Economy & Market

In Wonder Land

Published

10 years ago

November 30, 2014

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RK Marble Group transformed Bhatkotri, a small village in Nimbahera, Rajasthan, into a township along with its modern cement plant that was set up in 2012. ICR visited this Wonder Cement facility to understand the specialities of the plant and infrastructure.

Part of the RK Marble Group, Wonder Cement is a greenfield project, a fully automated plant with world-class technology, anchored by a group of experienced entrepreneurs from the house of the Patnis, better known as the marble family in the country. Built with a cutting – edge technology, this state-of-the-art project has made its footprint in the burgeoning market of cement industry in the country within a short span of three years. It is the only plant in North India and among the few in India which is fully automated with the latest world-class technology from ThyssenKrupp and Pfeiffer, a German technology major.

The project was commissioned in April 2012 with an installed capacity of 3.25 million tonne per annum (mtpa) of cement. "This plant was conceptualised in 2010 and built in record time of 18 months, whereas normal period to construct similar plant, according to consultants and major companies, is 28-32 months. We completed the project in 18 months for clinkerisation and 21 months for cement production," says SM Joshi, President – Works, Wonder Cement.

A futuristic plant
Wonder Cement is a plant of 21st century, fully automated with the latest German technology and quality control by Automated Po-Lab (Robotic Lab) with AQCNET Software. The plant is centrally controlled and there are various technological features which are hallmarks of the latest technical developments.

There are various other features which are the hallmarks of the latest technology in the international market. Raw material acquisition and refining, considered to be the most important stages in cement production, are carried out by VRM technology, supplied and installed by Pfeiffer while equipment for processing and clinker grinding has been done by ThyssenKrukpp. Latest packaging technology has been also installed at the plant. Other auxiliary equipment have been sourced from the best vendors in the industry.

"When the plant was being coneptualised, our Chairman wanted to give the best product out of the facility. Therefore we selected machinery from ThyssenKrupp and Pfeiffer, Germany," Joshi explains.

Vivek Patni, Director, Wonder Cement, says, "When we were conceptualising this plant, we kept all provisions for modernisation and future expansions. Our infrastructure is suitable for supporting additional capacity. While planning the infrastructure, we were having consultants for architecture and landscaping. You can see the results here. We have very well planned buildings, roads, and landscaping which is difficult to find in other cement manufacturing facilities.

Raw materials mining
Wonder Cement has an installed capacity of 3.25 mtpa of cement, for which 3.75 mtpa ROM (Run-Of-Mine) limestone is required. The company has two mining leases known as Bhatkotari lime stone mines. The total area of mines is 7.4093 sq km. In the mines, there are more than 506 million tonne proved reserves and more than 25 million tonne probable reserves. The total mineable reserves are more than 477 million tonne. Open cast mining is done in both the mines. Chittorgarh area in Rajasthan is known for its superior quality lime stone deposits, possessing high lime content that gives high early strength and ultimate long term strength. Another characteristic feature of this lime stone is low alkali, low magnesia and low chloride contents which are highly desirable parameters for concrete durability.

Crushing and screening
ROM up to maximum feed size of 1.1×1.0x1.0 cu m is dumped in crusher dump hopper. Speed regulated apron conveyor below the dump hopper feed this material to grizzly feeder. The -80 mm material goes to the screening plant and +80 mm material is fed to impactor having the capacity of 1,600 tph. Impactor reduces the size to 75 mm. In screening plant, -10 mm material (mainly containing clay) is separated and rejected. Rest +10 mm material is again mixed with crusher main product. This mixed material is stored in surge bin. From surge bin, this material is fed to limestone stacker through apron conveyor and belt conveyors. For better blending, the material is stacked in layers in yard with the help of stacker. Pile formation takes place in Chevron method. And online quality control by cross belt analyser, which is the world?s best Combi CBA having CNA technology also, which is introduced in India for the first time. Approximately 93-95 per cent of materials, limestone and marl, is used from captive mines for the preparation of raw mix for manufacturing the desired quality of clinker. The other additives (5-7 per cent) used after pre-blending by stacker and reclaimer to control the moduli values in the mix. To get consistent quality of in process material, pre-blending equipment are installed for each raw material.

Raw material grinding
The state-of-the-art technology adopted at the plant consists of vertical roller mill of Pfeiffer, Germany, for grinding raw material to achieve the optimum fineness, and controlled particle size distribution of raw material particles. The capacity of the raw mill is 550 tph. After the complete process, the finely ground raw material is collected in a set of cyclones installed after the mill. Through air slides below multicones, the product is transported to silo with the help of elevator. The dust-laden air after multiclones is de-dusted in the bag house.

