EBTC CTM Energy Efficiency Industries

7/23/2019 EBTC CTM Energy Efficiency Industries

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Clean Technology MappingEnergy Efficiency- Industries (Cement, Paper & Pulp, Chemical, Iron & Steel and

Aluminium)

June 2012

www.ebtc.eu


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Promoting European clean technologies in India & tackling climate change www.ebtc.eu | 2

Clean Technology Energy Segments

Energy & Power

Energy StorageEnergy Generation Energy EfficiencyEnergy Infrastructure

Solar

Bio power Geothermal Wind Hydro Wave/Tidal Clean Coal Technology Coal bed Methane

Fuel cells

Advanced Batteries Flywheel Pumped Hydro Storage

(PHS) Compressed Air

Energy Storage(CAES)

SMES Ultra capacitors

Smart Grid

Energy Efficiency (Industries) segments has been covered in this report

Buildings HVAC,

Lighting, BuildingAutomation, Insulation& Windows

Industries Energy

Intensive Industries


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Overview of Energy Intensive Industr ies

Production of the five key materials: Steel, Chemicals,Aluminum, Cement & Paper is expected to increase

tenfold by 2050

Source : IEA

Above five industries accounts for about 66 % ofenergy consumption across Industrial segments

Cement

Energy Intensive Industries withHighest Savings Potential

Sugar

Tobacco

Iron & Steel AluminumPulp &paper

Rubber Chemical

Pharma

Iron & Steel Aluminum Pulp & paper Chemical Cement

Key Materials Production ForecastSelection o f Energy Intensive Industries
http://www.iea.org/work/2010/india/wp2.pdfhttp://www.iea.org/work/2010/india/wp2.pdf


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Overview of Energy Intensive Industries

EJ / yr Mtoe / yr Mt CO2 / yr

Chemicals /

Petrochemicals

5.0 6.5 120 155 370 470

Iron and steel 2.3 4.5 55 108 220 360

Cement 2.5 3.0 60 72 480 520

Pulp & Paper 1.3 1.5 31 36 52 105

Aluminium 0.3 0.4 7 10 20 30

Manufacturing industry can improve its energy efficiency byan impressive 18 to 26%, while reducing the sectors CO2

emissions by 19 to 32%, based on proven technology

Accounts for 30% ofglobal industrial

energy use and 16%

of direct CO2

emissions

Accounts for about19% of final energy

use and about a

quarter of direct CO2

emissions from the

industry sector

Non-metallic mineralsub-sector accounts

for about 9% of global

industrial energy use,

of which 70 to 80% is

used in cement

production

Accounts for about5.7% of global

industrial final energy

use

Global avg. electricityuse for primary

aluminum production

is 15 300 kWh/t

Chemical Iron & Steel Cement Pulp & Paper Aluminium

Energy Intensive Industries _ Consumption & Emissions

Above mentioned industries are the most energy consumingindustries globally and have the highest potential for energy

savings

Total Energy & Feedstock savings PotentialLow High Estimates of

Technical Savings Potential

Source : IEA


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CEMENT INDUSTRY


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Raw MaterialClinker

ProductionProcess Milling

CementDispatch

Clinker Gypsum Slag Fly Ash Lime stone

Dry Wet Semi wet Semi dry

Drying Preheating Clinkerization Clinker cooling Crushing

Grinding Crushing Storage

Rotary packer Bulk Dispatch

Higher energy consumptionMore man-power requirementsCostly

50- 70% 30-40%EnergyConsumption

Energy Efficiency Overview in Cement

Manufacturing

97% penetration ofDry processes

Wet process

Semi Dry Process

Semi Wet processDry Process

Wet processDry Process

Dry process

Tradition Technology Matured Technology

Time

Energy

Effici

entProcess

90% penetration ofDry processes

Matured ManufacturingProcessMore Energy EfficientMore Economical


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Overview of Energy Efficient Cement Technologies

Cement plants which use modern grinding technologies

o High pressure grinding rolls (HPGR)

o Vertical roller mills (VRM) for raw materials and cement

comminution instead of ball mills (BM) usually have a lower

energy consumption

Changing from long wet kiln technology to modern dry

process kiln precalciner saves up to 5 kWh/t clinker

Grinding with HPGR & VRM, if need be in combination with

ball mill for cement finish grinding, is state of the art

Electrical Efficiency ofCement Production

Alternative fuels & biomass use in the cementindustry

In some European countries the avg. substitution rate reaches more

than 50% for an industry sector and up to 80% as early average for

single cement plants

Principally, cement kilns can utilize up to 100% of alternative fuels. The

calorific value of most organic material is comparatively low (10-18

GJ/t).For the main firing of the cement kiln an avg. calorific of at least

20-22 GJ/t is required

In the precalciner of modern cement kilns, in which up to 60% of the

fuel input is realized, the lower process temperature allows also the

use of low calorific fuels

Reduction of clinker content in cement

Cements that contain other constituents

besides clinker exhibit a lower clinker-to-

cement-ratio than Portland cement have

Less energy demand for the clinker

burning

Less process CO2 emissions due to

decarbonization of the limestone

Granulated blast furnace slag

Cements containing GBFS

usually show a lower early

strength if ground to the

same fineness and a lower

heat of hydration

Fly Ash (FA)

Cements containing FA

typically show a lower early

strength compared to ordinary

Portland cement (OPC) at

similar fineness. They also

exhibit a lower water demand

2 KeyTechnologies



Other Technologies & Its Impact

Technology Descripti on Impact (Efficiency Improvement)

Improve raw mixburnability

By adding mineralizers clinker compound formation is promoted Thermal : decrease 50 - 180 (MJ/t cli)

Preheater / Precalcinerkilns

Preheater technique with 3 to 6 cyclone stages improves calciningefficiency by drying & preheating the raw materials using the kilnexhaust gas

Thermal : decrease 50 - 180 (MJ/t cli)Electric : decrease 0 - 5 (kWh/t cli)

Multi-Channel burner Retrofit mono-channel burner to modern multi-channel burner whichallows the use of different kinds of fuels at comparatively low primaryair ratios

Thermal : decrease 25 - 75 (MJ/t cli)

Fluidized bed advancedcement kiln system

Clinker is produced in a fluidized bed system , under addition ofgrinded coal, and raw material injection

Thermal : decrease up to 300 (MJ/t cli)

Cement grinding withvertical roller mills & rollerpresses

Significant reduction of the specific energy demand for cementgrinding can be achieved either by combined grinding in VRM orHGR

Electric : decrease 12 - 16 (kWh/t cem)

Variable speed drives Decreasing throttling can reduce energy losses in the system andcoupling losses through the installation of variable speed drives

Electric : decrease 3 - 9 (kWh/t cem)

Source : World Business Council for Sustainable Development

Parameters Low Technology Plants Modern Plants Green Technology

Pyro Processing Wet Process Semi Dry Process Dry process 4 stage preheater Conventional cooler Single channel burner

Dry Process 5/6 stage preheater High Efficiency Cooler Multi Channel Burner

Dry Process 6 stage preheater High Efficiency Cooler Multi Channel Burner Co-processing of WDF Low NOX/SO2emission technologies

Energy consumptionlevel

90-100 kWh/t cem.900-1000 kcal/kg cl

75-85 kWh/t cem.700-800 kcal/kg cl.

