Acc Revised Pdd

8/3/2019 Acc Revised Pdd

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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02

CDM Executive Board page 1

This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.

CLEAN DEVELOPMENT MECHANISM

PROJECT DESIGN DOCUMENT FORM (CDM-PDD)

Version 02 - in effect as of: 1 July 2004)

CONTENTS

A. General description of project activity

B. Application of a baseline methodology

C. Duration of the project activity / Crediting period

D. Application of a monitoring methodology and plan

E. Estimation of GHG emissions by sources

F. Environmental impacts

G. Stakeholders comments

Annexes

Annex 1: Contact information on participants in the project activity

Annex 2: Information regarding public funding

Annex 3: Baseline information

Annex 4: Monitoring plan


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SECTION A. General description of project activity

A.1 Title of the project activity:

>>

ACC Blended cement projects at:

New Wadi Plant

Tikaria Cement Plant

Chanda Cement Works

Kymore Cement Works

Lakheri Cement Works

Chaibasa Cement Works

Version 7, 21/05/2010

A.2. Description of the project activity:

>>

The project activity consists of an increase in the blending of fly ash in the Suraksha brand of PPC

cement produced by The Associated Cement Company Limited (ACC). The current average percentage

blend of fly-ash in the brand is 19.5%, and the project activity will enable ACC to increase this to 30%

and above.

Suraksha is ACCs flagship blended cement brand. The average blend of fly ash in the Suraksha brand

across all ACC cement plants is 19.2%. ACC wishes to increase the blend of fly ash in PPC. However,the current level represents a plateau, and to increase the blend above this level requires significant effort

and investment and involves a number of barriers. To help overcome these barriers ACC is utilising the

CDM.

The project activity will displace clinker with fly ash in the production of PPC. This will reduce clinker

production and the associated CO2 emissions.

The project contributes to sustainable development in a number of ways. A key impact of the project

activity is environmental limestone is a finite resource, and the (open cast) mining of limestone can

have adverse environmental effects. Fly ash is a by-product of electricity generation, and is a product

for which disposal can be difficult. Replacing limestone-derived clinker with fly ash therefore providestwo benefits. Moreover, clinker production is highly energy intensive. Reducing clinker production will

therefore conserve energy and given the power shortages that are prevalent in many parts of India, will

assist Indias overall development process. Finally, the project will reduce emissions of greenhouse

gases.


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A.3. Project participants:

>>

Name of Party

involved

Private and/or public entity(ies)

project participants

(as applicable)

Kindly indicate if the Party

involved wishes to be

considered as a project

participant

India (host) Private entity: Associated Cement Companies

Ltd.

No

United Kingdom Private entity: Agrinergy Ltd. No

A.4. Technical description of the project activity:

A.4.1. Location of the project activity:

>> The projects take place at four of the cement plants owned and run by ACC. The location of each

cement plant is outlined below:

New Wadi Plant

P.O. Wadi

Pin 585 225

District Gulbarga

Karnataka

Co-ordinates: 17003N & 76

058E

Tikaria Cement Grinding and Packing Plant

Tikaria Industrial AreaP.O. Tehsil Guariganj

District Sultanpur 227 409

Uttar Pradesh


042E

Chanda Cement Works

P.O. Cementnagar

Pin 442 502

District Chandrapur

Maharashtra


006E

Kymore Cement Works

P.O. Kymore

Pin 483 880

District Katni

Madhya Pradesh


036E

A.4.1.1. Host Party(ies):

>> India


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A.4.1.2. Region/State/Province etc.:

>>

See above

A.4.1.3. City/Town/Community etc:

>>

See above

A.4.1.4. Detail of physical location, including information allowing the

unique identification of this project activity (maximum one page):

>>

The details of plant locations are outlined above. The cement plants are easily visable and uniquely

identifiable.

A.4.2. Category(ies) of project activity:

>> Manufacturing industries

A.4.3. Technology to be employed by the project activity:

>>

The cement plants undertaking the CDM project activities range in capacity from 1 million tonnes to 3.2

million tonnes.

Plant Capacity in Million tonnes per

annum

New Wadi 3.2

Tikaria 2.31

Chanda 1

Kymore 2.2

The technology involved in blending fly ash has been developed indigenously by ACC. However, the

Research and Development department of ACC has referred of a number of scientific studies that have

been carried out in Annex 1 countries on options available for increasing the blending of fly ash and on

the properties of PPC.

A.4.4. Brief explanation of how the anthropogenic emissions of anthropogenic greenhouse

gas(GHGs) by sources are to be reduced by the proposed CDM project activity, including why the

emission reductions would not occur in the absence of the proposed project activity, taking into

account national and/or sectoral policies and circumstances:

>>

The project activities consist of increasing the blending of fly ash in PPC produced at the project sites.

This will reduce clinker production and associated GHG emissions. As outlined in the methodology,

these emissions arise from the calcination of limestone, fossil kiln fuel combustion and consumption of

electrical energy.

The proposed projects will take the additive blend to a level that is not common practice and which will

require a number of barriers to be overcome. Suraksha is ACCs flagship blended cement brand, and a

considerable R&D effort has been and will continue to be made to enable the increase in fly-ash blending

associated with the project activity, whilst crucially maintaining the quality and reputation of the

Suraksha brand. At the same time, considerable marketing and educational effort must be undertaken to


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ensure that customers are aware that the quality and properties of the brand remains the same, despite the

increased fly ash content.

In the absence of the project activity, these actions would not be undertaken, and the fly ash blend ofPPC produced by the ACC cement plants would remain at the current level. Under this (baseline)

scenario, clinker production per tonne of cement and hence GHG emissions would also be higher.

A.4.4.1. Estimated amount of emission reductions over the chosen crediting period:

>>

Years Annual estimation of emission reductions in tonnes of CO2e

New Wadi Tikaria Chanda Kymore

Year 1 93,001 56,617 0 38,772

Year 2 178,538 77,701 38,372 57,766

Year 3 213,718 106,494 36,434 72,163Year 4 248,699 154,021 33,724 77,011

Year 5 238,320 144,617 30,960 72,309

Year 6 227,733 135,025 28,141 67,513

Year 7 216,934 125,242 25,266 62,621

Year 8 205,920 115,262 22,333 57,631

Year 9 194,685 105,083 19,341 52,541

Year 10 183,225 94,700 16,290 47,350

Total estimated

reductions (tonnes

of CO2e) 2,000,774 1,114,763 250,861 605,677

Total number ofcrediting years 10 10 10 10

Annual average

over the crediting

period of

estimated

reductions (tonnes

of CO2 e) 200,077 111,476 25,086 60,568

A.4.5. Public funding of the project activity:

>>The project activity has received no public funding.


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SECTION B. Application of a baseline methodology

B.1. Title and reference of the approved baseline methodology applied to the project activity:

>>

ACM0005

Consolidated Baseline Methodology for increasing the Blend in Cement Production

B.1.1. Justification of the choice of the methodology and why it is applicable to the project

activity:

>>

The methodology used has been specifically designed for project activities of this kind. In terms of the

specific applicability conditions:

There is no shortage of additives to prevent leakage related to the lack of blending materials The project activity will result in an increase in the percentage of fly ash blended in PPC

produced at the specified ACC cement plants. The ACC plants are situated in India. Fly ash

production in India is estimated at around 90 million tonnes per year, whilst annual utilisation is

estimated at 13 million tonnes1. Disposal of fly ash in India is considered an environmental

problem. We can therefore conclude that there is sufficient supply of fly ash that the project

activity will not lead other PPC producers to reduce their fly ash blend rate.

The methodology is applicable to domestically sold output of the project activity sold plant andexcludes export of blended cement types This is the case.

Adequate data are available on cement types in the market This is the case. An extensivedatabase has been obtained from the Cement Manufacturers Association of India.

B.2. Description of how the methodology is applied in the context of the project activity:

>>

Baseline Scenarios

The first element of the methodology is to identify the baseline scenario. Production of fly ash based

PPC in India is subject to the Bureau of Indian Standards specification IS: 1489 (Part 1). This specifies

that the percentage of pozzolana material (i.e. fly ash) in PPC must fall between the ranges of 15% to

35%. The current blend level varies between 16% and 27%. This is an optimum level that has been

reached based on the clinker and fly ash quality at each plant, and taking into account the views of PPC

users. These levels all fall within the range specified by IS: 1489 (Part 1) and there is no requirement or

need for these levels to be increased. The likely baseline scenario is the continuation of the current

blend level, although in Section B.3 we also evaluate the project activity as a potential baseline scenario.

