ENERGY TRANSITION IN CEMENT INDUSTRY'S POWER PLANT

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1.

INTRODUCTION

1.1   WHAT IS CEMENT

1.2   CEMENT INDUSTRY: A GLOBAL OVERVIEW

1.3   CEMENT INDUSTRY: AN INDIAN PERSPECTIVE

• • • Historical development
• Growth drivers for cement in India

1.4          CEMENT MANUFACTURING PROCESS

• • • Cement to concrete
    • Types of cement
    • Characteristics of cement
• Grade of cement

1.5   INDIAN CEMENT INDUSTRY ANALYSIS

• • • Market size
    • Investments
    • Government initiatives
• Road ahead

1.6   EMISSIONS IN THE CEMENT INDUSTRY

1.7   IMPACT OF CLIMATE CHANGE POLICY ON THE CEMENT INDUSTRY

1.8   COVID-19 PANDEMIC’S IMPACT ON THE SECTOR

• Going for ward

1.9   CONCLUDING REMARKS

1.10 OBJECTIVES OF THE STUDY

2.

REVIEW OF LITERATURE

2.1   RESEARCH PAPERS AND RESEARCH GAPS

2.2   CONCLUDING REMARKS

3.

RESEARCH METHODOLOGY

3.1   OVERVIEW

3.2   STATEMENT OF THE RESEARCH PROBLEM AND RATIONALE

3.3   RESEARCH DESIGN

3.4   SAMPLING DESIGN

• Population
• Sampling frame

• Sampling method and sample size

3.5   TYPES OF DATA USED

3.6   DESIGNING OF TOOLS FOR DATA COLLECTION

• Questionnaire design

3.7   DATA ANALYSIS METHOD

3.8   VARIABLES AND SCALE OF THE STUDY

• Reliability Testing of Scale based primary Data
• Interpretation

3.9   HYPOTHESIS

3.10 LIMITATIONS OF THE STUDY

3.11 CONCLUDING REMARKS

4.

RESULTS AND DISCUSSION 

4.1   OVERVIEW

4.2   DATA ANALYSIS AND INTERPRETATION

• The analysis of demographic data
• Gender wise distribution of respondents
• Age wise distribution of respondents
• Techno- commercial education wise distribution of respondents
• Techno-commercial profession wise distribution of respondents

4.3   THE ANALYSIS OF THE DATA ON PLANT AGE, STRUCTURE, SIZE, AND CAPACITY

• Plant age wise distribution of respondents
• Size of the power plants
• Installed capacity of the captive power plants (cpp)
• Type of fuel utilised in the power plants
• Daily fuel requirement of the power plants

4.4    THE ANALYSIS OF THE DATA COLLECTED ON THE TECHNICAL ISSUES CONCERNING THE UTILIZATION OF COAL AS FUEL IN CEMENT POWER PLANTS

• Respondents’ level of agreement whether calorific value of coal is less than natural gas
• Respondents’ level of agreement whether stoichiometric air requirements of natural gas are greater than coal
• Respondents’ level of agreement whether natural gas mixes with the air and burns more quickly as compared to coal
• Respondents’ level of agreement whether an increase in clinker production can be achieved by firing natural gas as compared to coal
• Respondents’ level of agreement whether coal-based production leaves behind ash that requires disposal
• Respondents’ level of agreement whether significant amount of water is needed to remove the impurities in coal-based production
• Respondents’ level of agreement whether emission of co2, so2, nox, and mercury compounds in coal-based production is higher
• Respondents’ level of agreement whether coal contains minor amounts of radioactive elements, namely ur and th. When coal is burnt, the fly ash contains ur and th at up to 10 times their original levels
• Respondents’ level of agreement whether coal-based captive power plants require heavy machinery and maintenance along with technical expertise
• Respondents’ level of agreement whether coal-based captive power plants require more water to get rid of impurities

4.5   THE ANALYSIS OF THE DATA COLLECTED ON THE COST ISSUES ASSOCIATED WITH THE UTILIZATION OF COAL AS FUEL IN CEMENT POWER PLANTS

• Respondents’ level of agreement whether continuous volatility in fuel prices in international markets, a probable ban on the usage of petroleum coke, and the uncertainty over the availability of domestic and linkage coal continue to pose challenges for the cement industry
• Respondents’ level of agreement whether power and fuel costs in the cement industry account for more than 50% of the total cost of production and around 20% of the total revenue
• Respondents’ level of agreement whether elimination of coal grinding can save electric power/ton cement if natural gas is used
• Respondents’ level of agreement whether in addition to the potential for higher clinker production and the falling price of natural gas energy, further benefits of firing natural gas are the savings on handling costs
• Respondents’ level of agreement whether cost of environmental damages from coal plants is higher as compared to natural gas-based plants
• Respondents’ level of agreement whether higher capital cost adjustment for size and time is required to shift captive power plants based on natural gas