70-80 kWh/t cem.675-740 kcal/kg cl

Energy Efficiency More consumption of energy Less Consumption of Energy Less Consumption of Energy

Status Outdated Popular form More Energy Efficient Form

Overall Technology Developments
http://www.wbcsdcement.org/pdf/technology/Technology%20papers.pdfhttp://www.wbcsdcement.org/pdf/technology/Technology%20papers.pdfhttp://www.wbcsdcement.org/pdf/technology/Technology%20papers.pdfhttp://www.wbcsdcement.org/pdf/technology/Technology%20papers.pdf



Cement Industry Comparison : EU & India

EU cement industry energy bill represents about 40% of total

production costs, while European cement production techniques

are amongst the most energy efficient in the world

Percentage of the dry process use in the EU production in the

cement industry has increased from 78 % in 1997 to 90 % in 2008

Cements containing granulated blast furnace slag (GBFS) are very

common in Europe

One of the main sources of CO2 emission reduction in Europe is the

decrease of the proportion of clinker in the cement, i.e. the clinker-to-cement ratio

Plants in Belgium, France, Germany, the Netherlands and

Switzerland have reached average substitution rates of from 35%

to more than 70% with some plants achieving 100% substitution

Major Initiatives taken are:

Process conversion away from less energy efficient processes

to dry and semi-dry processes

Using blast furnace slag, power station fly ash, natural

pozzolana or limestone as a constituent of the final cement

reducing the clinker required per tonne of cement

Key players in cement technologies are FL SMIDTH,KHD

Humboldt Wedag, ABB, Loesche GmbH, AUMUND Group

At present 96-97% of Indias cement production is from dry

process kilns, a further 3% of production is accounted for by

wet process kilns, with the remainder of Indian production

about 1% now coming from semi dry & semi wet process kilns

A number of plants are still using ball mills, many have

installed pre-grinders like roller press to improve energy

efficiency

Best reported energy performance figures in India is 69 kWh/t

of cement & 665 kCal/kg of clinker as compared to 65 kWh/t &

650 kCal/kg respectively for the rest of the world

Government of India to attach top priority to encourage

application of nano-technology in the production of cement in

view of the limited and finite nature of mineral resources

available in the country

Shree cement, India was the first cement company in the

world to be certified EN 16001, which is designed to

continuously monitor and document energy use, identify

action targets, and provide the necessary resources and

employee training

Key players in cement technologies are Ashoka Technologies,

Kakatiya engineering equipments Pvt ltd, Supertech

International, Tata Steel Growth shop

Source : CEMBUREAU

New generation plants installed in India have excellent energy efficiency norms comparable with the best and most energy

efficient plants in the World and there is deep penetration of advanced technologies in India
http://www.wbcsdcement.org/pdf/tf1/cc_cement_and_eu.pdfhttp://www.wbcsdcement.org/pdf/tf1/cc_cement_and_eu.pdf



Opportunit ies in Indian Cement Sector

Opportunities listed by Bureau of Energy Efficiency India

Slip power recovery

Variable voltage & frequency

drives

Soft starter for motors

High efficiency fans

Energy Efficient Equipments Process Optimization

Reducing idle running

Installation of improved insulating

bricks/blocks in kilns & pre-heaters

Effective utilization of hot exit

gases

Optimization of cooler operation

Waste Heat Recovery

Increasing percentage of additives

Use of alternative, waste fuels

Adoption of technologies for

reducing emission of So2& NOx

Other Opportunity Areas

CCS has been identified as a prominent option to reduce CO2emissions from cement production in the medium term Currently, the main evolution of the sector to improve its energy and environmental performance is towards higher uses

of clinker substitutes in the cement, higher use of alternative fuels such as waste and biomass and the deployment ofmore energy efficiency measures

Source : BEE India

Area Of Improvement Future Use % (2015) Likely GHG Reduct ion (%)

Blended Cements 75-80 22-24

Compress ed Natural Gas fuel 20 8-9

Waste Derived Fuel 20 8-9

Non-Conventional Energy 8 2-3

Energy Efficient Plant/Machinery 10 8-10



Energy Efficiency_ Cement Industry : India

Cement Technologies

Granulated blast furnace slag and Fly Ash(FA) are the two energy efficient cementtechnologies

Major players of cementtechnologies:

Shree cement Kakatiya Ashoka SuperTech

At present 96-97% of Indias cement production is from dry process kilns, a further 3% ofproduction is accounted for by wet process kilns

Shree cement, India was the first cement company in the world to be certified EN 16001,

Rajasthan

Maharashtra

Uttar Pradesh

Tamilnadu

Andhra Pradesh

The demand for cement is expected to grow

at 10 per cent over 2011, as per ACC Ltd's

annual report. India's total installed capacity

of cement stood at 320 million tonnes perannum (MTPA).

Madhya Pradesh



EU cement industry energy bill represents about 40% of total production costs, while European cement productiontechniques are amongst the most energy efficient in the world

Energy Efficiency _Cement Industry : European

Union

Cement Technologies

Switzerland

FranceGermany

Belgium

Netherlands

Belgium, France, Germany,the Netherlands andSwitzerland have reachedaverage substitution rates offrom 35% to more than 70%with some plants achieving100% substitution



Current Strategic Partnerships: European Union

vs. India

FL Smidth along with JK Cements Ltd created the dry process white cement plant in an arid, inhospitable and

remote village known as Gotan on Sep, 2009

ABB India successfully commissioned integrated electrical, control and automation systems at one of the

biggest cement plants , for Podilisky Cement in Ukraine in Spring 2007 and in June 2009, ABB India

successfully commissioned integrated electrical, control and automation systems at one of the biggest cement

plants , for Podilisky Cement in Ukraine

o The plant used a wet process for clinker production

o

This project is the worlds first Track 2 Joint Implementation project registered with the United Framework Conventionon Climate Change (UNFCCC)

Cement

technologies


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R&D Initiatives

Eco-friendly cement

based on local raw

materials (2010)

Project focuses on developing new types of reactive

Supplementary Cementitious Materials (SCM) and on the

necessary process technology for large scale production and use

of such materials. The process technology is being developed for

sale to the global market and will be centered around the

manufacture of SCM materials based on locally available raw

materials. The whole process will be tailor-made for specific

cement plants

Stakeholders

Danish National Advanced

Technology Foundation,

FLSmidth

Project Objective

Following Thrust Areas of R&D have been identified for taking up specific projects:esearch for newer methods of manufacturing such as

application of Nanotechnology to cement and concrete

Synthesis/ generation of nano-particles and investigations on their role in improving cement and concrete performance

Investigations for geo-polymeric cements, Portland Limestone Cement

Improved Refractory engineering practices

Processing of fly ash for enhanced use in cement/concrete

R & D work to identify new pozzolanic materials for use as additives in cement

R & D studies for reduction of green house gases (GHGs) in cement manufacture such as adaptation of best available Technology for

reduction of NOx and SO2; and sequestration of carbon-dioxide in Algae culture

R & D studies for use of Alternate Source of Energy/ fuels and raw materials

38 technology papers are developed by the European Cement Research Academy (ECRA) sponsored by the CSI. The papers focus on four

distinct reduction levers available to the cement industry: thermal and electric efficiency, alternative fuel use, clinker substitution, and

carbon capture and storage (CCS)


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PULP & PAPER


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Raw MaterialPulpingProcess

Bleaching &Blending

Screening& Cleaning

PaperMaking

Wood ships Non wood

chips Recovered

paper Recycled Fiber

Chemical Mechanical Semi chemical

Washing

DE-INKING

Refining

Wire Press Dryer

Roll paper

Flat paper Reel Paper product

DEBARKING &CHIPPING FINALPRODUCTCOOKING/ GRINDING

CALENDERBLEACHING PROCESS

EnergyConsumption

60-85% 15-30%2-5% 100%

Recycled Other (e.g.

