Cement Manufacturers Association

9 Power Generation from exhaust It’s necessary to dissociate economic growth associated with GHG emissions. Energy productivity is required as 50% of total energy consumed by industrial sector is wasted in the form of heat losses. In this context, Waste Heat Recovery (WHR) system installation has played a vital role in capturing waste heat utilization for power generation. In accordance with the Ministry of New and Renewable Energy (MNRE), the Indian Cement Industry sector has the highest potential to generate 1100 MW (2016 estimates) of clean energy through WHRS installation. This capability continues to grow proportionally with an increase in cement manufacturing capacity, bringing it close to 1.3 GW at current production capacity levels. WHRS with its full potential will help replace energy requirements equivalent to 8.6 MT of coal, resulting in emissions savings of 12.8 MT of CO 2 by the Indian Cement Industry. Alternate Raw Material for clinker production Focusing on usage of alternate raw materials for clinker production without compromising on parameters and quality. Selected waste and by- products containing useful minerals such as alumina, calcium, iron, and silica can be used as raw materials in kiln rather than using clay, limestone, and shale. Some extent of 3% slag can even be used in raw material replacing few traditional raw materials. One of the KHD plants in Novotroisk, Russia, replaced upto 30% of raw material for clinker production by copper slag which is byproduct from nearby industry. This iron corrective component (Martin Slag) material not only acts as alternate raw material but also produces heat and fulfills the heat requirement for the process. This has led to World Record of specific heat consumption of only 600 kCal/kg clinker (Fig 2). Figure 2 KHD Plant in Novotroisk, Russia Utilization Assessment of Alternate Fuels Presently, Utilization of alternate fuel in Indian Cement Industry is at low level. The country’s average stands at less than 6 % of thermal substitution rate (TSR) as compared to average TSR of about 40% in the European Cement Industry. The usage of alternate fuel can be enhanced through concerted effort of characterization, evaluating various types of Waste Figure 1 Calciner modifications by KHD for AFR usage Product Range of PYROCLON ® Claciner PYROCLON ® R LowNOx ILC with staged combustion PYROCLON ® R LowNOx ILC with staged combustion PYROCLON ® R In Line Calciner PYROCLON ® R with Combustion Chamber In Line Calciner First Genration: replaced by