4.6    THE ANALYSIS OF THE DATA COLLECTED ON THE ENVIRONMENTAL AND REGULATORY ISSUES SURROUNDING THE UTILIZATION OF COAL AS FUEL IN CEMENT POWER PLANTS

• Respondents’ level of agreement whether coal fuel contains sulphur and when it mixes with air, it makes a toxic substance that is responsible for causing pollution in many lakes and rivers
• Respondents’ level of agreement whether air pollution from coal-based power plants is linked with asthma, cancer, heart and lung ailments, neurological problems, acid rain, global warming, and other severe environmental and public health hazards
• Respondents’ level of agreement whether lakes, rivers, streams, and drinking water supplies are all heavily impacted by coal-based power plants in Rajasthan
• Respondents’ level of agreement whether wildlife activity in Rajasthan is changing dangerously as conditions become hotter and drier due to climate change
• Respondents’ level of agreement whether coal combustion produces more greenhouse gases than the combustion of any other fossil fuel, consequently adversely affecting the environment

4.7   THE ANALYSIS OF THE DATA COLLECTED ON THE SUPPLY AND LOGISTICS ISSUES SURROUNDING THE UTILIZATION OF COAL AS FUEL IN CEMENT POWER PLANTS

• Respondents’ level of agreement whether lack of adequate supply of coal within the time frame of your cement plant is a challenge
• Respondents’ level of agreement whether stocking coal is always a challenge since coal mines are too distant from the captive power plants
• Respondents’ level of agreement whether inbound and outbound logistics and logistics planning is difficult in case of coal-based captive power plants

4.8    THE ANALYSIS OF THE DATA COLLECTED ON SEVERAL EMERGING ISSUES SURROUNDING THE UTILIZATION OF COAL AS FUEL IN CEMENT POWER PLANTS

• Respondents’ level of agreement whether coal-based plants emit not only carbon dioxide but also several other toxins that have an immediate and direct impact on people’s health, including Hg
• Respondents’ level of agreement whether avoiding burning coal would save hundreds of million dollars every year in healthcare costs by avoiding illnesses caused by pollutants, including asthma attacks, heart attacks, and deaths linked to the coal-based power plants' emissions
• Respondents’ level of agreement whether proximity to suppliers of coal and markets is a challenge and affects sales volume and price per unit
• Respondents’ level of agreement whether maintaining the quality standards of coal during the supply throughout the year is a challenge
• Respondents’ level of agreement whether capacity utilization and increasing plant capacity both are more feasible for natural gas-based power plants as compared to coal-based power plants
• Respondents’ level of agreement whether group captive power plants based on coal, solar, and wind energy are operational in large numbers in the cement industry of Rajasthan. The concept was evolved by the industry to avoid the cross-subsidy charges levied on the inter-state sale of electricity and is seen as a threat to state discoms

4.9   THE ANALYSIS OF THE DESCRIPTIVE STATISTICS OF THE STUDY

4.10 NORMALITY TEST

4.11 RELIABILITY TEST

4.12 HYPOTHESIS TESTING

4.13 MEAN BASED COMPARISON

• Mean Based Comparison for various issues related to uses of coal as a fuel in captive power plant in cement industry on the basis of plant size
• Mean Based Comparison for various issues related to uses of coal as a fuel in captive power plant in cement industry on the basis of Installed capacity of the plant
• Mean Based Comparison for various issues related to uses of coal as a fuel in captive power plant in cement industry on the basis of Capital power plant Age

4.14 ANALYSIS ON CASE BASED STUDY: NATURAL GAS AS CLEAN FUEL IN COMPARISON OF COAL: EVIDENCE FROM FOREIGN NATIONS

• Overview
• Evidence from north america
• Evidences from nigeria
• Evidences from japan
• Evidences from India

4.15 COAL AS FUEL IN CEMENT INDUSTRY IN INDIA

4.16 CONCLUDING REMARKS

5.

SUMMARY AND CONCLUSION 

5.1   FINDINGS OF THE STUDY

5.2   FINDINGS OF CASE STUDY

5.3   HYPOTHESIS TESTING RESULT

5.4   RECOMMENDATION FOR THE STUDY

5.5   SCOPE FOR FUTURE STUDIES

5.6   CONCLUSION

BIBLIOGRAPHY