Dissolving, on-wood

Energy Efficiency process

Manufacturing process Energy Efficient Technology

Save Energy

20-30%Chemical Pulp Process

Energy Efficiency : Pulp & Paper Manufacturing


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Energy Efficient Technologies .. 1/2

Plant Power % of Total

MechanicalPulp Mills

120 MW 67%

PaperMachines

32 MW 18%

Kraft Pulp Mill 17 MW 9%

Pumping 3 MW 2%

Fibre Supply 2 MW 1%

EffluentTreatment 2 MW 1%

General site 2 MW 1%

Generation 24 MW 13%

MECHANICAL PULPING OPERATIONS ACCOUNT FOR

THE MAJORITY OF POWER CONSUMPTION (67%)

Mechanical Pulping relies more so on mechanical actions to separate

and develop wood fibers, rather than using chemical means

Electricity is the main source of energy for generating the mechanical

forces necessary to produce mechanical pulp

Chip pre-treatment

Refiner plates

High efficiency refining

High Consistency

Low Consistency

High Intensity TMP Process Optimized = RTS

High speed refining technology that provides sufficient heating to

withstand high intensity refining, thus achieving both energy savings

and preservation of pulp strength

A thermomechanical pulping process that operates at: Lower retention time (R)

Higher temperature (T) Higher refiner speed (S)

Reduced electricity requirement is attributed to 2mechanisms during RTSrefining: During high intensity refining a higher proportion of bar impacts results in

adhesive failure rather than deformations At higher temperatures, lower stress levels are required for viscoelastic

failure

Energy Efficient Technology Pulping Process

RTSENERGY REDUCTION STRATEGIES


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Energy Efficient Technologies .. 2/2

High Speed Refining

An increase in disc speed decreases

residence time

At constant SEC, < residence timeresults in > refining intensity (SEC per

bar impact)

More short fibres are generated at >

intensity

Shive level decreases along with the

energy reduction

Fibre properties are developed faster,

with reduced electrical energy a sideeffect of refining intensity

Low consistency refining is a technology that has been around for many years

New breed of LCR refiners have been developed for TMP strength development

A number of mills have installed them in TMP lines as a third refining stage.

Energy reductions of 50 - 150 kWh/BDMT have been claimed per LCR installed

Low consistency refiners in series allow higher displacement of High Consistency Refining

(HCR) energy, increasing the potential to reduce power cost per ton

Low Consistency Refining

Cradle Debarking

Cradle debarker can remove bark from

logs in a manner that reduces energy

consumption by as much as 33% per

log compared with traditional debarkingmethods

This could save a paper mill as much

as US$30 per ton of wood in debarking

costs

Cradle debarking is also reported to

result in less damage to logs, leading to

a greater wood recovery rate

Energy efficiency gains can be made in the process steps which convert logs to wood chips.

They include:

Replacing pneumatic chip conveyors operating at 18.2 kWh/tonne with more efficient belt

conveyors operating at 1 kWh/tonne can result in savings of 17,200 kWh/day, or aroundUS$100,000-$200,000/yr in electricity costs, depending on the size of the convey

Incorporating automatic chip handling and thickness screening which can provide

downstream benefits by reducing the steam required in the digester and evaporator, and

increasing digester yield by 5-10%

Using bar-type chip screens which use less energy than other types of screens, but have

very similar upfront capital costs. Energy savings are estimated to be 0.34 GJ/tonne

chemical pulp

Improve efficiency of chip handling, screening and conditioning


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Pulp & Paper Industry Comparison : EU & India

Europe is the global technology leader, the technology suppliers mainly

develop modular-based solutions for the EU pulp and paper industry that

operates in a stable market

Sweden and Finland are the countries with the highest number of pulp

mills (around 35 each), followed by Germany(19)

2 countries with the highest number of paper mills are Italy and Germany

with around 170 mills each

Potential emerging and breakthrough technologies, although most are

currently at a standstill are :

Bio-route is the route towards integrated biorefinery complexes

producing bio-pulp, bio-paper, bio-chemicals, biofuels, bioenergyand possibly bio-Carbon Capture and Storage

Innovative drying technologies: impulse drying, the

Condebelt process or the steam impingement drying have only

had a first-of-a-kind implementation and have not been replicated

Half of the energy used by the industry (54.4 % in 2008) comes from

biomass and approximately 38 % from natural gas

EU estimated more than 66% Pulp & paper process on chemical and 34

% on mechanical

Key technology providers are METSO, Andritz, Alfalaval, ABK Machinery,Clextral

The Indian paper industry is highly energy-intensive. The share of

energy costs in the total manufacturing cost is close to 25%

Paper mills operating in India, particularly small mills, are very old

using out-dated technology including plant & machinery

There is a need to adopt new and efficient technologies because of

high product quality, international competition, mounting pressure from

environmental regulatory, rise in energy prices

Consumption of steam in a wood based paper mill is 10 to 11 tons/ ton

of paper compared to international standards of 6.5 8.5 t/t while the

power is 1500-1700 kWh/ton of paper compared to 1150-1250 kWh

achieved in more efficient units Most of the paper mills are using old equipments and in the event of

breakdown get them replaced either internally or locally. As such the

equipments installed:

Do not meet the best efficiency levels available

Are mostly over designed capaciti es lead ing to inef fi cient

operating levels

India estimated more than 70% Pulp & paper process on mechanical

and 30 % on Chemical

Key technology providers are Arjun Technologies, J&K Engineers,Prominent, Ballarpur Industries ltd.

Existence of substantial energy saving potential in Indian paper industry arising from out-of-date technologies employed in themills and lack of energy saving devices in the industry

Plausible options that would help limit the growth in energy use in the pulp and paper industry consists of increasing waste heatrecovery, implementing better paper-drying technologies, switching to more energy efficient fuels and increasing the use ofrecovered paper


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Opportunity in India

Technology /

Equipment

Present Status Options Available for EE Improvement

Boiler Generally operating on low efficiency

level because of lack of monitoring andcontrol systems

Monitoring and control systems like oxygen control in flue gas,

etc. are available readily that contribute to overall efficiencyimprovement of boiler

Boiler Auxiliaries Operating efficiency of fans and pumps

are being used in boilers is generally on

the lower side. Lack of monitoring and

control systems also lead to loss of

energy

High efficiency boiler auxiliaries are available

Adequate monitoring and control systems are available to

optimize the performance of boiler auxiliaries leading to energy

savings

CondensateRecovery System

Most of the mills have poor condensaterecovery systems leading to tremendous

heat loss through flash steam and

radiation

Smart and efficient condensate recovery systems are available torecover entire heat energy being lost from steam Condensate

Digester Blow

Down Heat

Flash steam generated during digester

blow down is not recovered and the heat

is lost to atmosphere

Possibility to recover the heat lost in flash steam and use it to

generate hot water for use in process

Steam Dryers Traditional condensate evacuationsystems are installed in paper mills.

