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With WHRS, power requirement can be reduced by about 20-25per cent

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O P Puranmalka Managing Director, UltraTech Cement

UltraTech a leader in cement industry has made considerable investments in captive power generation. Apart from generating power from coal fired captive plants, the company satiates a large portion of its power demand through renewable sources. O P Puranmalka elaborates on some of the initiatives in an interaction with ICR. Excerpts from the interview.

What is your current requirement of power and how much of it is met through captive power production?
Our pan-India presence with 12 integrated plants, 12 grinding units and five bulk terminals demands a focused approach towards captive power production to meet our requirements. Our captive power plants with a combined capacity of 707 MW and Waste Heat Recovery System (WHRS) based power plants with a capacity of 55 MW ensure smooth and efficient operations at our units.

We have further extended the wheeling of power to some of our cement grinding units. These measures have resulted in UltraTech being able to meet over 80 per cent of its power consumption through captive sources.

Are you using renewable resources for power generation?
In our quest to explore more options for reducing our dependence on fossil fuels, our unit at Awarpur Cement Works has installed 6 solar arrays in a parallel combination through channel partner Tata BP Solar. The Awarpur unit constitutes an ideal location for a solar power plant installation because it has sufficient shadow-free land area. In addition, the intensity and clarity of light rays in the area are optimal to generate maximum power through the installation of solar arrays. Since 2009, a wind farm has been installed at our Reddipalayam unit. In 2013-14, we generated 2.9 million units from solar power panels and 2.05 million units from wind power.

Brief us about the latest investments made in the captive power generation at your plant.
UltraTech recently invested in brownfield capacity expansion projects in Karnataka, Chhattisgarh, and Rajasthan. These projects include commissioning a clinkerisation plant of 3.3 MT capacity at Rawan Cement Works, Chhattisgarh; a clinkerisation plant of 3.3 MT capacity at Rajashree Cement Works, Karnataka; grinding unit of 1.6 MT capacity at Hotgi, Maharashtra; grinding unit of 1.6 MT capacity at Jharsuguda, Orissa, and grinding unit of 1.5 MT capacity at Rajashree Cement Works, Karnataka.

Further, UltraTech acquired an integrated unit and a grinding unit from Jaypee Cement in Gujarat in June 2014. The integrated plant at Sewagram and grinding unit at Wanakbori in Gujarat together have added 4.8 million tonnes to our capacity, taking our installed capacity to 62 million tonnes.

Recently, UltraTech commissioned captive power plants incorporating latest technologies at three location; Rawan Cement Works in Chhattisgarh 1 x 30 MW, Rajashree Cement Works at Karnataka 2 x 25 MW, and Andhra Pradesh Cement Works 1 x 25 MW (commissioned) + 1 x 25 MW (commissioned).

The two captive power plants at our Sewagram Cement Works plant include a total capacity of 57.5 MW (CPP-I: 35 MW and CPP-II: 22.5 MW). The power requirement of the plant is around 57 MW. The plant also has a standby source of power of around 35 MW.

As part of its commitment to reduce its carbon footprint, UltraTech Cement commissioned a Waste Heat Recovery System (WHRS) producing 13.2 MW of electricity at Awarpur Cement Works in Maharashtra. UltraTech also has a 3.5 MW waste heat recovery plant operational at Andhra Pradesh Cement Works, Tadipatri. We are in the process of installing a WHRS at Rawan Cement Works in Chhattisgarh, Aditya Cement Works in Rajasthan, and Rajashree Cement Works in Karnataka. Post the commissioning of these three plants, UltraTech Cement will be the leader in WHRS in India with a combined capacity of 55 MW. With WHRS, power requirement can be reduced by about 20-25 per cent of total requirement for cement manufacturing. The cost of electrical power for the cement plant gets reduced to a considerable extent.

Are you facing any issues in availability of the raw materials of appropriate quality/price or any kind of logistical challenges?
Majority of our products originate from minerals extracted from quarries, such as limestone, gypsum rock and clay. We have made the use of alternative materials a strategic priority in order to reduce the consumption of natural resources and to extend the life of the quarries.

One of the raw materials used in the manufacture of cement is gypsum. Gypsum can be sourced naturally from quarries or from chemical gypsum, which is a by-product of the process used to treat flue gas from fuel or coal-fired power plants. Chemical gypsum generated during this process is an industrial waste, and depositing it in landfills could be toxic to the environment.

This chemical gypsum is now being used as a part replacement of natural gypsum in cement manufacturing at UltraTech, resulting in effective use of industrial waste as an alternative to a natural raw material, a step ahead in our sustainability journey.

India has huge potential to tap solar and wind energy. What can be done to ensure that these resources are utilised effectively?
After the two oil shocks that our country suffered in the 1970s, a lot of interest has been evinced in new and renewable forms of energy. Solar and wind energy with their "clean energy" tag have received their fair share of research and investment. At the end of last calendar year, it is estimated that India had 20,140 MW of wind power and 2,200 MW of solar power. These numbers are low considering that India generates over 967 TWh (Terra Watt-hour) of energy from non-renewable sources. To give a push to renewable energy sector in the country, we need friendly policies that will incentivise businesses to invest in such forms of thinking. We also need innovative ideas, plans and the will to implement them, even on a pilot basis. For example, the offshore wind farm is one such idea. Our country is blessed with a lot of sunshine and geographical areas like the Thar desert that lend itself to solar power generation.

With governmental will, access to suitable capital and cost effective distribution policies, there is good opportunity to become a world leader in this space, especially as there are still about 300 million people in India who have no access to electricity.

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

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Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.

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