In addition to the project activity and maintenance of the current blend level, other theoretically possible

baseline scenarios consist of:

A reduction in the blend level A switch to production of Ordinary Portland Cement (OPC) A switch to production of another type of cement (e.g. Portland Blast Furnace Slag Cement)

1Source: http://www.tifac.org.in/news/flymgm.htm . TIFAC is an autonomous organisation under the Indian

Department of Science and Technology


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Given the barriers to increasing the blend of fly ash in PPC, and the continued prevalence of customer

resistance to high fly-ash blended cements, there is a possibility that ACC would reduce the fly-ash

blend. However, demonstrating that this would occur is difficult. We can exclude this course of action

as doing so is a conservative assumption. A switch to OPC can also be excluded as doing so addsconservativeness. A switch to PBFS is a potential possibility. However, PBFS production is limited to

areas where there is availability of slag from steel plants. This is not the case at any of the project

activities cement plants, and this option can therefore also be ruled out.

The realistic and credible alternatives can therefore be restricted to two the existing practice of cement

production and the proposed project activity and therefore the tool for demonstration of additionality is

used to determine the most likely baseline scenario (see Section B.3.).

Baselines Emissions

The first element in the calculation of baseline emissions is the baseline benchmark share of clinker in

PPC. In line with the applied methodology this is calculated as the lowest value among the following:

(i) The average (weighted by production) mass percentage of clinker for the 5 highest blendcement brands for the relevant cement type in the region; or

(ii) The production weighted average mass percentage of clinker in the top 20% (in terms ofshare of additives) of the total production of the blended cement type in the region; or

(iii) The mass percentage of clinker in the relevant cement type produced in the proposed projectactivity plant before the implementation of the CDM project activity.

The first step is to define the relevant region for each project. As outlined in the methodology:

Definition of Regions

The Region for the benchmark calculation needs to be clearly determined and justified by projectparticipants. The default is the national market but PPs can define a geographic region as the area where

each of the following conditions are met: (i) at least 75% of project activity plants cement production is

sold (percentage of domestic sales only); (ii) includes at least 5 other plants with the required published

data; and (iii) the production in the region is at least four times the project activity plants output. Only

domestically sold output is considered and any export of cement produced by the project activity plant

are excluded in the estimation of emission reductions.

We choose not to define the region as the national market. This can be justified because India is a large

country the key elements which define the extent of additive blending (fly ash and clinker quality and

market perceptions) vary greatly within the country, and therefore the region is defined as the area that

meets the above three criteria for each project activity plant:

Cement Plant Region

Wadi New Maharashtra, Karnataka

Tikaria Madhya Pradesh, Uttar Pradesh

Chanda Maharashtra, Madhya Pradesh

Kymore Madhya Pradesh, Uttar Pradesh


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The sales data used to establish the above regions is highlighted below. This is combined with data from

the Cement Manufacturers Association of India on the production of other cement plants in the country.

ACC - Plantwise Despatches to States - 2003-2004 (000 tonnes)State Tikaria Kymore Chanda Wadi

New

PUNJAB 0.0 32.6 11.6 0.0

CHANDIGARH 0.0 1.0 1.0 0.0

HARYANA 0.0 0.6 1.4 0.0

HP 0.0 0.0 0.0 0.0

J&K 0.0 6.9 9.3 0.0

DELHI 0.0 2.4 7.1 0.0

UP 1600.7 434.6 76.9 0.0

HARYANA 0.0 0.2 0.0 0.0

RAJASTHAN 0.0 0.0 0.0 0.0UTTARANCHAL 0.0 171.9 2.3 0.0

WB 0.0 30.0 0.0 0.0

N.E 0.0 42.0 56.0 0.0

ORISSA 0.0 5.0 9.5 0.0

BIHAR 0.0 0.0 0.0 0.0

JHK 0.0 16.2 0.0 0.0

NEPAL 0.0 41.3 0.0 0.0

MP 0.0 481.3 105.9 0.0

MAH 0.0 0.0 593.2 787.0

KAR 0.0 0.0 0.0 1250.4

GOA 0.0 0.0 0.0 11.3

TN 0.0 0.0 0.0 160.7

KERALA 0.0 0.0 0.0 83.2

AP 0.0 0.0 47.7 309.3

Total 1600.7 1266.0 921.9 2601.9

Source: ACC

Determination of benchmark

Having established the regions, the next step is to determine the benchmark clinker and additive content

of PPC in each region. As outlined in the applied methodology, the benchmark for baseline emissions is

defined as the lowest among the following:

(i) The average (weighted by production) mass percentage of clinker for the 5 highest blendcement brands for the relevant cement type in the region; or

(ii) The production weighted average mass percentage of clinker in the top 20% (in terms ofshare of additives) of the total production of the blended cement type in the region; or

(iii) The mass percentage of clinker in the relevant cement type produced in the proposed projectactivity plant before the implementation of the CDM project activity.

To determine (ii) and (iii) above, the methodology stipulates either statistically significant random

sampling or the use of reliable and up to date annual data from a reputable and verifiable source. Data on

OPC and PPC production and on clinker production and grinding at cement plants in India is provided by


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the Cement Manufacturers Association of India (CMA). This data, which is from a reputable source and

is verifiable, is used to derive the clinker content in PPC produced in each region as defined above.

Project activity plant Region Benchmark clinker content, 2003-4Wadi New Maharashtra, Karnataka (i) 74.9%

(ii) 73.9%

(iii) 73.8%

Tikaria Madhya Pradesh, Uttar Pradesh (i) 72.4%

(ii) 72.0%

(iii) 75.0%

Chanda Maharashtra, Madhya Pradesh (i) 73.0%

(ii) 72.7%

(iii) 74.3%

Kymore Madhya Pradesh, Uttar Pradesh (i) 72.4%

(ii) 72.0%(iii) 74.2%

Source: CMA data

The methodology stipulates that the lowest value among the three options be selected as the benchmark

baseline for the base year (2003-4). These are illustrated below:

Plant Selected benchmark baseline for base year

Wadi New 73.8% (option iii)

Tikaria 72.0% (option ii)Chanda 72.7% (option ii)

Kymore 72.0% (option ii)

Trend increase in additive blend

As outlined in the methodology, we have selected to specify ex-ante an annual increase in the additive

blend. The reason for this is to alleviate the monitoring burden and importantly to increase the certainty

of CER volumes. There is no clear trend evident in the additive blend in the above regions, nor sufficient

data to estimate such a trend. Therefore we have selected the default annual 2% increase in additives.


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Baseline Emissions Factors

Having determined the benchmark for baseline emissions, specific baseline emissions factors must be

calculated. As outlined in the methodology, baseline emissions per tonne of blended cement type are:

BCADDeleyBlendclinyBCBEBBEBE __,ker, * +=

where

yBCBE , = Baseline CO2 emissions per tonne of blended cement type (BC) (tCO2/tonne BC)

kerclinBE = CO2 emissions per tonne of clinker in the baseline in the project activity plant

(tCO2/tonne clinker)

yBlendBE , = Baseline benchmark of share of clinker per tonne of BC updated for year y (tonne of

clinker/tonne BC)

BCADDeleBE __ = Baseline electricity emissions for BC grinding and preparation of additives (tCO 2/tonne

of BC)

Calculation of kerclinBE :

kerclinBE = CLNKsgeleCLNKgridelefuelfossilcalcin BEBEBEBE _____ +++

calcinBE is the baseline emissions per tonne of clinker due to calcinations of calcium carbonate and

magnesium carbonate (tCO2 /tonne clinker). The table below outlines calcinBE for each project activity

plant for the year 2003-4, calculated from actual company data.

Plantcalcin

BE (tCO2/tonne

clinker)

Wadi

New

0.524

Tikaria 0.551

Chanda 0.534

Kymore 0.551

Note: Figure for Tikaria is the same as Kymore, as this is the source of its clinker.

fuelfossilBE _ is the baseline emissions per tonne of clinker due to combustion of fossil fuels for clinker

production (tCO2 /tonne clinker). The table below outlines fuelfossilBE _ for each project activity plant for

the year 2003-4, calculated from actual company data.

Plantfuelfossil

BE _


Wadi New 0.292

Tikaria 0.334

Chanda 0.411

Kymore 0.334


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Notes: Figure for Tikaria is the same as Kymore (the source of its clinker).

CLNKgrideleBE __ are the baseline grid electricity emissions for clinker production per tonne of clinker

(tCO2 /tonne clinker). The table below outlines CLNKgrideleBE __ for each project activity plant for the

year 2003-4, calculated from actual company data.