These have a low operating efficiency

and mechanical reliability

Efficient condensate evacuation systems are available thatimprove the condensate evacuation from dryers leading to

improved heat transfer in dryers

Pulping Traditional pulpers are installed in most

of the paper mills

High consistency pulpers are available that provide better slushing

at lower specific energy, chemicals and thermal energy

consumption levels. It also provides good quality of pulp leading to

higher production by reducing the number of paper breaks

E Effi i P l & P I d t


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Energy Efficiency_ Pulp & Paper Industry:

India

Pulp & Paper Technologies

The Indian paper industry is highly energy-intensive. The share of energy costs in the total manufacturingcost is close to 25%

India estimated more than 70% Pulp & paper process on mechanical and 30 % on Chemical

J&K

Maharashtra

Uttar Pradesh

Delhi

Andhra Pradesh

Orissa

Pulping, High-speed refining and Cradledebarking are the two energy eff icient pulp &paper technologies

Major players of pulp & papertechnologies:

Arjun Technologies J&K Engineers Prominent Ballarpur Industries

West Bengal

E Effi i P l & P I d t


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Energy Efficiency _Pulp & Paper Industry :

European Union

Pulp & Paper Technologies

Italy

Germany

Finland

Sweden

Sweden and Finland are

the countries with the

highest number of pulp mills

(around 35 each), followed

by Germany(19)

2 countries with the highest

number of paper mills are

Italy and Germany with

around 170 mills each



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vs. India

Two key Swedish institutes involved in Environmental and Pulp and Paper research, industry body CII and

paper industry body IPMA have formed a consortium for Facilitation of Clean Technologies in India in Pulp &Paper Sector

o The two year facilitator project from 2011 will have fund backing by Swedish International Development Agency (SIDA)

o A letter of intent has been signed by IVL Swedish Environmental Research Institute, Innventia - the Swedish pulp and

paper research institute, CII Sohrabji Godrej Green Business Centre and Indian Paper Manufacturers Association

(IPMA)

o Key objective of the project is to broaden and deepen bilateral collaboration between Sweden and India for improving

the environment performance by introduction of cleaner technologies in Indian pulp and paper sector

o Key outcome of the project is the introduction of new technologies best suited for Indian context

Pulp & paper

technologies


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R&D Initiatives : EU & India

Project

SONOPULP

(Sonication of natural fibres and

agro-waste for production and

up-grading of papermaking

pulps and biogas)

To develop a process principle for producing pulps for papermanufacturing from annual plants, including agro-waste, utilizing

high-power ultrasonic (US) pulping technology and to influence by

means of US the pulps used in papermaking to develop the

desired fibre properties

SUNPAP

(Sonication of natural fibres and

agro-waste for production and

up-grading of papermaking pulpsand biogas)

Objective Cost Timeline

9.8 Million Nov 2009 - June 2012

Development and up-scaling of novel processes for the energy

efficient production of nanomaterials, namely NFC, in pilot scale

Development and up-scaling of NFC modification processes to

address the challenges of papermaking and to provide added-value active functionalities

W2PHeat

(Upgrading of waste heat to

process heat for different

industries (From Waste Heat to

Process Heat)

New technology (high temperature heat pump HT HP) is to be

developed, aiming at upgrading process heat by the use of

unavoidable waste heat. That includes the selection of suitable

working fluids, the definition of proper cycle architecture, the

optimization of heat exchangers and the elaboration of economical

compressor driving technologies

Jan 2012 Dec 2013

Central Pulp & Paper Research Institute (CPPRI) is collaborating with Federation of Mass Printer Association of India & Ingrin Institute of Printing &

Graphics, Netherlands

R&D thrust areas of the institute include :

Raw Material Process Research

Up gradation of Raw Materials

Process Optimization in Pulping & Bleaching/ Research in the area of Chemical Recovery & Energy Management

Application of Biotechnology in Paper Industry


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CHEMICAL


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Overview of Chemical Industry

Chemical

Petrochemical

Chemicals made from crude oil andnatural gas and coal

Petrochemical includes: Olefins: Ethylene, Propylene

and Butadiene Aromatics: Benzene, Toluene,

and Xylenes Methanol

Major energy consuming processesare:

Steam Cracking Methanol Production

Inorganic Chemical

Inorganic chemicals are non carbonbasedtypically of mineral origin

Segments:

Basic Inorganic Chemicals: Aluminium

Fluoride, Calcium Carbide, CarbonBlack, Potassium Chlorate, SodiumChlorate, Titanium Dioxide, RedPhosphorus

Alkali Chemicals: Soda Ash, CausticSoda, Liquid Chlorine

Carbon Black is the major EnergyConsuming Process

Ammonia (Fer ti lizer)

Ammonia is produced by combiningnitrogen and hydrogen

Ammonia is widely used as afertilizer; also used for the production

of plastics, fibers, explosives, andintermediates for dyes andpharmaceuticals

Ammonia production is a highlyintensive process accounted for 20%of all energy used in chemicalindustry (2004)


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Technology Overview . 1/2

Feedstocks widely used are: Naphtha, Ethane and Gas-Oil Naptha based cracking is predominant in Asia-Pacific and

Western Europe while Ethane cracking is more used in NorthAmerica

Stream cracking is a energy intensive processused more than33% of chemical & Petrochemical industrys final energy (2007)

Steam Cracking Technology has two major components:

Cracking Furnaces...major energy consumer

Separation Section

More than four decade of Improvements in area like gas turbineintegration, more extensive process-to-process heat recoveryschemes, integral steam super-heaters, higher efficiency rotatingequipment and integrated heat pump systems has led to 50%decrease in specific energy consumption of steam crackers

Average energy consumption of North American and Europeancrackers is higher than Asian crackers

China and India have higher energy consumption than theaverage energy use by Asian crackers

Steam cracking Methanol Production

Most commonly produced from natural gas. Other feedstocks usedare Coal, Naphtha, biomass

Methanol technologies have following processes involved:

Synthesis Gas Preparation (Reforming or Gasification)

Methanol Synthesis

Purification

Synthesis gas preparation & Compression is a energyintensive process

Reforming Technologies available for producing synthesis gas are: One-step reforming with fired tubular reforming: synthetic

gas is produced by tubular steam reforming alone; mainlyused for up to 2,500MTPD plants

Two-Step Reforming: combines tubular reforming andoxygen fired adiabatic reforming

Autothermal Reforming (ATR) : features a stand-alone,oxygen-fired reformer. Preferred technology for large scaleplants energy efficient process


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Technology Overview . 2/2

Carbon Black is a finely divided pellet or powder and is black inappearance

Used in Tire industry, paint and varnish industry, inks and plastics

Approximately 90% of carbon black is utilized in rubber applications,9% as a pigment, and the remaining 1% as an essential ingredient inother diverse application

Manufacturing Process:

Furnace Blackaromatic oil used as feedstock; produces about95% of carbon black

Thermal black Processuses natural gas as feedstock; hasenvironmental issues

Acetylene Black Processobtains carbon black form thermaldecomposition of acetylene gas

Lampblack Processvery old process, generates carbon black bycollecting sot from fumes resulting from burning of oil or pine wood

Energy efficient measures adopted are preheating, waste heatrecovery from tail gas, tail gas combustion steam boilers, etc.

