Green cement: Indian producer opens 6MW rice husk fueled biomass plant

Indian cement producer Barak Valley Cements, announced its 6MW biomass-based thermal power plant is ready to be taken into operation to reduce carbon emissions and to ensure secure supplies of reliable energy. The bioenergy project, developed by its subsidiary Badarpur Energy Private Limited, will provide all the power for cement production and clinkerisation at Barak's cement plant in Badarpurghat, in India's Assam state.

Cement production, a highly energy intensive process, is one of the key contributers to climate change with 5% of all anthropogenic CO2 emissions coming from this sector. According to the IEA, the non-metallic mineral sub-sector accounts for about 9% of global industrial energy use, of which 70 to 80% is used in cement production. CO2 is emitted from the calcination process of limestone, from the combustion of fuels in the kiln, as well as from power generated within the industry. India's cement industry alone releases around 89 million tonnes of CO2 per year, roughly 5 per cent of the country's total. Per ton of cement produced, around 0.9 tons of CO2 get released, putting India amongst the most carbon intensive producers (compare with the carbon intensity of Japan's and Europe's cement sector: 0.45 tons of CO2 per ton.)

A Report of the Working Group on the Cement Industry, commissioned by India's Planning Commission, suggested a reduction of CO2 emission levels in the next five years to about 80 million tons while output is growing (that is, reducing CO2 emissions to 0.5/tons per ton of cement) by adopting a range measures such as the increased production of blended cements, optimising the pyro-processing system, recovering waste heat for cogeneration of power, increasing the use of marginal grade limestone and switching to green fuels.

With increased energy prices, switching to renewable fuels like biomass has become a cost-effective way to cut the sector's emissions. Barak Valley Cements is choosing this option, using rice husks as a fuel in the biomass power plant, a major by-product of the rice industry in which Assam takes a leading place. The average cost of power is estimated to be about Rs 2.20 (€0.038 / $0.056) per kWh, highly competitive with fossil based electricity for industrial consumers.

The power generated by this plant will meet the entire energy requirement of the cement production facility and contribute towards conservation of fossil-fuels. The multi-fuel, environment-friendly power plant will be the first of its kind in the North-East of India.

The project in particular helps Barak Valley Cements solve its problems related to increasing power cost, frequent power cuts, variations in voltage and lack of energy at times of peaks in demand for cement products. Its access to quality power at cheaper rates puts it at an advantageous position vis-à-vis its competitors:
energy :: sustainability :: biomass :: bioenergy :: biofuels :: rice husks :: cement :: greenhouse gas emissions :: Assam :: India ::

Badarpur Energy Private Limited was as a Private Limited Company in February ’2005. Barak Valley Cements Limited has acquired the 100% stake of this company in the financial year 2005-06. The 6MW biomass power plant had a total project cost of Rs 25 crore (€434,000/$638,000). Power generated in the plant will be transmitted through a dedicated transmission line to Barak's operating plant and its subsidiary’s plant Cement International Limited. The power project has been appraised by NEDFi (North Eastern Development and Financial Institution).

The North East Industrial and Investment Promotion Policy (NEIIPP), 2007 announced by the Government of India, provided for a capital investment subsidy at 30% of the investment made in the plant and machinery.

BEPL's biomass plant has locational advantages resulting in the smooth production of power. The project is located on the national highway connecting Guwahati and Silchar due to which it has following locational advantages: access to a well-developed paddy growing area which will provide rice straw/husk, which can support 6MW power generation capacity; a railway station being only 2.5km away, which allows efficient transportation of the biomass and the presence of the River Barak, 1.5 km from the project site, which will act as source of water throughout the year.


Barak Valley Cement is a manufacturer of cements of different grades starting production in 2001 with a 300 ton per day capacity. The plant was upgraded an now produces 460 tons. The technology Barak uses in manufacturing our product is the Dry Process Rotary Kiln Technology with 4 stage Suspension Pre Heater technology.

The company is located in Assam and all the operations of the company are concentrated in the North Eastern region, where demand for cement is high. Its operations include raw material procurement, crushing, blending, grinding and packaging of cement. The company's product portfolio includes both Ordinary Portland Cement (OPC) and Portland Pozzolana Cement (PPC).

Picture: a view inside Barak Valey Cements' kiln in Badarpurghat. Credit: Barak Valley Cement.

References:
India PRWire: Assam cement plant's biomass power unit ready now - January 9, 2007.

Badarpur Energy Private Limited.

Indian Ministry of Commerce & Industry, Dept. of Industrial Policy & Promotion: Cement industry.

International Energy Agency: Tracking Industrial Energy Efficiency and CO2 Emissions [*.pdf], 2007 [provides an overview of the energy and carbon intensity of the global cement industry].