PlantCLNKgrideleBE __


Wadi New 0.001

Tikaria 0.065

Chanda 0.005

Kymore 0.065

Note: Figure for Tikaria is the same as Kymore (the source of its clinker)

CLNKsgeleBE __ are the baseline emissions from self generated electricity for clinker production per tonne

of clinker (tCO2/tonne clinker). The table below outlines CLNKsgeleBE __ for each project activity plant for

the year 2003-4, calculated from actual company data.

PlantCLNKsgeleBE __


Wadi New 0.097

Tikaria 0.006

Chanda 0.133

Kymore 0.006

Note: Figure for Tikaria is the same as Kymore (the source of its clinker)

Calculation ofBCADDele

BE __

ADDsgeleADDgrideleBCsgeleBCgrideleBCADDeleBEBEBEBEBE __________ +++=

BCgrideleBE __ are the baseline grid electricity emissions for BC grinding (tCO2/tonne of BC). The table

below outlines BCgrideleBE __ for each project activity plant for the year 2003-4, calculated from actual

company data.

PlantBCgridele

BE __

(tCO2/tonne BC)

Wadi New 0.0005

Tikaria 0.0031

Chanda 0.0018

Kymore 0.0213


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BCsgeleBE __ are baseline self generated emissions for BC grinding (tCO2/tonne of BC). The table below

outlines BCsgeleBE __ for each project activity plant for the year 2003-4, calculated from actual companydata.

PlantBCsgeleBE __

(tCO2/tonne BC)

Wadi New 0.0447

Tikaria 0.0602

Chanda 0.0482

Kymore 0.0021

ADDgrideleBE __ are baseline grid electricity emissions for additive preparation (tCO2/tonne of BC). The

table below outlines ADDgrideleBE __ for each project activity plant for the year 2003-4, calculated from

actual company data.

PlantADDgridele

BE __

(tCO2/tonne BC)

Wadi New 0.0000

Tikaria 0.0001Chanda 0.0001

Kymore 0.0002

ADDsgeleBE __ are baseline self generated electricity emissions for additive preparation (tCO2 /tonne of

BC). The table below outlines ADDsgeleBE __ for each project activity plant for the year 2003-4,

calculated from actual company data.

PlantADDsgele

BE __

(tCO2/tonne BC)

Wadi New 0.0000

Tikaria 0.0015

Chanda 0.0037

Kymore 0.00002


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B.3. Description of how the anthropogenic emissions of GHG by sources are reduced below

those that would have occurred in the absence of the registered CDM project activity :

>>

As outlined in the methodology, we use the additionality tool developed by the EB, modified for the

specifics of the project type, to evaluate additionality of the project activity.

Step 0: Preliminary screening of projects started after 1 January 2000 and prior to December 2005

The project activity started (i.e. real action began) in March 2004. This falls between 1 January 2000

and the first registration of a CDM project activity (18th

November 2004). Extensive discussions were

held between ACC and CDM consultants prior to the start of the project activity, and a PIN was

submitted to the Austrian JI/CDM programme in May 2004.

We can therefore provide evidence that the CDM was seriously considered at the time the decision was

taken to proceed with the project activity and may move to additionality Step 1.

Step 1: Identification of alternatives to the project activity consistent with current laws and

regulations.

Sub-step 1a.

As outlined in the Section B.2., plausible baseline alternatives have been determined as:

The project activity not carried out as a CDM project activity

The continuation of current practice

As discussed as part of the baseline scenario determination, the blending of fly ash at the project sites

will exceed the level that occurs in the region that level at those plants that face similar economic,

market and technical circumstances. Moreover, as also outlined, switching to production of slag based

cement is not an option at the project sites as they are not situated in steel producing areas.

Whilst switching to production of OPC at the project sites is a realistic option, we exclude it for

conservativeness.

As outlined in the additionality tool, we use the following steps of the additionality tool to establish

which of the two plausible alternatives outlined above is the likely baseline scenario.

Sub-step 1b. Enforcement of applicable laws and regulations:

Production of fly ash based PPC in India is subject to the Bureau of Indian Standards specification IS:

1489 (Part 1). This specifies that the percentage of pozzolana material (i.e. fly ash) in PPC must fall

between the ranges of 15% to 35%. Both of the above alternatives will meet this requirement.

The Ministry of Environment and Forests requires coal and lignite power plants subject to environmental

clearance conditions to submit an action plan showing how they will achieve full utilisation of fly ash.

However there are no regulatory requirements on cement plants to assist in accomplishing this.

From the above discussion, we conclude that both alternatives are in compliance with applicable laws

and regulations.


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Step 2. Investment analysis OR

Step 3. Barrier analysis.

Step 3. Barrier analysis is selected.

Sub-step 3 a.

As has been highlighted, the increase in fly ash blending that will occur as a result of the project

activities will take the blend to a level that exceeds that which represents the best common practice

within each project activity plants region.

Blending targets for each ACC cement plant producing Suraksha are set at a central level, based on

marketing and research advice and taking account of plant specific factors, including limestone, clinker

and additive quality. As a result of the project activity, ACC has increased the target blend rate at theplants where the CDM project activities will be undertaken. However there are a number of important

barriers preventing implementation of the target rate. These barriers can be characterised as:

1. Technical barriers

It is very difficult to increase the percentage of fly ash in PPC to the levels anticipated as part of the

project activity whilst maintaining the quality of the cement. Early strength at 1st

and 3rd

days is a very

important element of cement quality, and increasing the fly-ash content will a priori reduce early

strength. This is the key barrier to increasing the share of fly ash (it should be noted that as the blend

level increases, incremental increases in the fly ash content are harder to obtain).

The quality and hydraulic potential of clinker acts as a barrier to increasing the fly ash blend as does the

fineness of high fly ash PPC and the distribution of fly ash components in coarse fractions of cement.

It is absolutely vital that the quality of Suraksha PPC is maintained as otherwise its reputation and hence

sales will suffer. Maintaining the quality of the cement, whilst increasing the blending of fly ash

additives represents a major technical barrier to implementation of the project activity.

There are also technical barriers relating to the use of high fly ash PPC. Builders must be educated on

the use of high fly ash PPC as well as reassured as to its quality (see below).

2. Market resistance to high fly ash blended cement.

It is crucial that the increased blending of fly ash neither reduces the quality of the Suraksha PPC

produced, nor results in a customer perception that the cement is of a lower quality.

In India there is still a general perception that the quality of blended cements is inferior to that of OPC,

and therefore that PPC with a higher fly ash blend is undesirable. PPC acceptance is in particular low in

some government agencies the Central Public Works Department has imposed a ban on the use of

blended cements in bridges and other concrete works and constructions. Moreover, there is a general

perception that fly ash reduces cement strength and increases setting time. Early strength at first and third

days is particularly important to the customers of ACC and the ability to increase the blend whilst


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maintaining early strength, and then convincing customers this is the case, represent major barriers to

implementation of the project activity. The a-priori assumption of customers is that a high fly ash PPC is

of an inferior quality and therefore they will tend not to purchase such cement. Moreover, there is the

potential that the brand name could be negatively impacted by the blend increase.

Sub-step 3b. Show that the identified barriers would not prevent the implementation of at least one of

the alternatives (except the project activity):

The alternative to the project activity is the continuation of current practice. This would face none of the

barriers outlined above.

Step 4. Common Practice Analysis

As outlined in Section B.2., the baseline level from which the project activity will increase the fly ash

blend in PPC exceeds common practice in the relevant system boundary. The project activities will bebest practice and represents first of its kind projects. This is reinforced by the fact that the projects

will only receive CERs when the blend exceeds not only common, but best practice.

Step 5. Impact of CDM Registration

The CDM will allow ACC to overcome the barriers to increased fly ash absorption. CDM status

provides two key benefits to ACC; the first is the prospect of CDM revenue. The second benefit, which

should not be underestimated, is a desire to gain experience in the CDM and to provide demonstrable

evidence that the company is making serious and concerted efforts to reduce GHG emissions. The

cement industry is acutely aware of the high emissions associated with cement production and is keen to

utilise the CDM to reduce these.

Both of the above factors crucially have and will continue to allow the company to dedicate R&D andmarketing effort to overcoming the barriers outlined in Step 2.

R&D

A team of eight scientists is now working on increasing the blending of fly ash and is integral to

implementation of the project activity. The R&D department is following a two pronged approach,

developing processes at the laboratory level and carrying out plant level trials that will, it is hoped,

enable the increase in fly ash blending inherent in the project activity whilst maintaining cement quality.