Carbon Black Ammonia production

Natural gas steam reforming is the most widely followed route forproducing ammonia. Forammonia, steam reforming natural gastechnology is close to the theoretical minimum in terms of energy

reduction

Globally around 77% of ammonia production is based on steam

reforming, 14% on coal gasification (mainly in China) and another 9%

on partial oxidation of fuel oil

Natural gas based ammonia production process is most energy efficientthan the gasification and partial oxidation process

Best Available technology option for ammonia production are:

Conventional steam reforming with a fired primary reformer

Steam reforming with mild conditions in a fired primary reformer

Heat exchange Autothermal reforming and a separate secondaryreformer

Energy Efficiency Options for Ammonia production include:

Use of gas heated reformers, palladium hydrogen membrane forhydrogen separation, use of Autothermal reforming technology


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EU Chemical Industry Most Energy Efficient

Huge gap exists between EU & India in terms of Energy efficiency in chemical industry


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Chemical Market Comparison : EU & India

Germany, France, Italy and Netherlands are the biggest chemical

market in EU accounting for 64% of sales of EU in 2010

Petrochemical

Petrochemicals accounted for 24% of total 491billion sales in

EU in 2010

Petrochemical Industry recovered strongly in 2010 from the

recession that affected it in 2009.

Steam crackers are the main energy intensive equipment

Carbon Black

Western Europe carbon black market is shifting towards central

& eastern Europe

Ammonia

EU Ammonia producing plants are one of the worlds most

energy efficient

In EU, steam reforming natural gas technology is the preferred

route for producing Ammoniathe best available technology is

close to theoretical minimum in term of energy reduction

The average energy consumption for existing natural gas plant

was 31.8GJ/t (2007); global average is 36.9GJ/t

Key Players are Linde AG, Technip, KBR, Stone & Webster and

Lummus, Lurgi AG, Haldor

Petrochemical

Technology for petrochemical industry is generally imported.Modern & state of the art technologies are used in new plants while

older plants operate on outdated technology

Energy efficiency potential exists in older plants through retrofitting

Establishment of special economic zones (SEZ), Petroleum,

Chemical & Petrochemical Investment Regions and allowing 100%

FDI in sector are some of the key government initiatives

Carbon Black

Carbon black and Soda Ash are the biggest segment in IndianInorganic chemical industry

Indian players are using latest reactor technology including preheat

and waste heat recovery, operating co-gen facilities thereby

utilizing waste tail gas

Ammonia Production

About 70% ammonia capacity is natural gas based, rest is Naptha

and Fuel Oil based

Average energy consumption in India for natural gas feedstockwas36.5 GJ/t, 39GJ/t for Naptha based and 48 87 GJ/ for fuel oil

based plants (2007)

Key Players are Linde Engineering India, Thermax India, Fenix

Process Technologies Pvt. Ltd., GEA Group

Technology penetration is improving considerably due to recent advances in process technologies and catalysts Internal heat recovery system have resulted in lower energy intensity and most of the technologies available abroad are

already in operation in India


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Hot air generator Dryers (Tray dryers)

Steam Boilers Reaction vessels (motors) Pumps Compressors Centrifuges Ballmills / Blungers Filter press ID& FD fans Thermic fluid heaters

Majority of chemical units in India use low end technologies/in-efficient equipments in their processes and utilities;

performance of those processes/equipments is poor as compared to the technologies available in the market

From technology audit studies conducted inAhmedabad Chemical cluster, below

mentioned areas were identified for technologyup gradations: Conventional wood fired hot air generator Conventional tray dryer system Horizontal agitator system Conventional filter press Design of waste heat recovery system in

exothermic reaction Replacement of conventional horizontal

agitator system with vertical agitator system Replacement of manual filter press with

mechanical filter press Replacement of conventional gear system with

planetary gear system in reaction vessels

Opportunities Listed by Bureau of EnergyEfficiency India

Energy Consuming Equipments whichneeds up gradation


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Energy Efficiency_ Chemical Industry: India

ChemicalTechnologies

Technology for petrochemical industry is generally imported Carbon black and Soda Ash are the biggest segment in Indian Inorganic chemical industry Indian players are using latest reactor technology including preheat and waste heat recovery

Gujarat

Maharashtra

Uttar Pradesh

Karnataka

Rajasthan

Punjab

Major players of Chemicaltechnologies:

Linde Engineering Thermax india GEA Group Fenix Process Technologies

Energy Efficiency Chemical Industry:


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Petrochemicals accounted for 24% of total 491billion sales in EU in 2010; Western Europe carbon black market isshifting towards central & eastern Europe

Energy Efficiency_ Chemical Industry:

European Union

Chemical Technologies

Italy

FranceGermany

Netherlands

Germany, France, Italy andNetherlands are the biggestchemical market in EUaccounting for 64% of salesof EU in 2010



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vs. India

British Petroleums US$ 7.2 Bn partnership with Reliance (RIL) will provide RIL access to the UK's major'sexpertise in finding and pumping oil and gas from deep below seabed

o Deal was announced in Feb 2011and the alliance will operate across the gas value chain in India, from exploration and

production to distribution and marketing

o Two companies would also form a 50-50 joint venture for sourcing and marketing of gas in India which will also

accelerate the creation of infrastructure for receiving, transporting and marketing natural gas

India based Haldia Petrochemicals (HPL) is in the final stages of discussion with leading European rubber

producer and two other Western technology providers , for its eight downstream projects

o HPL has announced nearly INR 4,000-crore investment plan in eight different projects over a period of three to three-

and-a-half years starting from 2012

Chemicals

technology

R&D I i i i


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R&D Initiatives

ProjectObjective Cost Timeline

CHEMWATER

(Coordinating European Strategies on

Sustainable Materials, Processes and

Emerging Technologies Development in

Chemical Process)

ChemWater will coordinate EU strategies across and beyond

ETPs on sustainable materials, technologies and process

development in the chemical and water industries, with the

final objective to integrating and exploiting NMP knowledge

and technologies addressing the emerging global challenge

of sustainable industrial water management

1 249 717 May 2011 - Oct 2013

CLEANEX

(Method for on-line cleaning of heat

exchangers to significantly increase

energy efficiency)

Develop an innovative projectile based on-line

cleaning and injection system that will work under the

required operating conditions to mitigate foulant

build-up throughout the heat exchanger

3 990 184 Sep 2009 - Feb 2013

CEREXPRO(Ceramic heat exchangerswith enhanced materialsproperties)

