Environment

The companys overall carbon intensity has been cut by 32 per cent since 1990

Published

11 years ago

May 31, 2014

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KN Rao
Director (Energy and Environment), ACC
Being the oldest manufacturer of cement, ACC had faced many technical and financial challenges while upgrading the old processes and equipment. Today ACC operates one of the largest kilns in the world and uses state-of-the-art technologies at its new plants. KN Rao Director (Energy and Environment), ACC Limited, elaborates on innovative measures taken for improvement of energy efficiency of the plants.

How do you rate your company when it comes to sustainable production of cement?
We closed the year 2013 with a sense of satisfaction when we received external recognition with the prestigious ?CII-ITC Sustainability Prize? in category ?A? for large companies. The award is acknowledged as being among the top honours for sustainability in organisations across all sectors. We were also ranked as ?The Most Admired Company in Cement Sector in 2013? by Fortune India magazine.

In 2013, we realised 94,459 Certified Emission Reductions (CERs) from our Clean Development Mechanism (CDM) projects registered with United Nations Framework Convention on Climate Change (UNFCCC) and have submitted verification reports recommending for issuance of 846,313 CERs.

What operational measures have you taken to improve sustainability of your plant?
During the year, we commissioned ACC?s first waste heat recovery power generation unit of 7.5MW, which has the potential to reduce ~44,180 tonnes of CO2 per year while providing 7.5 per cent green energy for the plants.

This shows us a way to set up similar systems at our other plants.
Have you done any modifications in the plant lately to reduce emissions?
On the environment excellence journey, the company?s overall carbon intensity has been cut by 32 per cent since 1990, thanks to proactive and consistent attention. Despite an increase in demand for more ?carbon-intensive? products like ordinary Portland cement (OPC), ACC was able to reduce overall specific CO2 emissions to 528 kg CO2 /tonne of cement through various initiatives in the entire business operations. Another area of improvement is the reduction of specific kiln dust emissions by as much as 18 per cent. Demonstrating greater transparency, ACC has started online reporting of kiln stack dust emission from various plants to the pollution control boards.

Please tell us in brief about the upgrades done and initiatives taken to improve energy efficiency of your plants.
ACC?s in-house R&D has been driving several innovative approaches to improve plant efficiency. Some of the initiatives are listed below:
Conversion of wet/semi dry kilns to long dry process/suspension pre heater kilns
Disengaging some of the inefficient wet kilns and converting them into the refractory kilns
Increasing the number of stages of suspension pre heater kilns to 5/6/7
Introduction of pre-calciners for increasing the thermal and electrical efficiency
Introduction of high efficiency coolers
Introduction of pre-grinders for improving the grinding efficiency
First to develop energy efficient indigenous (1 MTPA) cement plant
Developed energy efficient mini cement plant with rotary kiln
First to introduce blended cements (PPC and PSC) in India and registered the largest CDM project in the Indian cement industry
Using latest grinding technology of vertical roller mills and roller press with efficient separators for grinding raw materials and finished products
Efficiency improvement of all process equipment like fans, compressors, pumps, material handling systems, size reduction equipments, etc
First to introduce alternative raw material in cement industry
Co-processing of waste and biomass in cement kilns to reduce the CO2 emission
Introduction of high efficiency burners, seals, expert control system and variable speed drives, etc
Conversion of low efficiency (stoker fired boilers) to high efficiency (FBC) boilers
Introduction of CFBC technology for CPP
Extensive use of biomass in CPP
Use of wind energy for cement manufacturing (9 MW), and
Efficient lighting and solar energy usage for water heating and operating small water pumps.

What are the challenges faced while adhering to pollution control norms, especially stack emissions and dust hazard. How have you tackled them?
By its very nature cement manufacturing process is based on size reduction where huge rocks of mined material are crushed to fine powder and then converted to cement. Thus the manufacturing process calls for handling of large amounts of dust mostly in dry form at various stages of manufacturing. ACC with its long experience spanning more than 7 decades, had implemented various measures on continuous basis and will continue to address the issue by deploying the latest available technologies and taking all possible measures.

With all these efforts ACC?s stack emissions have reduced considerably to the current levels of <50mg/Nm3. All our latest air pollution control systems are operating at <20mg/Nm3. ACC has also installed various continuous emission monitoring systems like opacity monitors, CAAQMS, CEMs, etc., for continuous tracking of these emissions and to trigger immediate corrective actions where required. These initiatives have led to reduction of specific kiln dust emissions by as much as 18 per cent. Demonstrating greater transparency, we have started online reporting of kiln stack dust emission from various plants to the pollution control boards.

Please tell us about your efforts in water conservation/water harvesting, etc.
Water stewardship is embodied as a critical part in our sustainable development approach. We strive to maintain zero process waste water discharge, and always look out for better ways to manage our water resources efficiently by way of recycling and rainwater harvesting in mine pits. While some of our plants have become near self-reliant with respect to their water requirements for industrial and domestic consumption by utilisation of harvested rain water, we have devised plans to address water-related risks and are taking measured steps to reduce current dependency on other sources of water. Some of our water conservation and management initiatives include water treatment, recycling and reuse of water. We have systems in place for treating water rejects from plant operations. The treated water is recycled back to the system helping to reduce fresh water requirement. Sewage treatment plants treat sewage generated in the residential townships. The treated sewage water is used for green belt development, while worked out mined pits are used to harvest rain water, which is subsequently consumed by the plant and nearby communities.

The ACC Jamul Cement Works Water Project is one of the examples of ACC?s ongoing projects to utilise water resources in a sustainable manner. ACC Jamul Cement Works in Chhattisgarh has always been conscious of water conservation and harvesting. Since decades, the plant has been harvesting large quantities of rain water in two mined out pits. Here on an average 12-15 lakh m3 of rainwater is collected in each pit every year. Numerous water saving projects were taken up in different areas of the 0plant and colony at Jamul, which resulted in substantial amount of water saving. The achievement of the last year, however, is not an end or a destination but it?s a journey, striving for new objectives and targets.

ACC was able to reduce overall specific CO2 emissions to 528 kg CO2 / tonne of cement through various initiatives in the entire business operations.

Concrete

India donates 225t of cement for Myanmar earthquake relief

Published

2 weeks ago

June 17, 2025

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On 23 May 2025, the Indian Navy ship UMS Myitkyina arrived at Thilawa (MITT) port carrying 225 tonnes of cement provided by the Indian government to aid post-earthquake rebuilding efforts in Myanmar. As reported by the Global Light of Myanmar, a formal handover of 4500 50kg cement bags took place that afternoon. The Yangon Region authorities managed the loading of the cement onto trucks for distribution to the earthquake-affected zones.

Concrete

Reclamation of Used Oil for a Greener Future

Published

2 weeks ago

June 16, 2025

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In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.

The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.

The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.

Circular economy in lubricants
In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt, and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.

Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.

Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)

The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.

On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:

Kinematic Viscosity
Flash Point
Total Acid Number
Moisture / Water Content
Oil Cleanliness
Elemental Analysis (Particulates, Additives and Contaminants)
Insoluble

The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.

Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.

About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

Concrete

Charting the Green Path

Published

2 months ago

May 13, 2025

admin

The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.