ELECTRIFICATION OF TRUCKS FOR CEMENT SECTOR IN INDIA
Transport Scenario for Cement sector
India, a rapidly growing economy, has a robust cement industry that is a significant contributor to national economic development. As the world’s second-largest cement producer, India has an installed cement capacity of ~670 million tons per annum (MTPA).
The logistics landscape within the Indian cement sector encompasses a variety of commodities:
- Cement & Clinker: Cement about ~74-76% transported by road.
- Clinker about ~15-20% transported by road.
- Limestone: Transported from mines to the plant primarily by road, supplemented by other equipment like belt conveyors.
- Slag: A significant portion is transported by both rail and road.
- Fly Ash: Mainly transported by road.
- Coal: Primarily transported by rail.
- Other Additives: Transportation of additives such as clay, bauxite, iron ore, and red mud is predominantly by road.
Daily Truck Trips for an Integrated Cement Plant
| Particulars | Plant Capacity | Commodity | Production(TPD) | Road Share Considered | Vehicle Capacity(Tons) | No of vehicle trips involved(Nos) | Logistic type | % Share |
|---|---|---|---|---|---|---|---|---|
| Clinker | 6,000 TPD | Limestone | 9,000 | 100% | 30 | 300 | International movement | 49% |
| Cement | 10,000 TPD | Cement | 10,000 | 75% | 30 | 250 | Outbound | 41% |
| Product Portfolio (OPC-20% PPC-50% PSC-15% CC-15%) Clinker factor:0.65 | slag (@63% in PSC/30% in CC) | 1,395 | 30% | 30 | 14 | Inbound | 2% | |
| Fly ash (@33% in PPC/25% in CC) | 2,025 | 90% | 40 | 46 | Inbound | 7% | ||
| Total trips | 610 Nos | |||||||
| Total km @ avg 60km/trip | 36,571 km | |||||||
| Diesel consumption @ 2.5 kmpl | 14,628 Ltrs | |||||||
| Co2 emission / day | 39,240 kg CO2 | |||||||
Considering India's total cement and clinker production, alongside a road transport scenario where 75% of transportation is using internal combustion engine (ICE) trucks, the estimated CO2 emissions are considerably significant, amounting to approximately 2.3 Million tons per annum (for cement and clinker transport only)
Emission scenario for ICE truck in cement sector transport:
| Particulars | Million Tons | Particulars | Unit | |
|---|---|---|---|---|
| Cement Production | 374.5 | Mileage | 2.5 | kmpl |
| Cement transported through road (considering 75% road share) | 281.2 | Diesel/km | 0.4 | Ltr |
| Clinker production (@ 65% clinker factor) | 243.8 | Tailpipe emission | 1.07 | kg CO2 |
| Clinker export / transport (considering 50% of total production) | 121.8 | One-way average distance | 100 | km |
| Clinker transported through road (considering 75% road share) | 91.4 | Total distance covered | 200 | km |
| Total material (cement + clinker) transported through road | 372.7 | Total CO2 | 214.4 | kg |
| CO2 emission | Pay load | 35 | MT | |
| With 100% ICE vehicleWith 100% ICE vehicle | 2.3 | CO2 emission | 6.1 | kg/ton |
| Reduction With 5% E Truck | 0.11 | |||
| Reduction With 10% E Truck | 0.23 | |||
| Reduction With 20% E Truck | 0.46 |