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Presented by:

Opportunities & Challenges in Fly Ash Utilization in Indian Cement Industry

K.N.Rao Director Energy & Environment

ACC Limited

This report is solely for the internal use. No part of it may be circulated, quoted, or reproduced for distribution outside the company organization without prior written approval from ACC Limited. This material was used during an oral presentation; it is not a complete record of the discussion.

Fly Ash Generation & Its Utilization In The Country

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ACC Limited 19.01.20132nd Annual International Summit - FAU 2013, New Delhi

Source: CEA REPORT ON FLY ASH GENERATION AND ITS UTILIZATION DECEMBER 2011

Fly Ash Utilization In Cement Industry

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Source: CEA REPORT ON FLY ASH GENERATION AND ITS UTILIZATION DECEMBER 2011

During the year 2012, ACC has consumed ~4.6 Million Tonnes of Fly ash which isequivalent to ~13% of Indian Cement Industry Fly Ash Consumption

Expected Fly Ash Absorption Capacity By Indian Cement Industry

Year

Expected Fly ash

absorption in

Cement (million

tons per annum)

2015 52.65

2020 73.01

Assumptions: Market share of PPC Cement is

assumed to be 65% of the total

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Source: WBCSD / CSI Low Carbon Technology Road Map for Indian Cement Industry

2025 94.63

2030 120.50

2035 143.72

2040 158.02

2045 167.74

2050 177.45

assumed to be 65% of the total cement production

The % of Fly ash utilization in PPC is expected to increase from ~23% in 2010 to ~35% in 2050

Benefits of Fly Ash Utilization In Cement Manufacturing ACC is the first Indian cement company to produce blended cement attheir Chaibasa unit in the year 1961 by using the blast furnace slag fromTiscoIn the year 1965 ACC produced flyash based blended cement (PPC)Benefits of flyash utilization in cement manufacturing process:

Substitution of fast depleting limited natural resources of limestone ~25 30% Conservation of fossil fuels like Coal, Oil & Gas etc can

be achieved due to the substitution of clinker with flyash

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be achieved due to the substitution of clinker with flyash ~15 20% Electrical energy savings which will reduce further

conserve fossil fuels due to avoidance of electricity generation CO2 reduction (direct): 220 280 Kg CO2 /t PPC (for Cement with

27 - 35% by mass fly ash) CO2 reduction (indirect): 1 KwH in specific power consumption

reduces CO2 emissions by 1 Kg hence, reduction in CO2 emissionsis expected to be 13 17 kg / t PPC (for Cement with 27 - 35% bymass fly ash)

Possibility of releasing vast space occupied by wet fly ash pondssubject to Governments support to Cement Industry

Avoidance of ground water contamination due to open storage offlyash

Environment friendly disposal of flyash and creating economic valuewhile conserving the fast depleting natural resources (coal,limestone)

Benefits of Fly Ash Utilization In Cement Manufacturing

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Production of Synthetic Sand Production of Aggregates Production of Composite Cement Production of Flyash Bricks for construction

Other Areas Of Flyash Utilization

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Limiting factors/ Challenges for utilization of fly ash inIndian cement industry Substantial increase in the landed cost of Flyash at Cement plant

(earlier the flyash was given free of cost to cement plants) Continuous increase of OPC demand in infrastructure projects The maximum permitted level of fly ash in India is 35% as compared

to European standards maximum of 55% by weight for siliceous flyash in cement production

Lack of composite cement standard

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Lack of composite cement standard

Many Indian cement plants have reached 35% flyash addition limit

Lack of coincidence of limestone available locations and the powerplant locations resulting non-viability of manufacturing PPC

The long lead distances between flyash generation sources andcement manufacturing units

Insufficient Domestic R&D efforts to increase the quality of flyash (atthe point of generation as well as at the point of utilization)

High transportation cost of flyash High infrastructure cost for loading at power plant, unloading at

cement plant & transportation of flyash by special wagons/bulkers Lack of economically viable and proven technologies for utilizing

huge deposits of pond / dump ash

Limiting factors/ Challenges for utilization of fly ash inIndian cement industry

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The Poor quality of Indian fly ash & large variation in terms of Low lime reactivity Low glass content High Carbon content Varying fineness level

Areas to be addressed to Enhance Fly Ash Utilization In Cement IndustryInterms of policy support

Need for modifications of existing standards and codes / newstandards for enhanced utilization of fly ash in Cementmanufacturing

Standard for Composite Cement Mandatory use of blended cements in Government Infrastructure

Projects Enhancing the consumer awareness about the blended Cements

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Enhancing the consumer awareness about the blended Cements Cement Industry should be allowed to use 100% of their Captive

Power plants for cement manufacturing

Areas to be addressed to Enhance Fly Ash Utilization In Cement IndustryInterms of financial

Concessional excise duty for flyash (PPC)/slag(PSC)/compositeCement

Concessional freight charges for the transportation of flyash if thelead distance from the power plant to cement plant is more than100 kms

Government to develop proper rail connectivity to cement plantsto enable for the economical transport of flyash

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to enable for the economical transport of flyash Power plants to create infrastructure facilities for the flyash

evacuation and loading Supply Flyash at free of cost to Cement Industry and power plants

may be suitably compensated Financing R&D initiatives for improving the quality of flyash

THANK YOU

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THANK YOU

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