Connect with us

Environment

In Pursuit of Greener India

Published

on

Shares

For many cement companies in India, AFR represents an important business opportunity because it reduces fuel costs and CO2 emissions. By dealing safely with wastes that are often difficult to dispose of in any other way, cement manufacturers are able to provide an important service to society.

Cement production is characterised by an extremely high-temperature combustion process (up to 20,000?C flame temperature), necessary for heating and fusing the raw materials. The traditional fossil fuels most commonly used in this combustion process are coal, heavy fuel oil or gas. Substitution of these fossil fuels by alternative, waste derived fuels is a common practice in the cement industry, in many parts of the world. The nature of the production process makes it eminently suitable for this purpose – by ensuring full energy recovery from various wastes under appropriate conditions. Any solid residue from the waste then becomes a raw material for the process and is incorporated into the final cement clinker. Sometimes, waste can also be used to substitute raw materials in the process, thereby also conserving the natural resources generally used in the manufacture of cement.Why is this issue important?

Waste is an important issue for society – as an example, Europe alone produces more than 350 million waste tyres per annum. Recycling and disposal options for many waste materials and industrial by-products are often limited – used tyres is but one example. Where recycling is not possible, incineration or landfill is the most common disposal practice available for many wastes. However, by using waste as an alternative fuel or raw material in the cement-making process, there are benefits for society as well as to the cement maker. For many cement companies in India, it represents an important business opportunity, because it reduces fuel costs and CO2 emissions. By dealing safely with wastes that are often difficult to dispose of in any other way, cement manufacturers are able to provide an important service to society.

India can achieve 25 per cent thermal substitution rate (TSR) by 2025. In comparison to global standards, the country is far behind, as in many countries the substitution is 60-100 per cent. The main differentiator is the waste characteristics and the lack of support by the required agencies for generating a good segregated quality waste. This long term plan of achieving 25 per cent substitution rate, is as it is very challenging.

Challenges
Why achieving 25 per cent substation rate is a challenge, is very well explained by Milind Murumkar, Advisor – AFR, Vicat India Group. The main challenges faced by any cement manufacturer in use of Alternative Fuels & Raw Materials (AFR), which can be classified into four.

Managements ‘will’ to use and improve the AFR utilisation in its plants. Which means, creating a suitable environment and commitment in their people to achieve the targeted short and long term plans. Initially no one is willing to bring and use waste – which may have strong or unpleasant odour, may be difficult to handle, store and use – from other industries in their plant. Management thus needs to build and develop the infrastructure in a manner that it can use all types of industrial wastes be it solids, semi-solids or liquid.

Secondly, skill development and infrastructure is important, as AFR utilisation requires special skills in cement plants. In this case, engineers need to be properly trained to understand the waste characteristics, raw material and fuel characteristics; and the point of dosage in the kiln. This is mainly due to the fact that while using higher quantities of wastes in cement plants, process stabilities are maintained, which may otherwise affect the quality of product and production levels. A cement plant has to know its raw material composition and fuel composition to decide on the types of waste that can be used in their system and accordingly decide on the feeding points of different types of waste that need to be co-processed.

Murmukar further enlightens the regulatory requirements. There are specific rules and guidelines for hazardous waste during transportation, storage and usage, that the cement plants have to comply with, while using hazardous materials. The equipment and storage area etc., needs to be selected based on the availability of waste and the plants for next 10-15 years. Here Murumkar’s advice is to have proper market data mapping and long term agreements with the waste generators to build trust and confidence in them.

Lastly, understanding waste and waste generators, is the most challenging factor. It is necessary to understand the pain points of the waste generating industry and work on providing a total solution for managing their waste in an environmental friendly manner. Business success depends on having a good ‘win-win’ model between the cement plant and the waste generating industry. Waste generators need total solution for the different wastes generated. The success in utilisation of different types of waste in cement plant lies in having co-processing ability for providing total solution to the generating industry.

AFR for Greener India
As rightly simplify by UltraTech officials, the advantages of co-processing of alternate fuel in cement plant ranks higher in the waste processing hierarchy. This is because, high flame temperature (2,000?C) – ensures complete destruction of harmful pollutants. Residence time of combustion gases above 1,000?C in excess of three-four seconds – ensures complete destruction of pollutants. Plus, a complete destruction of organic compounds. Importantly, co-processing of AFR in cement ensures total neutralisation of acid gases, sulphur oxides and hydrogen chloride, by the active lime in the kiln load, in large excess to the stoichiometry. And, for the betterment of environment, there will be no production of by-products such as ash or liquid residue from gas cleaning.

