How the Cement Industry is Adopting Alternative Fuels and Raw Materials

The Drive Towards Sustainability

India possesses the second-largest cement industry in the world with an installed capacity of about 545 MTPA. But this large capacity entails a very high cost to the environment. Accounting for approximately 8 percent of the total global CO2 emissions, the industry is significantly influenced by the energy consumption related to cement production and the calcination process that includes the decomposition of limestone to obtain lime, which is one of the primary components of cement. Thus, the industry has had to cut down the emissions of carbon and enhance the sustainability of its operations.

AFR is considered one of the best practices in overcoming these challenges. AFR covers the utilization of wastes, biomass, and industrial residues as fuels and as a source of materials for the cement manufacturing process. From fossil fuels like coal, pet coke, etc, the industry has an opportunity to shift towards sustainable fuel sources such as municipal solid waste, agricultural waste, used tires, etc which can minimize the CO2 emission drastically. Just like the case with fly ash, slag, and foundry sand as used materials in construction work similarly help to minimize the use of virgin materials, meaning that natural resources will be conserved and energy used in the process will be minimal.

Types and Benefits of AFR

The types of AFR being adopted by the cement industries in India are both organic as well as inorganic waste materials. These include biomass, rice husks and coconut shells, industrial waste, fly ash and slag, municipal solid waste, waste tires, and some chemical wastes. Among the many advantages, one can name a considerable decrease in the level of CO2 emissions. If the industry shifts to the use of these other fuels, then it will be possible to cut down on the use of fossil fuels hence promoting climate change. AFR also offers the best way of dealing with different types of waste like municipal waste, industrial waste, and agricultural waste. This also goes a long way in trying to ease the pressure on landfills and stop environmental pollution.

In addition, the industry can use industrial by-products as raw materials instead of natural resources like limestone, clay, and shale. This has the effect of minimizing mining and quarrying activities that are often linked with adverse effects on the environment. This has shown that the application of AFR can result in considerable cost reductions for the cement industry. Such fuels and raw materials are usually cheaper than conventional fuels and raw materials hence cutting down on the costs of production and increasing the profitability of the business. It is seen that AFR can improve the energy efficiency of cement production. For example, the utilization of high calorific value waste material can enhance the thermal efficiency of cement kilns and hence the energy consumption.

Challenges in Implementing AFR

Even though AFR presents many advantages, the process of its implementation is not devoid of problems. The Indian cement industry experiences several challenges in its effort to enhance the utilization of AFR. AFR also entails certain changes to the cement plants and these changes are expensive and time-consuming. Also, the fluctuating quality and supply of AFR could have an impact on cement production’s steadiness and productivity. The norms for AFR in India are not very favorable at the moment as it is still under development with strict norms and a long approval time. Hence, there is a need for the more favorable legal regulation of AFR.

The task of collecting, transporting, and processing waste materials for use as AFRs may not be easy, especially in a country that has yet to develop its waste management systems. The major challenge, however, arises from local communities and environmentalists who oppose the use of waste materials in cement production due to the perceived risks to the environment and human health. To tackle these issues, awareness should be created and communication should be done openly. AFR can be useful for achieving cost savings in the long term, however, the costs that have to be incurred initially include the changes that have to be made in cement plants and the creation of a stable supply chain.

The Road Ahead

Going forward, it can be asserted that the future of AFR in India’s cement industry is rather promising. The government has been encouraging sustainability and the industry’s goal to minimize its emission of greenhouse gases has led to the increased use of AFR. “The AFR usage can decrease environmental impacts, and lower consumption of fossil fuels to reduce the economic impact to the cement industry. Fast depleting natural resources like limestone, increased cost of conventional fuels like pet coke and coal, have become a matter of great concern for cement industry all over the world,” said Sanjay Joshi, Chief Projects and Manufacturing Officer, Nuvoco Vistas Corp to Indian Cement Review. The Cement Manufacturers’ Association (CMA) has laid down the goals for the utilization of AFs where it wants to achieve a TSR of 25% by 2025 from the current 4%. To realize this target, all the stakeholders such as the government, industry players, and waste management companies will have to pull their socks.

Therefore, the strategies of innovation and collaboration will be crucial in addressing the issues relating to AFR. For example, the application of co-processing technologies which is the processing of waste material and conventional fuels at the same time can be useful in achieving the optimum use of AFR. In the same way, cooperation between cement companies and waste management organizations can be useful for obtaining a constant source of AFR.