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Role of AFR in Meeting PAT
Target and Reducing CO2 Emission
Presentation by :
K.K.CHAKARVARTI
BUREAU OF ENERGY EFFICIENCY
NEW DELHI
2nd International Conference on
ENHANCED USAGE OF ALTERNATE FUELS AND
RAW MATERIALS IN CEMENT INDUSTRY
20TH FEBRUARY, 2015
Perform Achieve and Trade
scheme
2
PAT Overview and Elements
The key goal of the PAT scheme under National
Mission for Energy Efficiency (NMEEE) is to
mandate specific energy efficiency improvements for
the most energy intensive industries
Covers 478 plants in 8 energy intensive industry (
Aluminium, Cement, Chlor-alkali, Fertilizer, Iron &
Steel, Paper & Pulp, Textile and Thermal Power
Stations), and gate to gate boundary concept
adopted.
Energy consumption of these plants was about
1/3rd of the total energy consumed in India in the
baseline year (2009-10).
3
PAT Overview and Elements
Key Goal :Mandate Specific Energy
Consumption improvement
Energy Intensity reduction target for each
unit based on its current efficiency in
base line (2009-10)
Multi- cycle process –First PAT cycle till
2014-15
Design based on extensive consultations
over 2010-12
4
Number of Designated Consumers (DCs) as notifiedunder Indian Energy Conservation Act and covered under
PAT Scheme
Industry Sector Annual Energy
Consumption Norm to
be DC (toe)
No. of Identified DCs
Aluminum 7500 10
Cement 30000 85
Chlor-Alkali 12000 22
Fertilizer 30000 29
Pulp & Paper 30000 31
Thermal Power 30000 144
Iron & Steel 30000 67
Textiles 3000 90
PAT - METHODOLOGY
Gate to Gate Concept
PROCESS
Electricity (KWH)
FO (Ltr)
NG (SCM)
Coal (KG)
Others (KG or Ltr)
Product (Kg)
All forms of Energy
E P
SEC = E / P
Plant Boundary
Baseline SEC
Target SEC
Reduction in SEC
Year 1 Year 2 Year 3
SE
C
As the SEC is calculated on a Gate-to-Gate concept, the definition of plant
boundary plays an important role.
National Target of Energy Saving among all Sectors
S.NO. SectorNo. of
Identified DCs
Annual Energy
Consumption (Million
toe)
Share Consumpti
on (%)
Apportioned Energy
Reduction For PAT Cycle-1
(Million toe)
1 Power (Thermal) 144 104.56 63.38% 3.211
2Iron & Steel 67 25.32 15.35% 1.486
3 Cement 85 15.01 9.10% 0.815
4Aluminium 10 7.71 4.67% 0.456
5 Fertilizer 29 8.20 4.97% 0.478
6Paper & Pulp 31 2.09 1.27% 0.119
7 Textile 90 1.20 0.73% 0.066
8Chlor- Alkali 22 0.88 0.53% 0.054
Total 478 164.97 100.00% 6.686
Total EE Projects planned in 2012-15: 2057
Total anticipated investment : US$ 3095 million
The direct benefit for the participating industries in this period is reductions
in input costs related to energy of approximately US$ 1250 million.
Sectoral Share in Energy Saving Target (%)
(2012-15)
Reduction in India's CO2
emissions by 24 million tons /
year in 2014-15.
8
CEMENT PLANTS(85 DCs)
PPC (55) OPC(16) PSC (7) White OPC(2)+
Grinding(2)+
Only clinker(1)
Based on Major Product
Wet Plant(2)
Grouping of DCs
National Target of Energy Saving among all Sectors
S.NO. SectorNo. of
Identified DCs
Annual Energy
Consumption (Million toe)
Share Consumption
(%)
Apportioned Energy
Reduction For PAT Cycle-1
(Million toe)
1Power
(Thermal) 144 104.56 63.38% 3.211
2 Iron & Steel 67 25.32 15.35% 1.486
3 Cement 85 15.01 9.10% 0.815
4 Aluminium 10 7.71 4.67% 0.456
5 Fertilizer 29 8.20 4.97% 0.478
6 Paper & Pulp 31 2.09 1.27% 0.119
7 Textile 90 1.20 0.73% 0.066
8 Chlor- Alkali 22 0.88 0.53% 0.054
Total 478 164.97 100.00% 6.686
DRAFT ENERGY CONSUMPTION RANGE IN INDIAN CEMENT PLANTS (85 DC’s) (2007-10)
Products/Process (No. of Plants)
Thermal Energy Consumption
(kcal/kg of clinker)
Electric Energy Consumption (kWh/Tonne
equivalent cement)
Normalized Energy Consumption gtg
(kcal/kg equivalent cement)
Total Energy Consumption of Sub-Sector
% Share of Sub- Sector
(Major Product)
Minimum Maximum Minimum Maximum Minimum Maximum (toe)
(%)
PPC (55 Plants)
658 1074.02 64.18 110.24 712.31 1227.1 10292843.975 68.57%
OPC (16 Plants)
727.33 1000.94 75.67 143.48 964.66 1368.43 3295349.387 21.95%
PSC (7 Plants)
701.02 1207.71 71.03 119.69 700.39 968.17 932008.497 6.21%
White Cement (2 Plants)
1093.72 1279.66 108.93 119.81 1452.23 1484.65 105566.281 0.70%
Wet Cement Plants (2 Plants)
1026.67 1415.07 79.75 113.86 1241.4 1244.56 152403.633 1.02%
Grinding Units (2 Plants)
