct CO₂ emission intensity was reduced by 32kgCO₂/t cement to 588kgCO₂/t cement in 2017 mainly due to an increased use of alternative fuel and blended cement production, coupled with a reduction in clinker replacement factor. However, the study also shows that significant efforts will be needed to meet the 2050 objectives of 40% reduction. The CO₂ emission intensity (including onsite or CPP power generation) has reduced by 49kgCO₂/t cement to 670kgCO₂/t cement in 2017 compared to the baseline year. The report has highlighted the adoption of waste heat recovery (WHR) systems by local cement plants.

The alternative fuels TSR increased to 3% in 2017 from 0.6% in 2010. More than 60 cement plants in India have reported continual usage of alternative fuels, with 24% of the total alternative fuels consumed as biomass. The share of blended cements used in the total quantity of cement manufactured increased to 73% in 2017 from 68% in 2010, largely due to the market’s growing acceptance of blended cement, emerging awareness of sustainability concepts, the availability of fly ash from thermal power plants and the use of advanced technology. The production of Pozzolana Portland Cement grew to 65% in 2017 from 61% in 2010. The share of Portland Slag Cement in cement production remained flat, at less than 10%, over the same period. The clinker factor reduced to 0.71 in 2017 from 0.74 in 2010.

In August 2018 the Global Cement and Concrete Association (GCCA) said it was taking over the work previously done by the CSI from 1 January 2019.

Pakistan: Thatta Cement has approved a waste heat recovery project with its associated company, Thatta Power, at its annual general meeting. The two subsidiaries of the State Cement Corporation of Pakistan have ratified a waste heat utilisation agreement. The cement producer operates a 0.6Mt/yr plant at Thatta near Karachi.