2 792 942

Develop a new generation of ceramic heat exchangers

for high temperature heat recovery with the target of

significantly reducing the size and weight as well as also

the price of such components by simplifying the

manufacturing process and allowing a higher flexibility inthe heat exchanger geometry

Apr 2009 - Mar 2013


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IRON & STEEL

Iron & Steel Manufacturing Process


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Iron & Steel Manufacturing Process

Energy consumption in Iron & Steel Industry is related to fuel & electricity

One of the largest emitter of CO2 in world

Highly Energy intensive; energy cost constitutes 20-40% of steel production costs

Important energy efficiency gains achieved in last two decadesmore EE is achievable

Crude Steel Process

Coke Oven Blast Furnace

Basic Oxygen Furnace ProcessElectric Arc Furnace Process

Uses Iron ore and scrap for steel making BOF processaccounts for majority share in steel production worldwide

Does not require external heat; utilizes heat generatedby exothermic reaction during melting operation

Almost 50% Steel is derived from Pig iron

Uses mainly Scrap, Direct reduced iron and cast iron forsteel Making

Lower capital cost compared to BOF

Features: High transformer capacity Oxy fuel burners, coal injection system, bottom purge holes

E C ti i ld id St l ki


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Energy Consumption in worldwide Steelmaking

India Energy consumption is higher than Germany and hencepresents potential for energy efficient technologies

Steel industry are the major sources for CO2emissionsin India. Emission intensity of the steel industry one thirdabove global average

Energy Efficient technologies for Iron & Steel Making


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Energy Efficient technologies for Iron & Steel Making

Process Energy-efficient Technologies

Coke making Coke Dry Quenching (CDQ) Automatic Combustion Control Automatic Ignition for Coke Oven Flare Tall batteries and stamp charged batteries

Sinter making Sinter Cooler Waste Heat Recovery Multi-slit Burners

Iron making Top Pressure Recovery Turbine (TRT) Hot Stove Waste Heat Recovery Coal Dust Injection (CDI) Bled BF Gas Recovery

Steel making Bled BOF Gas Recovery BOF gas Sensible Heat Recovery

Casting Continuous Casting replacing Ingot Casting Thin Slab Casting / Near-net-strip Casting

Rolling Walking Beam Furnace Reheating Furnace Waste Heat Recovery

Technology Overview 1/2


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Parameter per ton of Coke Wet Quenching Dry Quenching

Environmental Aspects per ton of coke

Water Consumption, m3 0.5 0.6 Nil

Air Emission, Unit-gram < 50 Nil

Energy Recovery Potential per ton of coke

Steam, kg Nil 500-600

Electricity, kWh Nil 40-50

Coke Dry Quenching (CDQ)

Energy conservation: 0.8 1.2 GJ/ton of coke Recovers sensible heat of coke Produces high pressure steam suitable for power generation Water conservation CDM BenefitCO2 emission reduction approx. 130 kg/ton of coke

Technology Overview .. 1/2

Sintering:Sinter Plant Heat Recovery, Reduction of Air Leakage, Increasing bed Depth, Improved ProcessControl, Use of Waste Fuels in Sinter Plant, Improve Ignition Oven Efficiency

Coke Making: Coal Moisture Control, Programmed Heating, Coke Dry Quenching

Blast Furnace: Pulverized Coal Injection, Charging Carbon Composite Agglomerates, Top Pressure RecoveryTurbines, Recovery of Blast Furnace Gas, Hot-blast Stove Automation, Improvement of Combustion in Hot Stove,Improved Blast Furnace Control Systems, Slag Heat Recovery

Basic Oxygen Furnace (BOF): BOF Heat and Fuel Gas Recovery, Variable-Speed Drives on VentilationFans, Improvement of Process Monitoring and Control

Energy Efficiency Options for Integrated Iron and Steel Production

Waste Heat Recovery from Sinter Cooler

Energy conservation: 0.55 GJ/ton of gross sinter Energy Efficiency : fuel savings Emission reduction Sox (3-10%), NOx (3-8%) and PM (30%) CDM Benefit CO2 emission reduction approx. 35-40 kg/ton of gross

sinter

Technology Overview 2/2


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Technology Overview .. 2/2

41

Top Gas Recovery Turbine

Energy conservation: save upto 0.4 GJ/ton of hot metal for 15MWturbine

Generate electricity of approx. 40-60 kWh/ton of hot metal Emission reduction Sox (3-10%), NOx (3-8%) and PM (30%)

CDM Benefit CO2 emission reduction approx. 36-48 kg / thm

Energy Saving Emission reduction CDM Benefit CO2 emission reduction approx. 60 kg / tcs

Recovery of BOF Gas

Innovative iron making process developed by Siemens and POSCO Process is simplified as sintering and coking steps, necessary in the

blast-furnace route, are eliminated Ability to use low cost raw material like ore fines and coal means

lower capital cost and production costs than the conventional BOFprocess

Reduction of pollution, producing significantly less sulphur andnitrogen oxide than current furnaces are the major environmentalbenefits of the technology commercialized by POSCO in 2007

FINEX Technology Kobes ITMK3 Technology

Used for smelting iron ore fines using non-coking coal to producepremium grade iron in the form of nuggets

Rotary Hearth Furnace is the most important component in ITMK3processiron ore is reduced and smelted using pulverized coal

The process of iron making through ITMK3 technology is simpler andenergy efficient when compared with blast furnace route

Sinter/Pellet Plant and coke oven plant is avoided in this processmaking it less capital intensive and also saving on energy

Other Options for Energy Efficiency in the


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p gy y

Iron and Steel Industry

Blast Furnace Route

e.g. use of Coal Dust instead of cokee.g. use of scrap

Top Gas Recycling Blast Furnace

CO2

CO

CO,CO2

BlastFurnace

GasSeparationPlant

Casting -The Castrip Process

From liquid steel to coil in just one step

Iron & Steel Market Comparison : EU & India


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Iron & Steel Market Comparison : EU & India

Crude steel production in EU for 2011 stands at 176Million tonnes,

BOF is the dominant technology used in steel manufacturing in EU

Netherlands, UK, Germany and France use Integrated route to

produce crude steel

Currently energy consumption for BOF in EU is in the range of 17

and 23 GJ/t of hot-rolled product.21GJ/t is the average value in EU

EAF or :Recycling route is a much less energy intensive process

when compared with BOF process

Currently energy consumption for EAF in EU is in the range of 3.5-4.5

GJ/t of hot-rolled product, 4.5GJ/t is the average value in EU

About 50% decrease in EUs energy consumption in steel industry

over the last four decades is due to increase in the adoption of

recycling route at the expense of the integrated route - share

increased from 20% in 1970s to 40% in 2010

Increasing recycling rate from the current 60% level is the possible

near term energy saving method in steel production.. Waste gas

recovery, improved process control are some of the efficient ways

utilized in EU

Key technology players are ThyssenKrupp, Siemens VAI, SMSSiemag, Akers, Paul Wurth

Indian Iron & Steel Industry is the largest energy consuming industry

Consumes about 10% electricity and 27% coal

Energy cost are about 30-35% of total production cost

National Mission for Enhanced Energy Efficiency & National

Environmental Policy promoting EE in Steel sector

High energy consumption is due to

Use of out dated technology in older plants

High alumina and high alumina & silica ratio in iron ore

Energy Efficient technology opportunity in Indian Steel industry:

Coke Making: Coke Dry Quenching, Automatic Combustion control Sinter Making: Waste heat recovery, Multi-Slit Burners

Iron Making: Stove waste heat recovery, Coal Dust Injection, Bled

BF Gas Recovery

Steel Making: Bled BOF gas Recovery

Casting: Continuous casting, Thin Slab casting

FINEX technology, energy efficient and eco-friendly technology, to be

utilized by POSCO for its proposed 12 MTPA green field integrated

steel project in Orissa (India) Iron making through BOF route accounts for nearly 70% of total energy

consumed by this sector

Key players are A R Group of Industries, SMS India Pvt. Ltd.