The research team is analysing the pozzolanic activity of fly ashes and evaluating technicallyfeasible options for enhancing clinker replacement in Suraksha at New Wadi.

Studies are being undertaken on methods of improving the quality of the clinker at the projectactivity sites through raw mix optimisation.

Work is underway to optimise the fineness of PPC.

An evaluation is being carried out on options for processing fly ash and therefore enhancing itspozzolanic activity. Both mechanical and chemical processing is being evaluated as a source of

activation, whilst use of separate activators is also being considered.

Research is also underway on methods of overcoming the retarding effect of the by-productphospho gypsum used, and therefore of enabling increased fly ash absorption.

Marketing


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Marketing activities associated with the project activity will be ongoing and as mentioned above, the

marketing department will work closely with the R&D department to reassure customers of the quality of

cement produced by ACC. This marketing effort will consist of a series of seminars, workshops and

events. ACC will issue circulars to customers free of charge and establish specially designed customerinformation centres. ACC has developed a marketing/customer information website (www.askacc.com)

and as a result of the project activity, explanatory and technical material will be placed on the site.

Information centres showing customers how to make good quality mortar and concrete using PPC have

and will be established. Such an information centre was established in Bangalore in November 2004,

whilst subsequent centres will be established in Mangalore, Belgaum and Mumbai by Mid-2005.

As highlighted earlier, CDM status is a key factor that has enabled the above R&D and marketing

initiatives to be undertaken.


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B.4. Description of how the definition of the project boundary related to the baseline

methodology selected is applied to the project activity:

>>

The project boundary includes the cement production plant, any onsite power generation and the power

generation in the grid.

Emissions from the following emission sources are accounted for:

Direct emissions at the cement plant due to fuel combustion for:Firing the kiln (including supplemental fuels used in the precalciner);

Processing (including drying) of solid fuels, raw materials, and additives;

On-site generation of electricity (if applicable).

Direct emissions due to calcination of limestone Indirect emissions from fossil fuel combustion in power plants in the grid due to electricity use at

the cement plant, including electricity consumption for:

Crushing and grinding the raw materials used for clinker production;

Driving the kiln and kiln fans;

Finish grinding of cement;

Processing of additives.

The (regional) power grids or plants from which the cement plant purchases electricity and its losses are

considered in determining indirect emissions. Transport related emissions from the delivery of additional

additives are included in the emissions related to the project activity as leakage. Emissions reductions

from transport of raw materials for clinker production are not taken into account as a conservative

simplification.

Gases included: CO2 only. Changes in CH4 and N2O emissions from combustion processes are

considered to be negligible and excluded because the differences in the baseline and project activity are

not substantial. This assumption simplifies the methodology and is conservative.

B.5. Details of baseline information, including the date of completion of the baseline study

and the name of person (s)/entity (ies) determining the baseline:

>>

21/05/2010Ben Atkinson, Agrinergy Ltd


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SECTION C. Duration of the project activity / Crediting period

C.1 Duration of the project activity:

C.1.1. Starting date of the project activity:

>>

1 March 2004

C.1.2. Expected operational lifetime of the project activity:

>>

20 years

C.2 Choice of the crediting period and related information:

The project activity has chosen a fixed ten-year crediting period.

C.2.1. Renewable crediting period

C.2.1.1. Starting date of the first crediting period:

>>

C.2.1.2. Length of the first crediting period:

>>

C.2.2. Fixed crediting period:

C.2.2.1. Starting date:

>>

1 April 2004

C.2.2.2. Length:

>>

10 years

SECTION D. Application of a monitoring methodology and plan

D.1. Name and reference of approved monitoring methodology applied to the project activity:

>>

ACM0005

Consolidated Monitoring Methodology for Increasing the Blend in Cement Production


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D.2. Justification of the choice of the methodology and why it is applicable to the project

activity:

>>

The monitoring methodology is applicable to projects using the allied baseline methodology. In terms of

the applicability conditions:

There is no shortage of additives to prevent leakage related to the lack of blending materials The project activity will result in an increase in the percentage of fly ash blended in PPC

produced at the specified ACC cement plants. The ACC plants are situated in India. Fly ash

production in India is estimated at around 90 million tonnes per year, whilst annual utilisation is

estimated at 13 million tonnes2. Disposal of fly ash in India is considered an environmental

problem. We can therefore conclude that there is sufficient supply of fly ash that the project

activity will not lead other PPC producers to reduce their fly ash blend rate.

The methodology is applicable to domestically sold output of the project activity sold plant and

excludes export of blended cement types This is the case.

Adequate data are available on cement types in the market This is the case. A database hasbeen obtained from the Cement Manufacturers Association of India.

2Source: http://www.tifac.org.in/news/flymgm.htm . TIFAC is an autonomous organisation under the Indian

Department of Science and Technology


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CDM Executive Board


D.2. 1. Option 1: Monitoring of the emissions in the project scenario and the baseline scenario

This option is selected and is specified in the monitoring methodology followed.

D.2.1.1. Data to be collected in order to monitor emissions from the project activity, and h

ID number Data variable Source of

data

Data unit Measured

(m),

calculated

(c) or

estimated (e)

Recording

frequency

Proportio

n of data

to be

monitored

How will the

data be

archived?

(electronic/

paper)

1 InCaOy Plant

records

% M,C Daily 100% Paper &

Electronic

2 OutCaOy Plant

records


Electronic

3 InMgOy Plant

records


Electronic

4 OutMgOy Plant

records


Electronic

5 Quantity of

clinker raw

material

Plant

records

Kilo tonnes M Annually 100% Paper &

Electronic

6 CLNKy Plant

records

Kilo tonnes

of clinker

M Annually 100% Paper &

Electronic

7 FFi_y Plant

records

Tonnes of

fuel i

M Monthly 100% Paper &

Electronic8 EFFi IPCC/

Plant

records

tCO2/tonne

of fuel i

C/M Annually 100% Electronic

9 PELEgrid_CLNK,y Plant

records

MWh M Monthly 100% Paper &

Electronic

10 EFgrid,BSL Calculated

ex-ante

tCO2 /MWh N/a N/a 100% Electronic

11 PELEsg_CLNK,y Plant MWh M Monthly 100% Paper &


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records Electronic

12 EFsg,y Plant

records

tCO2 /MWh C Monthly 100% Electronic

13 ADDy Plantrecords

Kilo tonnes M Monthly 100% Paper &Electronic

14 PELEgrid,BC,y Plant

records


Electronic

15 PELEsg,BC,y Plant

records


Electronic

16 PELEgrid,ADD,y Plant

records


Electronic

17 PELEsg,ADD,y Plant

records


Electronic

18 Fi,j,y Plant

records

Tonnes of

fuel i

M Monthly 100% Paper &

Electronic

19 COEFi,j,y

IPCC/

Plant

records

tCO2/tonne

of fuel i

C/M Annually 100% Electronic

20 GENj,y Plant

records

MWh M Annually 100% Paper &

Electronic

21 PEcalcin,y Plant

records

tCO2/tonne

clinker

C Annually 100% Electronic

22 PEfossil_fuel,y Plant

records

tCO2/tonne

clinker


23 PEele_grid_CLNK,y Plant

records

tCO2/tonne

clinker


24 PEele_sg_CLNK,y Plant

records

tCO2/tonne

clinker


25 PEele_grid_BC,y Plantrecords

tCO2/tonneblended

cement


26 PEele_sg_BC,y Plant

records

tCO2/tonne

blended

cement


27 PEele_grid_ADD,y Plant

records

tCO2/tonne

blended

cement



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28 PEele_sg_ADD,y Plant

records

tCO2/tonne

blended

cement


29 Pblend,y Plantrecords

Tonne ofclinker/

tonne

blended

cement



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CDM Executive Board


PBlend,y = Share of clinker per tonne of BC in year y (tonne of clinker/tonne of BC)

PEele_AD,D_BC,y = Electricity emissions for BC grinding and preparation of additives in year y (tCO2/tonne of BC

CO2 per tonne of clinker in the project activity plant in year y is calculated as below:

PEclinker,y= PEcalcin,y + PEfossil_fuel,y + PEele_grid_CLNK,y+ PEele_sg_CLNK,y

where:

PEclinker,y= Emissions of CO2 per tonne of clinker in the project activity plant in year y (tCO2/tonne clinker

PEcalcin,y = Emissions per tonne of clinker due to calcinations of calcium carbonate and magnesium carbon

PEfossil_fuel,y = Emissions per tonne of clinker due to combustion of fossil fuels for clinker production in year y