Coal grinding
For grinding of petcoke/coal, again there is a vertical roller mill having capacity of 35 tph. The operation of this mill is same as in the raw mill. The only difference is to have a constant watch over the mill outlet temperature to avoid any explosion and dust laden gases are de-dusted in bag house.

Pyro processing
Wonder Cement plant has a 75 m long kiln having diameter of 5 m for manufacturing OPC clinker supplied by Polysius ThyssenKrupp. The clinker is produced by burning the finely ground raw meal known as kiln feed in a rotary kiln. The temperature in the burning zone is usually 1,400-1,450oC and the residence time in the kiln is 15 minute. The process taking place in the kiln system consist of a temperature dependent decomposition of the raw material minerals according to the nature, followed by a recombination of the liberated free reactive oxides forming clinker minerals. The overall chemical reactions transforming the mixture of raw material minerals in the raw meal to the mixture of the clinker minerals in the clinker is endothermic (heat consuming). The clinker formed in kiln is cooled inside the polytrack cooler from 1,450oC to around 110oC and then it is stored in clinker silo having a storage capacity of 45,000 tonne.

Cement grinding
The final manufacturing stage at a cement plant is the grinding of cement clinker from the kiln, mixed with gypsum, into a fine powder.

It is important to obtain a certain specific surface for the finished cement so that hydration can take place and concrete strength develops within a reasonable time. In addition to the specific surface, also the particle size distribution influences the strength properties especially the late strength. At WCL, cement grinding circuit is having roll press with closed circuit single chamber ball mill.

At the outlet of the grinding mill, the ground material flows through an outlet grate to dynamic separator by mechanical conveyors, for fine separation as grinding system is closed circuit mill. Grinding in close circuit makes it possible to obtain a very finely ground cement. Another advantage is that it is easy to change from one grade of cement to another grade by adjustment of the separator speed. Cement produced in closed circuit mill has narrow particle size range and the quantity of 3 to 30 micron fraction is more in comparison to open circuit mill, resulting in higher late strength. The mill ventilation air carries a small portion of the fine material, which is de-dusted in a highly efficient bag-house. Finished product with separator air is passed through multi-clones where finished product is separated and stored in cement silos with the help of mechanical conveyors.

Cement packaging
Cement is stored in four cement silos, extracted, bagged by three electronic roto packers of capacity 240 tph each with an accuracy of +50 gm and -0 gm, and transported by trucks.

Quality product
Wonder Cement produces three grades of cement: OPC 43, 53 and PPC. Joshi claims, "We produce much higher strength cement than what is required by BIS. Our 53 grade cement is giving a strength of 68-70 Mpa against a requirement of 53 Mpa. The 53 Mpa strength is required after 28 days of setting time. Our cement crosses 53 Mpa in eight days and reaches 68-70 Mpa in 28 days. This type of performance is not available in any other cement in India. This is achieved due to very narrow and uniform particle size distribution of our cement and exceptionally good quality control system."

The market
The present capacity of the plant is 3.25 million tonne per annum (1,80,000 bags per day). The company has a wide network of 2,500 dealers who keep and maintain the supply chain in Rajasthan, Gujarat, Madhya Pradesh, Haryana, Uttar Pradesh, Delhi and Punjab. The company has a team of over 500 dedicated professionals. "We sell 50 per cent of our production in Rajasthan itself. Remaining 50 per cent is sold in the other states adjoining Rajasthan. Right now we are focusing on in and around Rajasthan because the best realisation is available at shortest distance. If you start sending cement to longer distances the realisation will be less," observes Patni.

Captive power
To ensure uninterrupted power supply to its plant in Nimbahera, the company has installed a captive power plan of 40 MW. The power plant uses petcoke as fuel sourced from IOC?s Baroda plant and Jamnagar refineries of Essar and Reliance. "We always use petcock as fuel for our power plant which is economical. In this area it is almost 25-30 per cent cheaper compared to other fuels," Joshi informs.

Keen on Green
The plant has complied with the norms of the environment ministry. The entire design of the plant is based on the latest environment norms, with the help of reverse air bag house and ESP and a number of nuisance bag filters installed having emission of much below the permissible unit. That enables the plant to be clean and dust free. An ecological balance has been maintained through massive plantation and development of ornamental gardens in the areas around the plant site. A fair measure of company?s concern on environmental issue is seen in the plantation of 55,000 tree saplings in 50 hectare in two years against a target of 75 hectare in 20 years.