Benefits of AFR is it produces overall environmental benefits by reducing releases to air, water and land. It also, maximises the recovery of energy while ensuring their safe disposal. Since, most of the cement plant use coal as a fuel, AFR definitely stands a chance to substitute coal, with savings made through resource conservation and associated CO2 emissions.

Meanwhile, one must understand that not every waste is suitable. In addition, according to Holcim, manufacturers must ensure that they do not impact product quality nor increase their atmospheric emissions by using a particular waste. At the same time, a key objective of AFR use is to achieve reductions in CO2 emissions. Meanwhile, stakeholder debate continues over the use of AFR in cement kilns. Some stakeholders are concerned about potential health or environmental impacts from the handling and combustion of alternative fuels. Others are concerned that product quality could be compromised. It has also been claimed that the use of waste and by-products as fuels actually perpetuates the production of these wastes, by offering a legal, cost-efficient solution to disposal.

However, other stakeholders are pleased by the ‘win-win’ possibilities of cutting GHG emissions and disposing of wastes by using AFR. It is therefore a challenge for cement manufacturers to manage stakeholder expectations and provide assurances to demonstrate their responsible use of these waste materials.

Cost Matter
Use of alternate fuels for TSR is a financial viable intervention with very good internal rate of return (IRR). It also depends on the type of waste proposed for usage and technical intervention. Many Indian cement plants have successfully implemented these options and substituted fossil fuel significantly. The payback period generally varies between two-four years.

Meanwhile, AFR is certainly beneficial in terms of earnings for the company (Refer Earning Benefits on page no 44). If managed properly, to have a blend of commodities and industrial waste in terms of TSR and thermi cost reduction, the benefits will be substantial. Unless AFR co-processing has a good economic viability, its long-term sustenance cannot be ascertained. The entire economic model needs to be such that the Rs/thermi is lower than that of fossil fuels.

Consistent Quality
Consistent supply and uniform quality are main constraints in utilising AFRs – for example, tyre carbon black. The cost of the carbon black depends upon the cost of waste tyres in the domestic market and import conditions. Due to high demand for waste tyres, the cost of carbon black is increasing and hence its adulteration too. There should be long term agreement with the manufacturers directly with clear quality parameters, thereby the traders can be avoided and can sustain the supply as well as quality. However, the essence of the agreement shall be the price factor with regards to the coal price. Regulatory authorities need to standardise all waste to streamline market operations.

Also, there is no existing standard for NOx from kiln Only SPM standard is 50 mg/Nm3 for new plants and 100 mg/Nm3 for old plants. NO2 standard from 1-1-2016 and SPM standard from 1-6-2016 for cement kiln will be 800 mg/Nm3 and 30 mg/Nm3, respectively. Now, most of the cement manufacturers have deployed online monitoring system and commissioned in plants stacks for monitoring SPM, SO2 and NOx. The online monitoring system has already started and likely to help manufacturers in controlling emissions while firing different type of AFRs.

Present Policy Framework
The Indian Waste Management policy frame-work, notified in 2016 is well designed for sustain-able waste management. It gives due recognition to co-processing. Its salient features are following.

  • These are based on the principle of Sustainability rather than disposal
  • Waste generator is required to manage his waste respecting the Waste Management Hierarchy and SPCBs are required to authorise the same. (Rule 4, HWM)
  • A facility is required to obtain authorisation from SPCB for receiving, storing, handling, transporting and pre-processing of wastes based on the availability of compliant infra-structure to handle them safely. (Rule 6, HWM)
  • Co-processing in cement plant is to be implemented based on the compliance to prescribed emission standards. Co-processing trial of any waste is not required anymore to receive authorisation for its co-processing. (Rule 9, HWM)
  • Interstate movement of wastes for recycling or co-processing is to be implemented by intimation to the respective SPCBs. (Rule 18, HWM)
  • Pre-processing centers to be developed rather than landfill sites
  • Convert SCF to RDF (Rule 15 (v), SWM)
  • For wastes recycling / utilisation (Rule 5.1 HWM)
  • Segregated Combustible Fraction (SCF) having calorific value >1500 Cal / gm to be sent to cement plant for co-processing (Rule 21.2, SWM)

The above provisions in the rules favor co-processing substantially. However, following is further required to be published by CPCB as mandated in the rules or for smooth implementation of these provisions in the rules
1.Guidelines on pre-processing and co-processing of wastes
2.Guidelines on co-processing of plastic wastes
3.Protocol for emissions monitoring from cement plants
The other important requirement that is desired to facilitate ease in achieving successful and responsible co-processing are following.
A)SPCBs must permit the waste generator to send his waste to any of the pre-processing or co-processing facility that is approved by SPCB of the respective State.
B)Transportation of the Hazardous wastes is per-mitted through a transporter that is approved by any of the SPCBs.

