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Name of the project:

Techno-Economic Feasibility of Alternative Fuels for partial replacement of coal in Zuari Cement Plant

Program Area:

E&E

Country:

India

Project Length:

November 2007 – February 2008

Sponsor:

Zuari Cement Limited

Contact:

sobhan@winrockindia.org

 

Background

Zuari Cement Limited (ZCL) had engaged the services of Winrock International India (WII) to study the feasibility of alternative fuels for its Erraguntla plant in Kadapa district of Andhra Pradesh and to recommend suitable alternative fuel options. The ZCL’s Erraguntla plant had an installed capacity of 5,000 tons of clinker per day and produces 43 OPC, 53 OPC & PPC grade cement. It consumed around 700 tons of coal per day out of which 420 tons is consumed in the Calciner alone.
 

Objectives
The objective of the study was to identify and recommend suitable alternative fuel options such as industrial wastes, MSW, and biomass for partial replacement of coal in ZCL’s Erraguntla cement plant in Andhra Pradesh.
 

Activities
 
  • WII conducted literature search and documented international experiences and success stories on alternative fuels in cement plants. Literature search and interviews were conducted with Indian cement companies on alternative fuels usage in Indian companies and the lessons learnt.
  • WII identified a range of potential alternative fuels (industrial wastes, waste products, municipal solid waste, crop residues, and agro industrial residues) suitable for ZCL’s Erraguntla plant and collated information on physical properties, chemical composition, and calorific value of the identified fuel sources; WII conducted resource assessment study for the identified options covering generation, consumption, and availability, price, current markets, and transportation issues.
  • Conducted techno-economic feasibility study for various alternative fuel options and recommended fuel options for blending in cement kilns for ZCL.
 

Achievements

The final report on “Feasibility of Alternative fuels in Cement Plants” to ZCL was submitted to ZCL. The report has been divided into two parts, Part I & Part II.

 

Part I:
  • International Experiences outlines the alternative fuel case studies and experiences in Europe, USA, Canada, Latin America, Australia and Asia.
  • The Indian experience and status of the use of alternative fuels in Indian cement industry.
 

Part II:
  • An overview of Zuari Cement Limited-Erraguntla Plant.
  • Feasibility of various alternative fuel options for Erraguntla Plant.
  • The proposed waste derived fuel (WDF) facility for ZCL’s Erraguntla Plant.

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