PEele_grid_CLNK,y= Grid electricity emissions for clinker production per tonne of clinker in year y (tCO2/tonne clin

PEele_sg_CLNK,y = Emissions from self-generated electricity per tonne of clinker production in year y (tCO2/tonne

PEcalcin,y = 0.785*(OutCaOy - InCaOy) + 1.092*(OutMgOy - InMgOy) / [CLNKy * 1000]

where:

PEcalcin,y = Emissions from the calcinations of limestone (tCO2/tonne clinker)

0.785 = Stoichiometric emission factor for CaO (tCO2/t CaO)

1.092 = Stoichiometric emission factor for MgO (tCO2/t MgO)

InCaO,y = CaO content (%) of the raw material * raw material quantity (tonnes)

OutCaO,y = CaO content (%) of the clinker * clinker produced (tonnes)

InMgO,y = MgO content (%) of the raw material * raw material quantity (tonnes)

OutMgO,y = MgO content (%) of the clinker * clinker produced (tonnes)

PEfossil_fuel, y = [ FFi_,y * EFFi] /CLNK,y * 1000

where:

FFi_,y = Fossil fuel of type i consumed for clinker production in year y (tonnes of fuel i)

EFFi = Emission factor for fossil fuel i (tCO2/tonne of fuel)


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CLNKy = Annual production of clinker in year y (kilotonnes of clinker)

PEele_grid_CLNK,y= [ PELEgrid_CLNK,y * EFgrid_y] / [CLNKy* 1000]

where:

PELEgrid_CLNK,y = Grid electricity for clinker production in year y (MWh)

EFgrid_y = Grid emission factor in year y(t CO2/MWh)


PEelec_sg_CLNK,y = [PELEsg_CLNK ,y* EFsg_y] /[CLNKy * 1000]

where:

PELEsg_CLNK,y = Self generation of electricity for clinker production in year y (MWh)

EFsg_y = Emission factor for self generated electricity in year y (t CO2/MWh)


PEele_ADD_BC,y = PEele_grid_BC,y + PEele_sg_BC,y + PEele_grid_ADD,y + PEele_sg_ADD,y

where:

PEele_grid_BC = Grid electricity emissions for BC grinding in year y (tCO2/tonne of BC)

PEele_sg_BC = Emissions from self generated electricity for BC grinding in year y (tCO2/tonne of BC)

PEele_grid_ADD = Grid electricity emissions for additive preparation in year y (tCO2/tonne of BC)

PEele_sg_ADD = Emissions from self generated electricity additive preparation in year y (tCO2/tonne of BC)

PEele_grid_BC,y = [ PELEgrid_BC,y * EFgrid_BSL,y] /[BCy* 1000]

PELEgrid_BC,y = Baseline grid electricity for grinding BC (MWh)EFgrid_y = Grid emission factor in year y(t CO2/MWh)

BCy = Annual production of BC in year y (kilotonnes of BC)

PEelec_sg_BC,y = [PELEsg_BC,y * EFsg_y] / [BCy* 1000]

PELEsg_BC,y = Self generated electricity for grinding BC in year y (MWh)


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PEele_grid_ADD = [ PELEgrid_ADD * EFgrid_y] /[BCy* 1000]

BELEgrid_ADD = Baseline grid electricity for grinding additives (MWh)

EFgrid_y = Grid emission factor in year y(t CO2/MWh)


PEelec_sg_ADD,y = [PELEsg_ADD,y * EFsg_y] / [BCy* 1000]

PELEsg_ADD,y = Baseline self generation electricity for grinding additives (MWh)




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CDM Executive Board


D.2.1.3. Relevant data necessary for determining the baseline of anthropogenic emissions

boundary and how such data will be collected and archived :

ID number

(Please use

numbers to

ease cross-

referencing to

table D.3)

Data variable Source of data Data unit Measured

(m),

calculated

(c),

estimated

(e),

Recording

frequency

Proportion of

data to be

monitored

H

30 InCaOBSL Plant records % M,C Daily 100% Pa

El

31 OutCaOBSL Plant records % M,C Daily 100% Pa

El

32 InMgOBSL Plant records % M,C Daily 100% Pa

El

33 OutMgOBSL Plant records % M,C Daily 100% Pa

El

34 Quantity of clinker

raw material

Plant records Kilo tonnes M Annually 100% Pa

El

35 CLNKBSL Plant records Kilo tonnes of

clinker

M Annually 100%

El

36 FFiBSLy Plant records Tonnes of fuel i M Monthly 100% Pa

El

37 EFFi IPCC/

Plant records

tCO2/tonne of

fuel i

C/M Annually 100% El

38 BELEgrid_CLNK,BSL Plant records MWh M Monthly 100% Pa

El

39 EFgrid,BSL Calculated

ex-ante

tCO2 /MWh N/a N/a 100%

40 BELEsg_CLNK,BSL Plant records MWh M Monthly 100% Pa

El


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CDM Executive Board


41 EFsg,BSL Plant records tCO2 /MWh C Monthly 100%

42 ADDBSL Plant records Kilo tonnes M Monthly 100% Pa

El43 BELEgrid,BC,BSL Plant records MWh M Monthly 100% Pa

El

44 BELEsg,BC,BSL Plant records MWh M Monthly 100% Pa

El

45 BELEgrid,ADD Plant records MWh M Monthly 100% Pa

El

46 BELEsg,ADD,BSL Plant records MWh M Monthly 100% Pa

El

47 Fi,j,BSL Plant records Tonnes of fuel i M Monthly 100% Pa

El

48 COEFi,j,BSL IPCC/

Plant records

tCO2/tonne of

fuel i

C/M Annually 100% El

49 GENj,BSL Plant records MWh M Annually 100% Pa

El

50 BEcalcin,BSL Plant records tCO2/tonne

clinker

C Annually 100% El

51 BEfossil_fuel,BSL Plant records tCO2/tonne

clinker

C Annually 100% El

52 BEele_grid_CLNK,BSL Plant records tCO2/tonne

clinker

C Annually 100% El

53 BEele_sg_CLNK,BSL Plant records tCO2/tonne

clinker

C Annually 100% El

54 BEele_grid_BC,BSL Plant records tCO2/tonne

blended cement

C Annually 100% El

55 BEele_sg_BC,BSL Plant records tCO2/tonne

blended cement

C Annually 100% El


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CDM Executive Board


56 PEele_grid_ADD,BSL Plant records tCO2/tonne

blended cement

C Annually 100% El

57 BEele_sg_ADD,BSL Plant records tCO2/tonne

blended cement

C Annually 100% El

58 Bblend,y Plant records Tonne of

clinker/tonne

blended cement

C Annually 100% El


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CDM Executive Board


D.2.1.4. Description of formulae used to estimate baseline emissions (for each gas, source

CO2 equ.)

>>BEBC,y = [BEclinker * BBlend,y] + BEele_ADD_BC

where:

BEBC,y = Baseline CO2 emissions per tonne of blended cement type (BC) (tCO2/tonne BC)

BEclinker = CO2 emissions per tonne of clinker in the baseline in the project activity plant (t CO 2/tonne clinker) an

BBlend,y = Baseline benchmark of share of clinker per tonne of BC updated for year y (tonne of clinker/tonne of B

BEele_ADD_BC = Baseline electricity emissions for BC grinding and preparation of additives (tCO2/tonne of BC)

CO2 per tonne of clinker in the project activity plant in the baseline is calculated as below:

BEclinker = BEcalcin + BEfossil_fuel + BEele_grid_CLNK + BEele_sg_CLNK

where:

BEclinker = Baseline emissions of CO2 per tonne of clinker in the project activity plant (t CO2/tonne clinker)

BEcalcin = Baseline emissions per tonne of clinker due to calcinations of calcium carbonate and magnesium carbo

BEfossil_fuel = Baseline emissions per tonne of clinker due to combustion of fossil fuels for clinker production (t C

BEele_grid_CLNK = Baseline grid electricity emissions for clinker production per tonne of clinker (t CO2/tonne clink

BEele_sg_CLNK = Baseline emissions from self generated electricity for clinker production per tonne of clinker (t C

BEcalcin = [0.785*(OutCaO - InCaO) + 1.092*(OutMgO - InMgO)] / [CLNKBSL * 1000]

where:

BEcalcin = Emissions from the calcinations of limestone (tCO2/tonne clinker)

0.785 = Stoichiometric emission factor for CaO (tCO2/t CaO)

1.092 = Stoichiometric emission factor for MgO (tCO2/t MgO)