Expansion plans
Wonder Cement has drawn up an ambitious expansion plan to double the production capacity in the next two years. The company has plans to expand its current capacity to 10 million tonne in due course by setting up a second and third production lines, for which land and layouts are ready. "Our second line is under execution with an expenditure of about Rs 1,200-1,400 crore. It will be ready by end of 2015," Joshi sums it up.

Concrete

Revolutionising Energy

Published

2 weeks ago

September 23, 2024

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The April-June 2024 quarter posed a challenging period for India’s cement industry, with softer prices putting pressure on the topline of many firms. While volume growth has been steady, muted revenues underline the pressing need for a price revival, which experts anticipate in the second half of fiscal 2025. However, the dip in revenue is counterbalanced with the spirit of optimism.
Given the Indian government’s ambitious infrastructure plans, involving a $1.7 trillion investment by 2030, the Indian cement companies are set to invest $14.3 billion over the next four years in capacity expansion.
However, with growth comes responsibility. The cement sector, being one of the most energy-intensive industries, is under increasing scrutiny for its environmental impact. As India marches towards becoming a global leader in sustainable development, all leading cement companies are aligning their strategies with decarbonisation goals, setting Net Zero targets for the coming decades. This commitment reflects the larger trend of industries embracing green manufacturing operations as both an ethical responsibility and a competitive advantage.
A significant part of this transformation will be powered by renewable energy. By 2030, India’s cement sector is estimated to add up to 5 GW of renewable energy, a crucial step towards reducing the industry’s carbon footprint.
The path forward also involves adopting the principles of a circular economy, which will be pivotal in minimising waste, reusing resources, and ensuring long-term sustainability. As we look ahead, it’s clear that the cement sector’s focus on energy efficiency and sustainability will not only help meet climate targets but also foster prosperity and growth in the years to come.
Further, ASAPP Info Global Group (the publisher of ICR) is hosting the RAHSTA (Roads & Highways Sustainable Technologies & Advancements) Expo from October 9-10, 2024 at the Jio World Convention Centre, Mumbai, to showcase latest developments in technologies and materials used for road construction. To know more, visit www.RAHSTAexpo.com

Follow me on twitter @PratapPadode

Concrete

Sustainable Procurement Practices

Published

2 weeks ago

September 23, 2024

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Partha Dash, Managing Director, Moglix, discusses how India’s cement industry, a key player in the country’s construction growth, is at a critical juncture as it faces the challenge of balancing expansion with sustainable practices.

According to research by construction blog Bimhow, the construction sector contributes to 23 per cent of air pollution, 50 per cent of the climatic change, 40 per cent of drinking water pollution, and 50 per cent of landfill wastes. Over the last decade cement has been one ubiquitous element in India’s construction growth story. As the world’s second-largest producer, we are seeing an impressive growth trajectory. Major players like Birla, Adani, Dalmia Bharat, JK Cement and Shree Cement are expanding fast, with plans to add 150-160 million tonnes of capacity over the next five years. This follows a substantial increase of 120 million tonnes in the past five years, pushing India’s total capacity to around 600 million tonnes. But with all this expansion, we have got a big question – How do we ensure sustainable procurement practices, in such an energy dependent industry?

Energy-intensive nature of cement production
Making cement takes a lot of energy. Process starts with limestone being mined, crushed, and grounded, using about 5-6 per cent of the total energy. The biggest energy use happens during clinker production, where around 94-95 per cent of the energy is used. Here is where limestone is heated to very high temperatures in a kiln, which needs a lot of energy from fossil fuels like coal and pet coke. Electricity is also used to run equipment like fans and kiln drives.
Once the clinker is made, it’s ground into cement. This grinding process uses another 5-6 per cent of the energy and usually happens at facilities close to where the cement is needed. Facilities that handle both clinker production and grinding in one place are generally more energy-efficient. Many of these places use coal-powered plants to supply the heat needed for the kilns, keeping production steady.