Social and Environmental Security
Different kinds of wastes that get generated during agricultural, industrial or municipal acti-vities pose severe environmental concerns to the society and can cause substantial damage to the environment in case they are not managed properly. All these wastes that may be hazardous or non-hazardous, can be co-processed in an envi-ronmentally sound manner in the cement kilns.

As per the new Waste Management Rules 2016, Government of India has abolished the earlier practice of granting waste by waste permit system. This system, says Ulhas Parlikar, Deputy Head, Geocycle India, ACC Ltd, "was in practice prior to the notification of these rules in which, the permit for undertaking co-processing of a waste used to be granted based on the review of the results of the co-processing trial of that particular waste."

"This action MoEFCC has implemented because the cement kiln co-processing has been demonstrated as an environmentally sound and ecologically sustainable solution for waste management," he added. To achieve this, according to Parlikar, environmentally compliant management of the wastes, proper control on inputs, process, output and emissions is required by way of implementing necessary facilities and process control measures.

The new Waste Management Rules 2016 have mandated that the permission for co-processing of all kinds of wastes can be granted by State Pollution Control Boards (SPCBs) based on the availability of the prescribed infrastructure in the plant to handle wastes in an environmentally sound & occupationally safe manner and while undertaking co-processing, compliance to the emission standards notified by MoEFCC for cement kilns undertaking co-processing. The Central Pollution Control Board (CPCB) has already prepared a circulated a draft of the pre- and co-processing guideline illustrating specific requirements to the stakeholders and is in the process of publishing the same after accommodating stakeholder comments.

Target: 25% TSR
Currently, the Indian cement industry’s average TSR is around four per cent, whereas the TSR in few countries are as high as 60 per cent (Austria, Germany). Now, with above stated challenges, it is a matter of interest to see how India will reach the set target of 25 per cent or more of TSR by 2025. A few is outlined by V Kannan, Counsellor, CII – Godrej Green Business Centre. The Government has already included necessary policy changes for adopting co-processing in the country. Further, capacity building on new rules and proper implementation of the rules will substantially increase co-processing levels in the country.

Under the Swachh Bharat Mission (SBM) and smart cities programme, management of municipal solid waste management (MSW) through sustainable practices is very vital. The new SWM rules also advocate source segregation of waste to channelise the waste-to-wealth by recovery, reuse and recycle. In addition, all industrial units using fuel and located within 100 km from a solid waste-based refuse derived fuel (RDF) plant shall make arrangements within six months from the date of notification of these rules to replace at least five per cent of their fuel requirement by RDF so produced. That apart, non-recyclable waste having calorific value of 1,500 K/cal/kg or more shall not be disposed of on landfills and shall only be utilised for generating energy either or through refuse derived fuel or by giving away as feed stock for preparing refuse derived fuel. And lastly, high calorific wastes shall be used for co-processing in cement or thermal power plants. Cement plants also working on various initiatives like pre-processing platforms, utilisation of hazardous waste, tie ups with urban local bodies to utilise MSW as a fuel increases TSR levels.

For experts to achieve the target there is an urgent need to implement necessary policy level reforms that are emission monitoring and infrastructure based. Further, there is a need for the cement industry to implement necessary facilities for waste handling, storing, pre-processing and feeding in the kiln. There is also investment required for creating facilities for monitoring and control of emissions. Further, the legislative process needs to bring the material in the market. For example, although, large quantities of tyres are replaced every year in the country, the same is not visible in the waste market. This is because there is no defined regulatory system in place to collect and divert them in the waste market. Once they become visible in the waste market, they will be available to the cement industry for disposal through co-processing.

Fact sheet

  • AFR substitution increased from less than 1% to more than 4% in 2016.
  • Recognition for co-processing in the policy framework.
  • >45 cement plants started co-processing in their production units.
  • Few state pollution control boards like Gujarat and Tamil Nadu, developed specific action plan & implementation schedule to promote co-processing.
  • >12 cement plants set up pre-processing facilities to convert non-homogeneous waste in to AFRs.
  • LCA (Life Cycle approach) is considered as a part of manufacturing process and extended producer responsibility.