InCaO = CaO content (%) of the raw material * raw material quantity (tonnes)

OutCaO = CaO content (%) of the clinker * clinker produced (tonnes)

InMgO = MgO content (%) of the raw material * raw material quantity (tonnes)

OutMgO = MgO content (%) of the clinker * clinker produced (tonnes)

CLNKBSL = Annual production of clinker in the base year (kilotonnes of clinker)


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CDM Executive Board


BEfossil_fuel = [ FFi_BSL * EFFi] /[CLNKBSL * 1000]

FFi_BSL = Fossil fuel of type i consumed for clinker production in the baseline (tonnes of fuel i)

EFFi = Emission factor for fossil fuel i (t CO2/tonne of fuel)CLNKBSL = Annual production of clinker in the base year (kilotonnes of clinker)

BEele_grid_CLNK = [ BELEgrid_CLNK * EFgrid_BSL] /CLNKBSL* 1000

BELEgrid_CLNK = Baseline grid electricity for clinker production (MWh)

EFgrid_BSL = Baseline grid emission factor (t CO2/MWh)

CLNKBSL = Annual production of clinker in the base year (kilotonnes of clinker)

BEelec_sg_CLNK = [BELEsg_CLNK * EFsg_BSL] /[CLNKBSL * 1000]

BELEsg_CLNK = Baseline self generation of electricity for clinker production (MWh)

EFsg_BSL = Baseline electricity self generation emission factor (t CO2/MWh)CLNKBSL = Annual production of clinker in the base year (kilotonnes of clinker)

BEele_ADD_BC = BEele_grid_BC + BEele_sg_BC + BEele_grid_ADD + BEele_sg_ADD

where:

BEele_grid_BC = Baseline grid electricity emissions for BC grinding (tCO2/tonne of BC)

BEele_sg_BC = Baseline self generated electricity emissions for BC grinding (tCO2/tonne of BC)

BEele_grid_ADD = Baseline grid electricity emissions for additive preparation (tCO2/tonne of BC)

BEele_sg_ADD = Baseline self generated electricity emissions for additive preparation (tCO2/tonne of BC)

BEele_grid_BC = [ BELEgrid_BC * EFgrid_BSL] /[BCBSL* 1000]

BELEgrid_BC = Baseline grid electricity for grinding BC (MWh)EFgrid_BSL = Baseline grid emission factor (t CO2/MWh)

BCBSL = Annual production of BC in the base year (kilotonnes of BC)

BEelec_sg_BC = [BELEsg_BC * EFsg_BSL] / [BCBSL* 1000]

BELEsg_BC = Baseline self generation electricity for grinding BC (MWh)

EFsg_BSL = Baseline electricity self generation emission factor (t CO2/MWh)



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CDM Executive Board


BEele_grid_ADD = [ BELEgrid_ADD * EFgrid_BSL] /[BCBSL* 1000]

BELEgrid_ADD = Baseline grid electricity for grinding additives (MWh)EFgrid_BSL = Baseline grid emission factor (t CO2/MWh)


BEelec_sg_ADD = [BELEsg_ADD * EFsg_BSL] / [BCBSL* 1000]

BELEsg_BC = Baseline self generation electricity for grinding additives (MWh)

EFsg_BSL = Baseline electricity self generation emission factor (t CO2/MWh)



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CDM Executive Board


D. 2.2. Option 2: Direct monitoring of emission reductions from the project activity (values shou

This section is left blank on purpose

D.2.2.1. Data to be collected in order to monitor emissions from the project activity, and h

ID number

(Please use

numbers to

ease cross-

referencing

to table

D.3)

Data

variable

Source of

data

Data

unit

Measured (m),

calculated (c),

estimated (e),

Recording

frequency

Proportion

of data to

be

monitored

How will the data

be archived?

(electronic/

paper)

D.2.2.2. Description of formulae used to calculate project emissions (for each gas, source,

CO2 equ.):

>>


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CDM Executive Board


D.2.3. Treatment of leakage in the monitoring planLeakage is restricted to any transport emissions that arise from the increased use of additive. The methodology does re

surplus. As outlined in Sections B.1.1 and D.2., fly ash utilisation in India is at best 14%. Disposal of fly ash is an envirodisposed of via land filling. Some 65,000 acres of land is devoted to ash ponds in the country. Annual fly ash production i

13 million tonnes are used, and fly ash production in India is forecast to increase to 180 million tonnes by 2015. The projec

no discounting is required ( = 0).

D.2.3.1. If applicable, please describe the data and information that will be collected in or

project activityID number Data

variable

Source of

dataData unit

Measured (m),

calculated (c)

or estimated

(e)

Recording

frequency

Proportion of data to be

monitored

How wil

archived

paper)

59 TFcons Plant

records

Kg of

fuel/kilomet

re

C Annually 100% Electron

60 Dadd_source IPCC Km M Per trip 100% Electron

61 TEF Plant

records

Kg CO2/kg

of fuel

E Annually 100%

62 Qadd Plant

records

Tonnes of

additive/ve

hicle

M Per trip 100% Ele

63 ELEconveyo

r_ADD

Plant

records

MWh M Monthly 100%

64 EFgrid Ex-ante

grid factor

or on-sitefuel

Tonnes of

CO2/MWh

C Annually 100% Electron

65 BCy Blended

cement

produced at

project site

and sold to

domestic

market

Tonnes of

PPC

C Annually 100% Paper an


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CDM Executive Board


D.2.3.2. Description of formulae used to estimate leakage (for each gas, source, formulae/

>>

Ladd_trans = [(TFcons * Dadd_source * TEF) 1/Qadd * 1/1000 + (ELEconveyor_ADD * EFgrid)*1/ADDy]

where:

Ladd_trans = Transport related emissions per tonne of additives (t CO2/tonne of additive)

TFcons = Fuel consumption for the vehicle per kilometre (kg of fuel/kilometre)

Dadd_source = Distance between the source of additive and the project activity plant (km)

TEF = Emission factor for transport fuel (kg CO2/kg of fuel)

ELEconveyor_ADD = Electricity consumption for conveyor system for additives (MWh)

EFgrid = Grid electricity emission factor (tonnes of CO2/MWh)Qadd = Quantity of additive carried in one trip per vehicle (tonnes of additive)

ADDy = Annual consumption of additives in year y (tonnes of additive)

And leakage emissions per tonne of BC due to additional additives are determined by

Ly = Ladd_trans * [Ablend,y Pblend,y] * BCy

where:

Ly = Leakage emissions for transport of additives (kilotonnes of CO2)

BCy = Production of BC in year y and sold into domestic market (kilotonnes of BC)

Ablend,y = Baseline benchmark share of additives per tonne of BC updated for year y (tonne of clinker/tonne of B

Pblend,y = Share of clinker per tonne of BC in year y (tonne of clinker/tonne of BC)


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CDM Executive Board


D.2.4. Description of formulae used to estimate emission reductions for the project activity (for e

emissions units of CO2 equ.)

>>The project activity mainly reduces CO2 emissions through substitution of clinker in cement by blending materi

difference in the CO2 emissions per tonne of BC in the baseline and in the project activity multiplied by the prod

There is no need to discount for the percentage of additives for which surplus availability is not substantiated as

ash.

ERy = [BEBC,y PEBC,y] * BCy + Ly

where:

ERy = Emissions reductions in year y due to project activity (thousand tonnes of CO2)

BEBC,y = Baseline emissions per tonne of BC (t CO2/tonnes of BC)PEBC,y = Project emissions per tonne of BC in year y (t CO2/tonnes of BC)

BCy = BC production in year y and sold into domestic market (thousand tonnes) (Any volume of PPC exported w

arrive at BCy)


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CDM Executive Board


D.3. Quality control (QC) and quality assurance (QA) procedures are being undertaken for data moni

Data

(Indicate table and

ID number e.g. 3.-1.;

3.2.)

Uncertainty level of data

(High/Medium/Low)

Explain QA/QC procedures planned for these data, or why such

TableD.2.1.1, ID

numbers 1-29

Low-Medium These data will be collected as part of normal plant level oper

checking these with other internal company reports. Local data

Independent agency verification will also be used.

All units have ISO9000 systems in place. Procedures are in plac

- training and monitoring of personnel- maintenance of monitoring equipment- record and data handling

Internal quality assurance and monitoring is already in place.

project will be incorporated in the ISO 9000 internal audit proc

Emergency preparedness and on site emergency manual are av

Factories Act requirements. This covers the CDM project activ

Grid electricity meters are provided by electricity authorities an

meters will be subject to calibration. Laboratory test equipmen

calibration.