Transitioning to bulk cement
Making cement use more efficient is key to reducing the industry’s carbon footprint. In India, as per research by World Economic Forum around 75-80 per cent of cement is sold in 50kg bags to small-scale builders and individuals. But there’s often little insight into how this bagged cement is used. Research from the World Economic Forum also shows that about 40 per cent of this cement is mixed by hand. Builders sometimes use more cement than needed, thinking it will make the structure stronger, which increases emissions.
It’s crucial to educate these small-scale users about using cement efficiently. Builders need accurate information on mixing ratios and should be encouraged to adopt design techniques that use less cement. One idea suggested in the report is to put embodied carbon labels on cement bags to provide this information, helping to promote more sustainable practices at the grassroots level.
On the flip side, bulk cement, which now makes up 20-25 per cent of India’s cement use, has its own set of challenges and opportunities. Bulk cement is often used for large-scale projects that need high-strength concrete, which tends to be more carbon-intensive. However, it also makes it easier to mix in supplementary cementitious materials (SCM), which can reduce the carbon intensity of the cement. As bulk cement use grows, especially in big infrastructure projects, balancing structural needs with lower-carbon solutions will be crucial.

Challenges in sustainable procurement
The cement industry finds it hard to adopt sustainable procurement because many companies aren’t fully on board with it. Sometimes, sustainability isn’t a big focus for the company, which means top management doesn’t fully support it. This lack of support slows down collaboration with environmental experts and limits the adoption of green practices. Additionally, many clients still prefer traditional materials, which means there’s less demand for sustainable options.
In terms of knowledge and innovation, there’s a gap in understanding how to incorporate green procurement into existing practices. Many companies aren’t fully aware of the benefits of adopting green strategies or getting environmental certifications. This lack of knowledge also affects the public sector, where innovation in sustainable practices is often held back due to a shortage of technical support and experts.
There’s also a common belief that green procurement is more expensive, which can be a significant barrier, especially when resources for sustainable products are limited. Awareness and readiness for green practices are still low. Many people don’t fully understand the importance of sustainable procurement in construction, and there’s a lack of information about the market for green materials. Without adequate training and a clear structure for green purchasing, it’s difficult for companies to fully commit to sustainability. Moreover, existing policies and regulations aren’t strong enough to drive real change and without enforcement and incentives, the availability of green materials remains limited.

Opportunities in sustainable procurement
To fully understand the opportunities in sustainable procurement, Indian construction companies need to make it a key part of their business approach. This requires strong support from top leadership, including CEOs and boards of directors. When sustainability is a central focus in a company’s goals, it not only improves environmental impact but also sets the company apart in the market. Firms that focus on green practices can attract clients who value sustainability.
Working together with industry, academic institutions and government bodies is crucial for advancing green procurement. Top institutions in India like IIMs and IITs should collaborate with agencies like the Central Pollution Control Board and the Ministry of Environment. These partnerships can help develop shared goals and standards, like ISO 14000 for Environmental Management Systems, and offer training programs across the country.
It’s crucial to help clients understand how green buildings can save money over time. These sustainable structures not only cut down on running costs but also enhance the quality of life for those who live or work in them. Organisations such as the Construction Federation of India and the Builders Association of India should promote green products, which can drive demand and reduce costs by boosting production.
The government’s role is also vital. Programmes like the Pradhan Mantri Awas Yojana should focus on using green materials to show that sustainable construction can be affordable. To encourage use of sustainable materials, giving incentives like tax breaks, just like the ones for electric vehicles, could make a big difference.
Establishing a national certification for green procurement professionals, backed by organisations like the Indian Green Building Council, can help create a skilled workforce that can lead sustainable practices in the construction industry. By seizing these opportunities, India can move toward a more sustainable future in construction.

India’s leadership in sustainable cement production
India has made impressive strides in sustainable cement production. As per a research report by JMK research and analytics in 2022, the global cement industry accounted for 26.8 per cent of industrial emissions, but Indian manufacturers have been proactive in reducing their carbon footprint. The same report also states that between 2017 and 2022, the industry cut its emissions intensity by 19.4 per cent, thanks to a rise in alternative materials like fly ash and slag Blended cements, which now make up 81 per cent of India’s output, are a big part of this progress.
Leading cement producers in India, including Ultratech Cement, Shree Cement and Dalmia Cement, have committed to reducing emissions by 20 per cent by 2030, with a long-term goal of achieving net-zero emissions by 2050. Recently, the industry introduced 150 electric trucks to reduce carbon footprints, though challenges like limited charging infrastructure and high costs remain. Still, this move is expected to cut logistics expenses by 25-40 per cent. The industry is also pushing for policy support to accelerate the adoption of electric trucks and further its sustainability goals. According to report published by India Brand and Equity Foundation, some of the major investments in renewable energy and energy storage solutions include:

UltraTech Cement plans to deploy 500 electric trucks and 1,000 LNG/CNG vehicles by June 2025, cutting transport emissions by 680 tonnes annually. They aim to reach 85 per cent green energy use by 2030 and boost production capacity to 200 million tonnes.
Shree Cement completed a 6.7 MW solar project in Haryana in September 2022.
Dalmia Cement aims to produce 100 per cent low-carbon cement by 2031, supported by a $405 million carbon capture investment.
JK Cement signed an agreement with PRESPL in October 2021 to increase the use of biomass and alternative fuels, reducing reliance on coal.

Is the impossible possible?
The Indian construction and cement industries are making prudent strides toward sustainability. Recent research shows a strong link between the use of renewable energy and economic growth, highlighting the importance of reducing reliance on traditional energy sources. The construction industry, which has a large environmental impact, must adopt greener practices to help reduce pollution and waste.
The Indian cement industry is leading the way, with plans to significantly increase its use of renewable energy by 2026. This shift not only helps reduce costs but also sets a positive example for other sectors. The focus on renewable energy, like solar and wind, and efforts to avoid new thermal power plants show a clear commitment to a more sustainable future.
As the cement industry continues to push for net-zero emissions by 2050, its proactive approach is setting a new standard. These efforts not only benefit the industry itself but also provide a roadmap for others to follow. By embracing greener practices, the cement industry is helping to pave the way for more sustainable and environmentally friendly procurement practices in India.

About the author:
Partha Dash, Managing Director, Moglix, is a sales and marketing professional with 15+ years of hands-on experience in shaping businesses especially in the emerging markets.

Concrete

Managing energy consumption and emissions is crucia

Published

2 weeks ago

September 23, 2024

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Raju Ramchandran, SVP Manufacturing (Cluster Head – Central), Nuvoco Vistas, discusses the company aims to reduce its carbon footprint and drive long-term environmental and operational improvements.

Can you provide an overview of your company’s current initiatives and strategies to enhance energy efficiency in cement production?
As a cement manufacturing company, managing energy consumption and emissions is crucial for achieving sustainable operations. At Nuvoco, significant measures have been taken to address this issue and leverage it as a competitive advantage. As part of its energy-efficient initiatives, Nuvoco is at the forefront of integrating green power and alternative fuels into its operations. This pivotal strategy significantly reduces Greenhouse Gas (GHG) emissions and underscores its dedication to sustainable practices. Additionally, by harnessing waste heat generated from manufacturing processes, Nuvoco converts it into clean energy, thereby reducing reliance on the grid and enhancing energy efficiency.
Furthermore, the company efficiently manages its power and fuel mix by incorporating alternative fuels into its operations. The manufacturing processes enable the use of waste materials from industries like steel and thermal power generation as alternative fuels. The company’s mix of alternative fuels includes solid waste, liquid solvents, biomass, refuse-derived fuels (RDF) from municipal solid waste, and other substances, with a focus on biomass. The company’s use of alternative fuels is a testament to its commitment to reducing its carbon footprint and supporting local areas by consuming waste, thereby making the city cleaner. The company has also implemented efficiency control measures by incorporating ‘Good Run Settings’ for kilns and mills and using an AI platform to strengthen Proportional Integral Derivative (PIDs).

How do advancements in technology contribute to improving energy efficiency in your cement plants? Can you provide some examples?
Nuvoco relies significantly on technological advances to improve energy efficiency. A key technology in this effort is the Waste Heat Recovery System (WHRS), which captures and utilises heat from clinker kilns to generate power, reducing dependence on fossil fuels.
This technology has been implemented across all the cement plants to reduce Specific Heat Consumption (SHC) and Specific Power Consumption (SPC) during clinker and cement manufacturing processes. The optimisation of power generation through WHRS contributes significantly in reducing environmental impact.
Additionally, Nuvoco has implemented an advanced system designed to utilise a wide range of waste materials, including agricultural waste, refuse-derived fuel (RDF), plastic waste, municipal waste, biomass, tyre chips, and other hazardous sources. This system integrates Alternative Fuel and Raw (AFR) feeding into the pyroprocess, ensuring uniform feeding and incorporating essential safety interlocks. By efficiently consuming alternative fuels, this initiative adheres to the environmental standards set by the Pollution Control Board of India.
Though the primary focus is on enhancing environmental sustainability, this project also significantly benefits clinker production and provides substantial cost savings through the alternative fuels programme.