Latest Technologies have higher penetration among the Tier I Iron & Steel plants in India but among the Tier II plants,Technological performance is considerably lower than existing international standards - Due to the inefficient use of technology,

obsolete technology, and incompatibility of Indian input materials with imported technology



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Energy Consumption in Milli on Gcal/year

2011-12 2019-20

SEC

Scenario

(Gcal/tcs)

6.5 4.5 PotentialLoss

6.4 4.5 PotentialLoss

NSP 2005 438.6 301.5 137.1 706.3 495.0 211.3

WGS 2006 523.7 360.0 163.7

IMG 2007 654.7 450.0 204.7 1284.2 900 384.2

Energy savings potential in Iron and Steel Industries in India

It is estimated that over 50% of the energy

currently used in integrated steel plants in

India is lost as exhaust and by-product

gases, which could be used for electricity

generation or low-heat steam production

BlastFurnace

Up-grading of plants

Control systems, reducing agents etc.

Pilot project: Co-processing of plastic waste e.g. Tata Steel, SAIL

DirectReduction

Focus on coal based DRI plants/companies Revamping, i.e. coal gasification (Syngas)

Electric InductionFurnaces

Efficiency improvement of furnaces

Re-rollingMills

Efficiency improvement of furnaces (walking beam furnaces)

Fuel: Substitution of coal by coal gasification biogas

Industry sectors/ process routes Opportunity Areas

Energy Efficiency_ Iron & Steel Industry:


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gy y_ y

India

Iron & Steel Technolog ies

Sintering, Coke maing, Finex, Kobes ITMK arethe key energy efficient cement technologies

Indian Iron & Steel Industry is the largest energy consuming industry, Consuming about 10% electricity and27% coal

Delhi

Orissa

Uttar Pradesh

West Bengal

Andhra Pradesh

Madhya Pradesh

Major players of iron &steeltechnologies:

AR Group SMS India

Energy efficiency _ Iron & Steel Industry :


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Crude steel production in EU for 2011 stands at 176Million tonnes, BOF is the dominant technology used in steelmanufacturing in EU

Currently energy consumption for BOF in EU is in the range of 17 and 23 GJ/t of hot-rolled product

gy y y

European Union

FranceGermany

UK

Netherlands

Iron & Steel

Technologies

Netherlands, UK, Germanyand France use Integratedroute to produce crude steel

R&D I iti ti


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R&D Initiatives

The ULCOS (UltraLow Carbon dioxide Steel making) project is the flagship of the industry to obtain a decrease of over

50 % of CO2emissions in the long term. The first phase of ULCOS had a budget of EUR 75 million. As a result of this firstphase, four main processes have been earmarked for further development

Top gas recycling blast furnace

is based on the separation of the

off -gases so that the usefulcomponents can be recycled

back into the furnace and used

as a reducing agent and in the

injection of oxygen instead of

preheated air to ease the CO2

capture and storage (CCS)

Implementation of the Top gas

recycling blast furnace with CCS

will cost about EUR 590 millionfor an industrial demonstrator

producing 1.2 Mt hot metal per

year

Tentative timeline to complete

the demonstration programme is

about 10 years, allowing further

market roll-out post-2020

The HIsarna technology

combines preheating of coal and

partial pyrolysis in a reactor, amelting cyclone for ore melting

and a smelter vessel for final ore

reduction and iron production

The market roll-out is foreseen

for 2030. Combined with CCS,

the potential reduction of CO2

emissions of this process is 70-

80 %

A pilot plant (8 t/h without CCS)is being commissioned during

2011 in Ijmuiden, Netherlands

The ULCORED (advanced

Direct Reduction with CCS)

direct-reduced iron is producedfrom the direct reduction of iron

ore by a reducing gas produced

from natural gas. The reduced

iron is in solid state and will

need an electric arc furnace for

melting the iron

An experimental pilot plant is

planned in Sweden, with market

rollout foreseen for 2030. Thepotential reduction of CO2

emissions from this process is

70-80 %

ULCOWIN and ULCOSYS

are electrolysis processes to

be tested on a laboratoryscale. There is a clear need

to support this ULCOS

research effort with a high

share of public funds, and to

lead the global framework

market towards conditions

that ease the prospective

deployment of these

breakthrough technologies

Source : SETIS
http://setis.ec.europa.eu/newsroom/library/technology-map-chapters/energy-efficiency-and-carbon-dioxide-emission-reduction-in-the-iron-and-steel-industryhttp://setis.ec.europa.eu/newsroom/library/technology-map-chapters/energy-efficiency-and-carbon-dioxide-emission-reduction-in-the-iron-and-steel-industry


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ALUMINIUM

Energy efficiency in Aluminum Industry


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Energy efficiency in Aluminum Industry

Product Manufacture

Semi Fabrication Smelting Aluminum Production process

Final products

For Transportations Energy Supply systems Housing Others

Use phase

Recycling

Recycling

5 %

energy

consumption

Recycle Process

Save 95%of energy consumption

Bauxite Mining Alumina Production

Production Process (100% of energy consumption)

Refining

Bayer Process4-5 Tonnes 2 Tonnes 1Tonnes

Smelting

Hall Heroult ProcessProduction

Electrolysis

Energy efficient process

Pre - Baked Technology

Soderberg Technology

The Pre-baked technology usesmultiple anodes in each cell

Energy efficiency is relatively high Electricity consumption ranging

between 1316.5 MWh / t Smelting process is energy incentive process in the Aluminium

Production The aluminium industry constantly focuses on the efficient use of

energy. There is no energy alternative for the sector to electricity,which represents a large part of aluminium production costs

Recycled aluminium saving up to 95% of the energy

AluminumProduction

process

Energy Efficiency Technology : Aluminum


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Manufacturing

Aluminum production: energy usage (per tonne aluminum) by section

Prebake Technology

In the prebake cells, the pots use multiple anodes

that are formed and baked prior to consumption in

the pots

Prebake technology has essentially two variantsbased on how alumina is fed to the cell, i.e. where

the pot working (crust breaking and alumina

addition) takes place

Centre Worked Prebake (CWPB)

Side Worked Prebake (SWPB)