Vicat’s proven track record
Vicat operates two plants in India as Kalburgi cement plant and Bharti cement plants, with an annual capacity of around 8 mtpa, to produce quality cement since 2009. Since the inception the focus was on utilisation of AFR material in both the plants and presently, Vicat could achieve TSR of around 20 per cent.

The journey started with substitution rate of around 5 per cent in 2012 and in last five years it has reached to a level of 20 per cent. The initial start-up was on utilisation of easy to use AF materials like biomass, segregated non-recyclable plastic waste etc. Presently, the company can co-process different types of waste like industrial wastes (hazardous and non hazardous), tyre derived waste, plastics derived waste, derived waste from MSW segregation process, animal waste, waste from windmill sources etc. The company also offers cradle to grave solution for different sectors like pharmaceutical industry, FMCG, tyre sector and municipal corporations for segregated MSW, food and beverage industries etc.

Understanding the main factors that led to this improvement in usage of AFR in Vicat will help the Indian cement industry have an introspection of their processes and preparedness for improving AFR utilisation in their plants.

Earning Benefits:
INCOME ITEMSEXPENDITURE ITEMS
Waste Generator
1.Sale price of Waste
2.Savings in cost of waste management due to co-processing
3.Reduction in the liability costs1.Tipping Fee for waste management
2.Marketing expenses
3.Pre-processing cost to convert waste into AFR

Cement Plant
1.Tipping Fees from waste generator
2.Substitution benefit derived due to use of AFRs1.Waste identification
2.Laboratory assessment
3.Handling and storage
4.Pre-processing cost to convert waste to AFR
5.Production impact
6.Fuel usage impact
7.Interest and Depreciation costs etc.

ACC: Leader in waste Management
The use of AFR essentially serves to move away from dependence on fossil-based fuels and other mineral resources.
In 2016, the company succeeded in co-processing 379,520 tonnes of AFR, achieving a TSR of 3.22 per cent. Following the commissioning and stabilisation of two pre-processing platforms and a third under execution, ACC expects the TSR percentage to increase in the long run, enabling company to cut its footprint even further.

ACC has taken the lead in providing safe waste management solutions to major waste generating industries and organisations. The core objectives of value creation, customer service and technical excellence together drive the company’s initiative towards providing sustainable waste management solutions under the brand name – Geocycle. A key challenge posed on environment today that is a cause of major concerns about the health and safety of all citizens comes from the enormous volumes of municipal waste being generated in our cities and towns. Recognising this problem, the company is extending the scope of its waste management solutions to developing safe and sustainable solutions for the efficient disposal of municipal wastes. In the course of providing waste management solutions to municipalities, ACC also seek to reduce reliance on traditional fuels.

ACC has increased co-processing of RDF and non-recyclable SCF of MSW in its facilities enabled by large scale investments in R&D made for the safe utilisation of these waste streams. ACC, in this case, is working with state governments and waste management agencies such as in Goa on a MSW Landfill Remediation Project, the first-of-its-kind project in India, wherein ACC received and co-processed around 4,800 tonnes of RDF at the Wadi plant in 2016.

ACC redoubled its endeavours in lobbying, advocacy and capacity building to achieve greater technical and legal recognition for co-processing technology in line with accepted international standards.

"Banned wastes" not to be pre-processed or co-processed:
Radioactive waste
Asbestos-containing waste
Explosives and ammunition / weapons
Anatomical medical waste

"Banned wastes" not to be co-processed (These wastes however can be co-processed after
pre-processing to remove the banned portion of the waste):
Electronic fraction of electrical and electronic waste (e-waste)
Whole batteries as a targeted material stream
Waste of unknown or unpredictable composition, including unsorted municipal waste

-RAHUL KAMAT

Continue Reading
Click to comment

Leave a Reply

Your email address will not be published. Required fields are marked *

Concrete

Sustainable Procurement Practices

Published

on

By

Shares

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.

Continue Reading

Concrete

The Circle of Life

Published

on

By

Shares

The circular economy offers a transformative approach for the cement industry, focusing on resource efficiency, waste minimisation, and sustainable practices. ICR finds out why integrating alternative materials, reducing carbon emissions and embracing innovative technologies, is crucial for the cement sector.

