NET ZERO Ambition of Cement Sector and role of NEPRA's efforts aiding the journey to towards its ambition.

NEPRA’s efforts towards combating the global climate crisis with Alternative Fuel Resource (AFR) contributing to the Cement Sector’s Net Zero AmbitionToday the average global temperature on Earth is 1.1?C warmer than it was in the late 19th century. 2023 is set to be recorded as the warmest year by the World

Meteorological Organization (WMO). Nations grappling with climate change are making efforts to limit the warming to 1.5?C above. ?

India is committed to transitioning to a low-carbon economy. The COP28 summit held in Dubai, in December 2023 focused on phasing out the use of fossil fuels in different activities.

There will always be Waste as long as Mankind Exists

In the light of managing the global earth’s temperature, waste management is a critical aspect being looked at under a magnifying lens. The global discussions at COP28 also discussed the role of circular economy and plastic waste management in tackling climate change. Waste is growing with the ever-increasing population and urbanization. Ill-managed waste is becoming a pressing global concern. On one hand, waste decomposition in unscientific landfills is adding to the release of methane and carbon dioxide, on the other open burning is contributing to the rising Green Hose Gas Emissions. Thus, efficient waste management and its best practices bring in opportunities to mitigate GHG emissions. By ensuring recycling for recyclables, the dependence on virgin material is reduced. On the other hand, by using non-recyclables as a source of energy, the use of fossil fuels is reduced. While efficient recycling channels are today in place, and there is a rise in the creation of value chains for different recyclable waste streams, non-recyclable waste, and its efficient sustainable disposal are of concern.

Indian cities produce 68.8 million tons of waste every year. It is further estimated that ~19% of it can be recovered as an Alternate Fuel Resource (AFR).? Alternative fuels are those that can replace conventional fossil fuels. Refuse-derived fuel (RDF) is one potential AFR derived from solid waste. The major challenge in its utilization for co-processing is its quality that can match the requirements of cement plants in terms of appropriate moisture content, calorific value, and composition- both physical and chemical. Addressing this challenge, highlights the crucial role of Material Recovery Facilities (MRFs), ensuring nth level segregation and processing of waste, in turn improving the levels of co-processing in cement plants, enhancing fossil fuel replacement, and reducing emissions.

Challenges in Use of RDF as AFR

India is the second largest cement manufacturer after China in the world and targets a Thermal Substitution Rate (TSR)* of 25% by 2030. The eminent factor attributed to the achievement of the same is the presence of waste segregation and pre-processing facilities, supplying the right type of waste required. However, challenges persist, such as lower net calorific value, non-homogenous & and non-shredded material, high moisture content present in the waste, offensive odour not ideal for co-processing, and contaminated waste with chlorinated compounds. Therefore, to achieve the targeted TSR, it is critical to create a sustainable supply chain for cement plants.

*TSR: Proportionate heat substitution of traditional fossil fuels by using alternative fuels such as waste and biomass.

NEPRA’s Role

NEPRA started its journey in 2011 with its immediate focus on organizing the highly unorganized waste sector. It developed an inclusive model collaborating with all formal and informal stakeholders and introducing technology and innovation in its operations to achieve the scale of impact. After its first successful project in Ahmedabad, Gujarat of a 100MT Material Recovery Facility (MRF), it went ahead to setup India’s largest and first-ever Automated MRF in Indore, Madhya Pradesh, with a capacity of handling 300TPD of dry waste. There has been no stopping since then, with today NEPRA boasting of five owned facilities of 700+TPD capacity and several controlled facilities for industries. NEPRA’s ambition strives to further its efforts and convert waste into valuable resources at a scale that reinforces the dreams of Zero Waste to Landfill Nation, which is NEPRA’s motto and recognizes the sector’s eminent role in ?meeting global targets of GHG emission mitigation.

A holistic circular economy approach is great in enabling GHG mitigation across different sectors. High-value waste (recyclable plastic, paper, wood, metal, etc.) easily finds its way through formal and informal routes into the recycling chain. The concern is the waste that gets left which is of low value and is commercially non-recyclable. Since its first MRF was installed in Ahmedabad, NEPRA continuously worked to ensure “Zero Waste to Landfill”.? In its journey to achieve the same, there were two challenges to resolve focusing on non-recyclables- one, lack of value chain for low-value waste and second, management of its demand and supply. NEPRA realized the potential of waste as a resource and understood that the energy of waste that can be harnessed from waste must not be wasted in landfills. For the same, it established processes to improve the calorific value (CV) value of waste, tied up with several cement plants, and started diverting waste as alternate fuel where the net calorific value ranged between 2500Kcal/kg to 2800Kcal/kg.

AFR presents itself as a great opportunity for cement plants to become environmentally conscious as they are associated with a higher carbon footprint and by using RDF as AFR replacing coal, cement plants can reduce it. ??Given the same, Cement Plants are seeking means to increase their thermal substitution rate (TSR) and reduce dependency on coal. NEPRA has been consistent in its efforts to help cement plant meet their TSR. It has installed automated shredders to ensure a consistent supply of high-quality AFR. Moreover, to maintain the moisture levels in the AFR, efficient sorting is ensured with maximum recovery of dry waste at the MRFs using AI and SCADA-integrated operations. The sorted material is transported to cement plants within a 100km of radius. Certain deliveries may range up to 200km as well considering the availability of infrastructure and its capacity.

NEPRA monitors its emissions to identify the GHG mitigation and gives a clear sustainable picture of its role in emission mitigation through dedicated diversion of wastes from landfills by following its Zero Waste to Landfill model.

With its ESG purpose of creating a circular and sustainable economy, NEPRA shall continuously work to achieve the vision of a Swachh Bharat and contribute to the Nation’s Net Zero Journey.

Creating Impact

Taking 2018 as the baseline, Nepra has diverted over 2.91 lakh metric tons of RDF as AFR for co-processing in cement plants since then. This diversion has resulted in GHG emission mitigation of 4.32 lakh MTCO2* due to avoided coal. In the FY of 2023, 1.37 lakh tons of RDF was sent for co-processing and the estimated emission reduction was 1.69 lakh metric tons. The GHG emissions from downstream transportation calculated is estimated at 0.08 lakh metric tons. These numbers fortify the important role of banking on AFR for solving issues of local pollution as well as contributing to climate change action at national and global levels, by reducing GHG emissions, reducing dependence on fossil fuels, reducing coal imports, improving waste management, being cost-effective, and promoting circular economy.

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Key Highlights of Environmental Impact Created with AFR Supply to Cement Plants PAN India

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*Source: TERI research; Assuming 1.48-ton CO2 emission reduction per tonne usage of RDF.

References:

Chandrashekar. K, Pandey. S: Co-processing of RDF in Cement Plants. Energy Recovery Processes from wastes.