Sderberg Technology

Sderberg cells use a single, monolithic, carbon anode

that is added as paste and baked in the cell itself through

the heat arising from the molten bath

Sderberg technology has two variants Vertical Stud Sderberg (VSS)

Horizontal Stud Sderberg (HSS)

In a VSS cell, the electrical connectors or studs are

placed vertically into the top of the anode, while in an

HSS cell, it is placed horizontally into the anode along

the longitudinal length on both sides of the cell

AluminaRefining, 14%

SecondaryProduction, 4%

PrimaryProduction, 82%

, 0

AnodeProduction,

2%

Smelting,93%

Casting ,5%

, 0

Other Technology Development of the Industry


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Other Technology Development of the Industry

Status of the currently prevailing technologies of the industry are well developed and widely accepted

While efficiency has been improving continuously, especially in primary aluminium production, there has been no technological

revolution in the past decades

Key technology developmentsOptions to impr ove the Bayer process

Bayer process is the prevalent technology

for converting bauxite to alumina

Two main options currently available to

increase energy efficiency are calcinations

with fluidized bed kilns replacing the rotary

kilns, and the application of cogeneration

First option allows both a more desirable

grade of alumina and a reduction of fuel

demand by two-thirds

Second option could save 15% of the

primary fuel consumption of the plant

Options to improve the primary electrolysis process

The point-feeding system with computercontrol

Conversion to the state-of-the-art PFPB

technology is the most accepted route for

increasing operational and environmental

efficiency for both CWPB and SWPB

Reduction can be achieved from 10 to 30%

depending on the starting technology and cell

design

Optimization of the electrolysis process

Potential improvement of the existing cell

performance includes several measures, e.g.

the composition of chemical bath, carbon

anode design, cell pot material, etc.

Optimization of the process has been

ongoing since the beginning of the industry.

The potential energy intensity reduction is

between 15 and 30%

Advanced technologies

Lower the electrolysis t emperature

(PBRTE) Several approaches for temperature reduction

have been investigated and the promisingresults come from new additives forelectrolyte

Theoretically, a reduction of temperature toaround melting point could decreaseelectricity use by 1-1,5 kWh/kg

Drained-cell technology

(wettable cathode) Involves the development of an inert titanium diboride (TiB2) cathode allowing the

cell design in ways that the molten aluminium

can be drained from the cathode to collection

sites in the cell, enabling the cell operation at

a much reduced interelectrolyte distance

Potential energy savings are estimated to beas high as 15-20%

Alloy separati on with laser/x -ray

Laser-induced breakdown spectroscopy

(LIBS) technique is an adaptation of the

optical emission spectroscopy chemical

analysis technique tested currently for

aluminium alloys separation

Aluminum Market Comparison : EU & India


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Europe is the world centre for primary aluminium technology

and research and development into secondary applications Currently, about 25% of the worlds aluminium production

takes place in Europe (including Russia) and more than 10%

in EU Member States. Netherlands, UK, Germany and France

use Integrated route to produce crude steel

Hall Hroult electrolysis process is a mature technology, but

improvements in its productivity and environmental

performance are still possible. The difference in efficiency

between the best and worst plants is approximately 20% andcan be attributed to different cell types and to the size of the

smelters, which is generally related to the age of the plants

Norway, which has considerable hydroelectric resources,

hosts seven aluminum smelters. Today, more than one-half of

the electricity used in primary aluminum production comes

from hydropower

Key Players are SMS Group, Erbslh Aluminium GmbH,

Outotec

Bayer-Hall-Heroult technology used by all producers

Plants have set internal target of 1-2% reduction in specificenergy consumption in the next 5 -8 years

Nearly 80% of India aluminum sector is already using pre-

baked anode system smelting technology the remaining 20%

Soderberg anode system

In India with aluminium smelting technology, the plants are

very favorably both with global best and prevalent practices,

but two aspects which are need to addressed are the

inefficiency of power production from coal-fired plants andhigh fuel consumption in alumina production

The old Soderberg anode system need be converted to

PFPB anode systems between 2015 and 2020

A long term decline in the real price of Aluminium will erode

margins of the firms manufacturing primary aluminium

More attentiveness on recycled aluminium

Key players are AP technology, Calderys,Apollo Heat

Exchangers, Minex Metallurgical

Aluminum Market Comparison : EU & India

Avg. energy consumption of 14,557 kWh/MT in the Indian plants is favorable when compared to a global avg. of 15,936kWh/MT(2008) - In terms of efficient smelter technologies 65% of Indias production are among the best in the world

Technologies adopted both in India and EU are same but they differ in energy efficiency as some of the units are still usingself-baking anodes instead of multiple prebaked anodes



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Replacing old smelter technologies with

modern pre-baked cells

Developing process controls that

Optimize cell-operating conditions

Saving electricity in auxiliary technology

such as compressors and fans

Indiacould save a significant amount of energy in the aluminium sector by applying BATs

Primary production process is relatively energy efficient, about two-thirds of these savings, 338 thousands of tonnes of

oil equivalent (ktoe), could come from improving the efficiency of the refineries

Overall, the savings would amount to 507 ktoe or about 18% of the total energy consumed by the sector in 2007

Introducing wetted drained cathodes

and inert anodes more widely from

2020 and reducing carbothermic

technologies from 2030 could reduce

the average electricity intensity of

smelting in 2050 to 10.9 MWh / t

primary aluminium

Major Opportunity Areas

Energy Efficiency Aluminium Industry: India


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Energy Efficiency_ Aluminium Industry: India

Aluminium Technologies

Nearly 80% of India aluminum sector is already using prebaked anode system smelting technology theremaining 20% Soderberg anode system

Bayer-Hall-Heroult technology used by all producers

Maharashtra

Uttar Pradesh

Orissa

Pre-bake and Soderberg are the key energyefficient Aluminium technologies

Chattisgarh

Major players of Aluminiumtechnologies:

AP Technologies Calderys Apollo Heat Exchangers Minex Metallurgical

Energy Efficiency_ Aluminium Industry:

E U i


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Europe is the world centre for primary aluminium technology and research and development into secondaryapplications

Hall Hroult electrolysis process is a mature technology

European Union

Aluminium

Technologies

Russia

FranceGermany

NetherlandsUK

Currently, about 25% of the worlds

Aluminium production takes place

in Europe (including Russia) and

more than 10% in EU Member

States. Netherlands, UK, Germany

and France use Integrated route to

produce crude steel

Norway, which has considerable

hydroelectric resources, hosts

seven aluminum smelters

Norway

R&D Init iatives


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R&D Init iatives

Project Objective Cost Start Date Duration

ENEXAL

Novel Technologies

for enhanced energy

and energy

efficiencies in primaryaluminium production

industry

8,456,398 01/Jun/2010 4 years

Research on following technologies

High temperature carbothermic reduction of

alumina in an electric arc furnace (EAF)

Moderate temperature carbothermic

reduction of alumina in a novel solar furnace

The red mud treatment in an innovative EAF


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DLTA Complex, South Block, 1st Floor

1, Africa Avenue, New Delhi 110 029, INDIA

Tel: +91 11 3352 1500

Fax: +91 11 3352 1501

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www.ebtc.eu

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