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CDM Executive Board


TableD.2.1.3, ID

numbers 30-58

Low-Medium These data will be collected as part of normal plant level oper

checking these with other internal company reports. Local data

Independent agency verification will also be used.

All units have ISO9000 systems in place. Procedures are in plac- training and monitoring of personnel- maintenance of monitoring equipment- record and data handling

Internal quality assurance and monitoring is already in place.

project will be incorporated in the ISO 9000 internal audit proc

Emergency preparedness and on site emergency manual are av

Factories Act requirements. This covers the CDM project activ

Grid electricity meters are provided by electricity authorities an

meters will be subject to calibration. Laboratory test equipmen

calibration.

TableD.2.3, ID

numbers 59-64

Low Round trip distance will be cross-checked with evidence of or

consumption data will originate from vehicle manufacturers an

industry norms.


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CDM Executive Board


D.4 Please describe the operational and management structure that the project operator will impleme

and any leakage effects, generated by the project activity

>>

The Manager (Production) at each site will be responsible for collating and archiving data at that plant. Al

operations. Records will be archived and filed at each plant and will be available at the time of verification.

The collated data will be transmitted in electronic format to the central ACC head office (Mr. B. Chakravarty).

this purpose. Mr Chakravarty and Ben Atkinson of Agrinergy Ltd. will then perform the data calculations a

monitoring methodology.

D.5 Name of person/entity determining the monitoring methodology:

>>Ben Atkinson, Agrinergy Ltd.


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SECTION E. Estimation of GHG emissions by sources

E.1. Estimate of GHG emissions by sources:

>>

Project emissions per tonne of blended cement are calculated as:

PEBC,y = [PEclinker,y * PBlend,y] + PEele_ADD_BC,y

where:

PEBC,y = CO2 emissions per tonne of BC in the project activity plant in year y(tCO2/tonne BC)

PEclinker,y = CO2 emissions per tonne of clinker in the project activity plant in year y (t

CO2 /tonne clinker) and defined below

PBlend,y = Share of clinker per tonne of BC in year y (tonne of clinker/tonne of BC)

PEele_AD,D_BC,y = Electricity emissions for BC grinding and preparation of additives in year y (tCO2/tonneof BC)

The following table outlines the projected decrease in the clinker content at the cement plants carrying

out the project activity over the crediting period:

2004-5 2005-6 2006-7 2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 2013-

14

Wadi New 69% 65% 63% 61% 61% 61% 61% 61% 61% 61%

Tikaria 69% 67% 65% 62% 62% 62% 62% 62% 62% 62%

Chanda 72% 65% 65% 65% 65% 65% 65% 65% 65% 65%

Kymore 67% 65% 63% 62% 62% 62% 62% 62% 62% 62%

Based on a these additive blend projections, we forecast the following values for PEBC,y over the crediting

period:

2004-5 2005-6 2006-7 2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 2013-14

Wadi New 0.572 0.538 0.521 0.505 0.505 0.505 0.505 0.505 0.505 0.505Tikaria 0.728 0.712 0.693 0.664 0.664 0.664 0.664 0.664 0.664 0.664Chanda 0.853 0.773 0.773 0.773 0.773 0.773 0.773 0.773 0.773 0.773Kymore 0.669 0.646 0.627 0.617 0.617 0.617 0.617 0.617 0.617 0.617


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E.2. Estimated leakage:

>>

Leakage is calculated as:

Ladd_trans = [(TFcons * Dadd_source * TEF) 1/Qadd * 1/1000 + (ELEconveyor_ADD * EFgrid)*1/ADDy]

where:

Ladd_trans = Transport related emissions per tonne of additives (t CO2/tonne of additive)

TFcons = Fuel consumption for the vehicle per kilometre (kg of fuel/kilometre)

Dadd_source = Distance between the source of additive and the project activity plant (km)

TEF = Emission factor for transport fuel (kg CO2/kg of fuel)

ELEconveyor_ADD = Electricity consumption for conveyor system for additives (MWh)

EFgrid = Grid electricity emission factor (tonnes of CO2/MWh)

Qadd = Quantity of additive carried in one trip per vehicle (tonnes of additive)ADDy = Annual consumption of additives in year y (tonnes of additive)

And leakage emissions per tonne of BC due to additional additives are determined by

Ly = Ladd_trans * [Ablend,y Pblend,y] * BCy

where:

Ly = Leakage emissions for transport of additives (kilotonnes of CO2)

BCy = Production of BC in year y and sold into domestic market (kilotonnes of BC)

Ablend,y = Baseline benchmark share of additives per tonne of BC updated for year y (tonne of

clinker/tonne of BC)

Pblend,y = Share of clinker per tonne of BC in year y (tonne of clinker/tonne of BC)

Leakage over the crediting period at each project activity plant is estimated as follows (tCO2e):

2004-5 2005-6 2006-7 2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 2013-

14

Wadi New -1141 -2190 -2622 -3051 -2924 -2794 -2661 -2526 -2388 -2248

Tikaria -663 -910 -1248 -1804 -1694 -1582 -1467 -1350 -1231 -1109

Chanda 0 -404 -376 -348 -320 -291 -261 -231 -200 -168

Kymore -454 -677 -845 -902 -847 -791 -734 -675 -616 -555

The above leakage figures are estimations. Leakage is an actual calculated figure as part of monitoring

and verification, and will be based on monitored actual variables. It is not based on an ex-ante emissions

factor or similar.


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E.3. The sum of E.1 and E.2 representing the project activity emissions:

>>

The following table shows project figures for BCy (blended cement production in year y, kt):

2004-5 2005-6 2006-7 2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 2013-14

Wadi New 2487 2500 2500 2500 2500 2500 2500 2500 2500 2500

Tikaria 2011 2000 2000 2000 2000 2000 2000 2000 2000 2000

Chanda 534 534 534 534 534 534 534 534 534 534

Kymore 982 1000 1000 1000 1000 1000 1000 1000 1000 1000

And based on this project activity emissions are calculated as (million tonnes CO2):

2004-5 2005-6 2006-7 2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 201

Wadi New 1.686 1.598 1.553 1.507 1.507 1.507 1.507 1.507 1.507

Tikaria 1.464 1.425 1.386 1.329 1.329 1.329 1.329 1.329 1.329

Chanda 0.456 0.413 0.413 0.413 0.413 0.413 0.413 0.413 0.413

Kymore 0.657 0.646 0.627 0.617 0.617 0.617 0.617 0.617 0.617

E.4. Estimated anthropogenic emissions by sources of greenhouse gases of the baseline:

>>

Baseline emissions per tonne of blended cement are calculated as:

BEBC,y = [BEclinker * BBlend,y] + BEele_ADD_BC

where:

BEBC,y = Baseline CO2 emissions per tonne of blended cement type (BC) (tCO2/tonne BC)

BEclinker = CO2 emissions per tonne of clinker in the baseline in the project activity plant (t CO 2/tonne

clinker) and defined below

BBlend,y = Baseline benchmark of share of clinker per tonne of BC updated for year y (tonne of

clinker/tonne of BC)

BEele_ADD_BC = Baseline electricity emissions for BC grinding and preparation of additives (tCO2/tonne of

BC)

The following table outlines the baseline clinker content for the project activity cement plants over the

crediting period:


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2004-5 2005-6 2006-7 2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 2013-14

Wadi New 73.3% 72.9% 72.5% 72.0% 71.6% 71.1% 70.6% 70.1% 69.6% 69.1%

Tikaria 71.6% 71.1% 70.6% 70.1% 69.6% 69.1% 68.6% 68.1% 67.6% 67.0%

Chanda 72.3% 71.8% 71.4% 70.9% 70.4% 69.9% 69.4% 68.9% 68.4% 67.8%

Kymore 71.6% 71.1% 70.6% 70.1% 69.6% 69.1% 68.6% 68.1% 67.6% 67.0%

Based on these baseline clinker contents, the following values for BEBC,y are arrived at over the crediting

period:

2004-5 2005-6 2006-7 2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 2013-14

Wadi New 0.606 0.603 0.599 0.596 0.592 0.588 0.584 0.580 0.576 0.572

Tikaria 0.756 0.752 0.747 0.742 0.738 0.733 0.728 0.723 0.718 0.712

Chanda 0.852 0.847 0.842 0.837 0.831 0.826 0.821 0.815 0.809 0.804

Kymore 0.709 0.705 0.700 0.695 0.691 0.686 0.681 0.676 0.671 0.665

And based on this baseline emissions are calculated as (million tonnes CO2):