38.78 40.38 138.73 201.05 88211.169 0.59%
Only Clinkerization (1 Plant)
869.33 87.47 1257.22 143790.367 0.96%
Total 15010173.309 100.00%
Cement Sector: Baseline and Targets
Energy Transition for Industry: India and the Global Context, IEA, Jan 2011
12
Although Indian Cement Sector being at par with the World
best energy intensity, but still has agreed for energy saving
targets of 0.85 million ton of oil equivalent energy under PAT
Japan
India
Development of new sector specific data Collection Form for Annual Energy Return with inbuilt SEC Calculation sheet -(Completed)
Development of Sector Specific Normalization Factors for
• Capacity Utilization or PLF
• Intermediary products
• Product Mix
• Power Mix
• Fuel and Raw material Availability
• Fuel Quality
• Alternate Fuels , Hazardous and Non- Hazardous fuel
• Environmental Concern
• Natural Disaster & Unforeseen Circumstances
(Normalisation factors developed for DCs)
Development of Normalization Factors, Monitoring , Verification and Trading
Finalization of the overall structure for issuance of Escerts ( Under progress)
Mandatory Energy Audit and Identification of New DCs
Identification of new DCs in 8 sectors
( Activities initiated)
Market place for Energy efficiency
Instruments ( Under Progress)
Making energy audit mandatory for
DCs to identify the energy saving
potential in the existing and new
plants ( Notified on 27th May,2014)
PAT Developments
13
Use of Alternate Fuels in Indian Cement Plants
14
Use of Biomass and Alternate Fuels
• Biomass and alternate fuels ( non-fossil fuels)energy used in Kiln is not included as InputEnergy to the Plant under PAT Scheme in theBaseline and Assessment year.
• This has boosted the use of Biomass andAlternate fuel (solid and liquid fuels) inCement Plants.
• Normalisation has also been considered, incase availability of Alternate fuels reduces inAssessment year in comparison to Base lineyear, due to external factors
15
Dalmia Cement (Bharat) Limited, Kadapa
• Utilization of waste rubber carbon asalternative fuels at a rate of 14 T/Hr.
• Reduction in usage of pet coke in2,438 MT /Month @ rate of 3000 MT/Month Carbon black consumption.
• 2% of Alternative Fuel usage forClinkerization.
16
JK Lakshmi Cement Limited, Sirohi
• Use of Bio Mass Such as Mustard, Moong, Mahendi, Soyabean husk, Sarason to replace some quantity of Coal used in PC firing of the kiln section.
17
Year 2011-2012 2012-13 2013-2014
Eq. Fuel SavingMT
10831 4348 8593
VASVADATTA CEMENT• Utilisation of Waste as fuel (Alternate Fuel
Utilization) : Tyre Chips, Carbon Black etc.
18
Different Types of AFR Consumed (in MT)
2012-13 2013-14 Coal Saved Indian (MT)
Coal Saved Imported (MT)
% Share of AFR
Rs.in lac Saved
Total 3,017.07 13,601.5 14876 2484 2.576 415.48
Dalmia Cement,Ariyalur
• By the use of Alternate Fuels, Carbon Emission reduced by 12583 tons of Co2 for the year 2013-14 is
• Trail run was conducted for usage of tannery sludge as a raw material- First in India .
19
Quantity of waste fuel used (Tons )
Equivalent of Conventional energy used (Tons of fuel)
Waste fuel as % of total energy
11210 4839 3.97
UltraTech Cement Limited- Unit: Vikram Cement Works
• PAT Benefits by using Alternate Fuel (Imported Tyre Chips-9057 kcal/kg GCV, plasticwaste, MSW, paint sludge, Opium Marc,Hazardous and Non-Hazardous Waste, DodaChura (Poppy Straw) Seized by Govt , paintsludge etc.
20
Quantity of Alternate fuel used (Tons )-2013-14
Avg CV Value of Alternative fuel (Kcal/Kg)
Potential PAT Benefit mToE (Metric tonnes of oil equivalent) (2013-14)
23001.77 4125.71 9489.90
Conclusion
21
The PAT scheme is a unique and innovative programme
with no precedence anywhere else in the world.
PAT Scheme has given a boost to the use of alternatefuels in Cement industry and helped in reduction of CO2
emissions.
PAT would become a valuable model for other countries
to adopt for their own energy efficiency programmes with
a business perspective.
It also highlights an innovative approach of introducing
market-based instruments within a regulatory framework
to encourage compliance.
Successful implementation of the scheme could serve as
a model for addressing upcoming challenges in a
transparent and economically efficient manner.
Conclusion
23
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