The circular economy is an innovative model aimed at minimising waste and maximising the use of resources by closing the loop of product life cycles through greater resource efficiency, recycling, and reusing. Unlike the traditional linear economy, which follows a ‘take-make-dispose’ pattern, the circular economy emphasises a restorative approach that seeks to maintain the value of products, materials and resources in the economy for as long as possible.
In the context of the cement industry, which is known for its resource-intensive processes and substantial environmental footprint, embracing circular economy principles is crucial. Cement production typically involves high energy consumption and generates significant greenhouse gas emissions. By adopting circular practices, the industry can reduce its reliance on virgin raw materials, lower waste and emissions and enhance overall sustainability.
The relevance of the circular economy in cement production is evident in several key areas:
• Resource efficiency: Utilising alternative and recycled materials, such as industrial by-products or waste, can significantly reduce the demand for raw materials and lower the environmental impact of cement production.
“Utilisation of alternative raw materials in the cement industry is a key strategy for enhancing sustainability and resource efficiency. Wonder Cement has substituted traditional raw materials like limestone with industrial by-products such as fly ash, marble slurry, chemical gypsum, red mud, mine telling reject, alumina slat, iron sludge, etc. Wonder Cement not only reduces its reliance on natural resources but also mitigates environmental impacts,” says Nitin Jain, Unit Head – Integrated Plant, Nimbahera, Wonder Cement.
“Low-carbon cement production is an innovative approach by Wonder Cement aimed to reduce the carbon footprint associated with traditional cement manufacturing. This process involves several strategies to minimise CO2 emissions, which are typically high due to the energy intensive nature of clinker production. The production of blended cement, Portland Pozzolana Cement (PPC) involves mixing clinker with supplementary materials like fly ash. This not only reduces CO2 emissions but also enhances the durability and performance of the cement,” he adds.

  • Waste management: Implementing strategies to manage and repurpose waste products not only helps in minimising landfill use but also creates valuable resources for reuse in cement manufacturing.
  • Energy optimisation: Circular economy practices promote energy-efficient technologies and the use of renewable energy sources, contributing to a reduction in carbon emissions associated with cement production.
  • Product lifecycle: By focusing on the entire lifecycle of cement products, from production to disposal, the industry can develop more sustainable practices and innovative solutions for recycling and reusing cement-based materials.

Adopting a circular economy approach is not only essential for reducing the environmental impact of cement production but also for driving innovation, enhancing resource security, and fostering long-term economic resilience in the industry.

Use of Alternative and Recycled Materials
The cement industry is undergoing a transformative shift with the increasing adoption of alternative and recycled materials. This shift is driven by the
need to reduce environmental impact, conserve natural resources, and enhance the sustainability of cement production.
Alternative materials: Alternative materials, such as industrial by-products and waste materials, are increasingly being used as partial replacements for traditional raw materials like clinker.

Common examples include fly ash, slag, natural pozzolans, etc.
Recycling plays a crucial role in minimising waste and promoting a circular economy within the cement industry. Key recycled materials include:

  • Recycled concrete aggregate (RCA): Reclaimed from demolished concrete structures, RCA can be used as a partial replacement for natural aggregates in new concrete, reducing the need for virgin resources.
  • Construction and demolition waste: Incorporating materials from construction and demolition activities not only diverts waste from landfills but also provides valuable resources for cement production.

The use of these alternative and recycled materials helps in reducing the environmental footprint of cement production by lowering greenhouse gas emissions, conserving natural resources, and minimising waste. Furthermore, it supports the industry’s transition towards more sustainable and circular practices, contributing to the overall goal of reducing the sector’s impact on the environment.
According to an article published by McKinsey & Company in March 2023, the cement value chain is well positioned to create closed loops, or automatically regulated systems, for carbon dioxide, materials and minerals, and energy (see sidebar ‘Three categories of circular technologies in cement’). This entails circular economies, which are based on the principles of eliminating waste and pollution, circulating products and materials, and regenerating nature. With these points in mind, circularity can work jointly with reducing carbon emissions in cement production because circular technologies follow the paradigm of three crucial decarbonisation strategies: redesign, reduce and repurpose. According to the organisation’s estimates and expected carbon prices, circularity technologies will be value-positive by 2050, with some already more profitable than today’s business-as-usual solutions.
The report estimates show that an increased adoption of circular technologies could be linked to the emergence of new financial net-value pools worth up to roughly €110 billion by 2050, providing a new growth avenue for cement players that would otherwise face shrinking demand for their core business and significant external costs. Adopting circularity is required to mitigate at least 50 percent of this value at risk. Emerging new technologies and business models will create additional value to mitigate the residual value at risk.