What role does renewable energy play in your overall strategy for energy efficiency, and how is it integrated into your cement manufacturing operations?
Energy efficiency refers to using less energy while increasing the output of a manufacturing unit. As part of Nuvoco’s ESG agenda, the company focuses on reducing reliance on fossil fuels and minimising its environmental footprint through smart energy sourcing and in-house capabilities. Nuvoco’s cement manufacturing units are equipped with alternative fuel capabilities, supported by investments in alternative fuel material handling facilities. This enables the company to achieve optimal levels of Specific Heat Consumption (SHC) and Specific Power Consumption (SPC) in its clinkerisation and grinding units.
The company has made significant strides in renewable energy integration, with 1.5 MW solar power plants, 150 MW captive power plants, and 44.7 MW waste heat recovery systems (WHRS) in place.
Nuvoco has also made remarkable progress in its Alternative Fuel Rate (AFR) mix, which improved to 13 per cent in FY24, positioning the company among the industry’s leaders in this area. These initiatives collectively contribute to Nuvoco’s overarching strategy of energy efficiency and sustainability in cement manufacturing.

How do you measure and monitor energy efficiency in your cement manufacturing processes, and what metrics are most critical for your company?
Nuvoco has established a rigorous system for measuring and monitoring energy efficiency across its cement manufacturing processes. Key metrics are tracked using advanced monitoring systems to ensure both optimal performance and strict regulatory compliance.
One critical aspect of this monitoring involves the consistent tracking of air emissions from fuel combustion in cement production and power generation operations. This includes pollutants like oxides of sulphur (SOx), oxides of nitrogen (NOx) and particulate matter (PM). Nuvoco employs Continuous Emission Monitoring Systems (CEMS) to observe these emissions in real-time, ensuring adherence to environmental standards.
Additionally, the use of Smart Motor Control Centers (MCCs) and the latest technology energy managers helps to monitor energy consumption at the lowest possible levels. This enables better energy consumption analysis and optimisation of energy usage, leading to significant cost savings and improved efficiency.

Looking ahead, what are your company’s strategic priorities for further improving energy efficiency, and how do you plan to address future energy challenges in the cement industry?
Nuvoco is steadfast in its commitment to enhancing energy efficiency as a key driver of sustainable growth. Looking ahead, the company has outlined several strategic priorities to further advance its energy efficiency efforts and address future challenges in the cement industry. One of the core priorities is the continued integration of renewable energy sources into operations. Nuvoco plans to expand its solar energy capacity and optimise its existing Waste Heat Recovery Systems (WHRS) to reduce reliance on non-renewable power sources. The company is also focused on increasing the use of alternative fuels, such as refuse-derived fuel (RDF), biomass, and other waste materials, to further reduce its carbon footprint and promote a circular economy.
Innovation and technology will play a crucial role in achieving these goals. Nuvoco is investing in advanced energy management systems and digital technologies to monitor and optimise energy consumption across its plants. This includes the implementation of smart grids, predictive maintenance systems, and real-time energy monitoring tools
that enable more efficient operations and reduce energy waste.
In alignment with its commitment to sustainability, Nuvoco’s ‘Protect Our Planet’ (POP) agenda, launched in FY 2022-23, has progressed significantly, representing a major step forward. By integrating sustainability into every facet of operations and utilising a governance system with monthly performance tracking, the POP agenda focuses on key areas identified through materiality assessments. This strategic approach has led to the creation of sustainability roadmaps that target decarbonisation, water management, circular economy, biodiversity and waste reduction.
Through these initiatives, Nuvoco not only meets regulatory requirements but also contributes positively to environmental conservation, reinforcing its role as a leader in sustainable cement manufacturing.

Can you discuss any specific projects or upgrades your company has undertaken to reduce energy consumption and increase efficiency in your cement production facilities?
The cement industry is inherently energy and resource-intensive, and at Nuvoco, we are committed to leveraging cutting-edge technologies to reduce energy consumption and increase efficiency across our production facilities.
The adoption of Industry 4.0 principles has been pivotal in driving this transformation. We’ve integrated advanced technologies such as IoT, Artificial Intelligence (AI) and Advanced Process Control (APC) into our operations. These digital innovations, coupled with specialised robots and online equipment, have significantly enhanced the production processes, reduced environmental impact while increased energy efficiency.

– Kanika Mathur