2004-5 2005-6 2006-7 2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 2013-14Wadi New 1.780 1.779 1.769 1.759 1.748 1.738 1.727 1.716 1.704 1.693

Tikaria 1.521 1.503 1.494 1.485 1.475 1.466 1.456 1.446 1.435 1.425

Chanda 0.455 0.452 0.450 0.447 0.444 0.441 0.438 0.435 0.432 0.429

Kymore 0.696 0.705 0.700 0.695 0.691 0.686 0.681 0.676 0.671 0.665

E.5. Difference between E.4 and E.3 representing the emission reductions of the project

activity:

>>

kt CO22004-5 2005-6 2006-7 2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 2013-14

Wadi New 93.0 178.5 213.7 248.7 238.3 227.7 216.9 205.9 194.7 183.2

Tikaria 56.6 77.7 106.5 154.0 144.6 135.0 125.2 115.3 105.1 94.7

Chanda 0.0 38.4 36.4 33.7 31.0 28.1 25.3 22.3 19.3 16.3

Kymore 38.8 57.8 72.2 77.0 72.3 67.5 62.6 57.6 52.5 47.4


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E.6. Table providing values obtained when applying formulae above:

>>

Wadi New

Year Estimation of

project activity

emissions (tonnes

of CO2e)

Estimation of

baseline emissions

(tonnes of CO2e)

Estimation of

leakage (tonnes of

CO2e)

Estimation of

emission

reductions (tonnes

of CO2e)

2004-5 1685613 1779755 -1141 93001

2005-6 1598476 1779205 -2190 178538

2006-7 1552766 1769106 -2622 213718

2007-8 1507055 1758805 -3051 248699

2008-9 1507055 1748299 -2924 238320

2009-10 1507055 1737582 -2794 227733

2010-11 1507055 1726651 -2661 2169342011-12 1507055 1715501 -2526 205920

2012-13 1507055 1704128 -2388 194685

2013-14 1507055 1692528 -2248 183225

Total 15386240 17411560 -24546 2000774

Tikaria

Year Estimation of

project activity

emissions (tonnes

of CO2e)

Estimation of

baseline emissions

(tonnes of CO2e)

Estimation of

leakage (tonnes of

CO2e)

Estimation of

emission

reductions (tonnes

of CO2e)

2004-5 1463539 1520820 -663 566172005-6 1424659 1503270 -910 77701

2006-7 1386384 1494126 -1248 106494

2007-8 1328973 1484798 -1804 154021

2008-9 1328973 1475284 -1694 144617

2009-10 1328973 1465580 -1582 135025

2010-11 1328973 1455681 -1467 125242

2011-12 1328973 1445585 -1350 115262

2012-13 1328973 1435287 -1231 105083

2013-14 1328973 1424782 -1109 94700

Total 13577391 14705214 -13060 1114763


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Chanda

Year Estimation of

project activity

emissions (tonnesof CO2e)

Estimation of

baseline emissions

(tonnes of CO2e)

Estimation of

leakage (tonnes of

CO2e)

Estimation of

emission

reductions (tonnesof CO2e)

2004-5 455737 455019 0 0

2005-6 412894 452388 -404 38,372

2006-7 412894 449704 -376 36434

2007-8 412894 446967 -348 33724

2008-9 412894 444174 -320 30960

2009-10 412894 441326 -291 28141

2010-11 412894 438421 -261 25266

2011-12 412894 435458 -231 22333

2012-13 412894 432435 -200 19341

2013-14 412894 429352 -168 16290Total 4171785 4425245 -2599 250861

Kymore

Year Estimation of

project activity

emissions (tonnes

of CO2e)

Estimation of

baseline emissions

(tonnes of CO2e)

Estimation of

leakage (tonnes of

CO2e)

Estimation of

emission

reductions (tonnes

of CO2e)

2004-5 656816 696042 -454 38772

2005-6 646146 704589 -677 57766

2006-7 627008 700016 -845 72163

2007-8 617440 695352 -902 770112008-9 617440 690595 -847 72309

2009-10 617440 685743 -791 67513

2010-11 617440 680794 -734 62621

2011-12 617440 675746 -675 57631

2012-13 617440 670597 -616 52541

2013-14 617440 665344 -555 47350

Total 6252047 6864819 -7096 605677


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SECTION F. Environmental impacts

F.1. Documentation on the analysis of the environmental impacts, including transboundary

impacts:

>>

The environmental impacts of the project are minimal the project activity represents an increase in a

current activity rather than an entirely new activity. Increased fly ash consumption will result in

additional transportation which may involve some environmental impact (the GHG emissions from this

transportation are deducted from the amount of CERs generated by the project activity). Increased dust

from the fly ash blending operation is also a potential environmental impact. However, ACC has taken

measures to minimise these adverse environmental effects:

Air pollution control systems are in operation efficiently and the stack/ambient air quality norms

are better than the standards laid down by Pollution Control Boards.

The fly-ash is transported in closed bulkers so as to eliminate fugitive emissions.

All the unloading points are covered and provided with dust collection systems for maintainingthe AAQ as per norms.

Fly ash is pneumatically conveyed with flow control system with dedusting systems installedto remove fugitive emissions.

F.2. If environmental impacts are considered significant by the project participants or the host

Party, please provide conclusions and all references to support documentation of an environmentalimpact assessment undertaken in accordance with the procedures as required by the host Party:

>>

An environmental impact assessment is not required for the project activity. All the cement plants have

undergone EIAs at the time of construction and each year must obtain consent to operate from the

relevant state pollution control boards.

SECTION G. Stakeholders comments

>>

G.1. Brief description how comments by local stakeholders have been invited and compiled:

>>Stakeholder comments have been obtained through five routes:

National stakeholder: The project has applied for approval from the Ministry of Environmentand Forests. As part of this application, the PDD and PCN have been submitted to the MoEF and

a presentation on the project provided. The MoEF has approved the project activities.

The projects have also received stakeholder approval through the application and obtaining ofconsents to operate from the state pollution control boards.


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Cement customers are key stakeholders in the project activity. Through its outreach andinformation activities on the benefits of PPC, these stakeholders have been informed of the

project activity.

The PDD will be posted on the UNFCCC website for 30 days and comments from internationalstakeholders invited.

There is no change to the local environment from the project activities, and the project activitiesprovide wider environmental benefits conserving limestone and utilising an industrial waste

product. However as part of its local relationship activities, ACC has sent letters to the local

Panchayat at each CDM project cement plant, outlining the project activity and inviting

comments.

G.2. Summary of the comments received:

>>All questions from the MoEF were answered at the presentation. No comments have been receivedfrom the state pollution control board with respect to the blending of fly ash. No comments have been

received from the 30 day international stakeholder assessment and no negative comments have been

received from the local Panchayats.

G.3. Report on how due account was taken of any comments received:

>>

Given no issues were raised no action was required. As highlighted in Section F, ACC have carried out

measures to mitigate any negative environmental effects of blending fly ash. Moreover the project

activity provides substantial positive environmental effects through the disposal of fly ash and

conservation of limestone.


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Annex 1

CONTACT INFORMATION ON PARTICIPANTS IN THE PROJECT ACTIVITY

Organization: The Associated Cement Companies LimitedStreet/P.O.Box: 121 Maharshi Karve Road

Building: Cement House

City: Mumbai

State/Region: Maharashtra

Postfix/ZIP: 400 020

Country: India

Telephone: +91 (0)22 56654321

FAX: +91 (0)22 56317431

E-Mail:

URL: www.acccement.com

Represented by:

Title: Mr

Salutation:

Last Name: Chakravarty

Middle Name:

First Name: Biprajit

Department: Safety, Environment and Corporate Social Responsibility

Mobile:

Direct FAX: +91 22 56317429

Direct tel: +91 22 56654512, 22075908

Personal E-Mail: [email protected]


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Organization: Agrinergy Ltd

Street/P.O.Box:

Building: Cornerways House

City: Ringwood

State/Region:

Postfix/ZIP: BH24 1LG

Country: UK

Telephone: + 44 (0)1258 830556

FAX: + 44 (0)1258 830556

E-Mail: [email protected]

URL: www.agrinergy.com

Represented by:

Title: Mr

Salutation:

Last Name: Atkinson

Middle Name:

First Name: Ben

Department:

Mobile: +44 7960 970974

Direct FAX: +44 870 7623034

Direct tel: +44 870 7623033

Personal E-Mail: [email protected]

8/3/2019 Acc

Acc Revised Pdd

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