Reducing and Managing Industrial Waste
Efficient waste management is critical for the sustainability of the cement industry. Reducing and managing industrial waste not only minimises environmental impact but also offers opportunities to turn waste into valuable resources. Here are some key strategies of waste-to-resource initiatives:

Waste minimisation at source

  • Process optimisation: Implementing advanced technologies and practices to improve process efficiency can significantly reduce the amount of waste generated. Techniques such as precise control of raw material inputs and process conditions help minimise production losses.
  • Cleaner production techniques: Adopting cleaner production methods, such as the use of less polluting raw materials and more efficient equipment, can reduce waste generation at the source.

Recycling and reuse

  • Alternative fuels: Industrial waste, such as tire-derived fuel or biomass, can be used as alternative fuels in cement kilns. This not only helps in reducing the consumption of traditional fossil fuels but also diverts waste from landfills.
  • By-product utilisation: By-products from other industries, such as fly ash or slag, can be integrated into cement production processes. These materials not only enhance the properties of the final product but also reduce the need for virgin raw materials.

Nitin Sharma, CEO and General Manager, Clariant IGL Specialty Chemicals (CISC), says, “As our climate gives us increasing and alarming signals of change, individuals and industries are looking for ways to reduce their environmental footprints, and the demand for bio-based chemicals is set to grow strongly in the coming years. In several applications, the use of petrochemicals and fossil carbon remains a significant issue. The transition to bio-based carbon chemistry represents a significant challenge for manufacturers.”

Waste-to-resource initiatives

  • Recycled concrete aggregate (RCA): Demolished concrete can be crushed and recycled into aggregate for use in new concrete mixes. This reduces the demand for natural aggregates and decreases the volume of construction waste.
  • Co-processing of waste: The cement industry is increasingly adopting co-processing techniques where various types of industrial and municipal waste are processed in cement kilns. This approach helps in recovering energy and material value from waste streams while simultaneously treating hazardous materials.
  • Zero-waste initiatives: Some cement plants are aiming for zero-waste targets by implementing comprehensive waste management systems that ensure all waste is either recycled, reused or recovered.

Partha Dash, Managing Director, Moglix, says, “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.”
These strategies and initiatives reflect a growing commitment to sustainability within the cement industry. By effectively managing and repurposing industrial waste, cement producers can not only reduce their environmental impact but also contribute to a more circular and resource-efficient economy.
According to the report Indian Cement Industry: A Key Player in the Circular Economy of India published July 2020, the Indian cement industry is playing a key role by enhancing the application of renewable energy for electrical power generation. The renewable energy installed capacity (wind and solar) in cement plants increased by more than 40 per cent to 276 MW from 2010 to 2017. Out of the total, 42 MW is solar power, while off-site wind installations account for 234 MW. A company has undertaken the target of switching over to renewable energy for 100 per cent of all electrical energy needs by 2030. Big players like UltraTech Cement are targeting 25 per cent share of their total power consumption by green energy technologies.
Apart from the solar photovoltaic route, the cement industry is making efforts to tap solar energy through thermal routes.

Government initiatives
The Indian government is actively promoting circular economy principles through various policies and regulations aimed at enhancing sustainability and resource efficiency. The National Clean Energy Fund (NCEF) supports innovative projects in energy efficiency and emission reduction, including those incorporating circular economy practices.
The Swachh Bharat Mission (SBM) and Solid Waste Management Rules, 2016, focus on improving waste management and recycling, encouraging the use of recycled materials in construction and cement production. The Plastic Waste Management Rules, 2016, emphasise recycling and the use of recycled plastic, including as alternative fuel in cement kilns. The National Resource Efficiency Policy (NREP) promotes resource efficiency across sectors, including cement, and the government’s clean technology schemes incentivise the adoption of green technologies.
Additionally, the draft National Circular Economy Policy, currently in development, aims to provide a comprehensive framework for advancing circular economy practices across all industries. These initiatives collectively support the transition towards more sustainable and circular practices in the cement sector.

Emerging trends in circular economy
The cement industry is witnessing several emerging trends in circular economy practices, reflecting a shift towards greater sustainability and resource efficiency. One notable trend is the increased use of alternative fuels and raw materials. Cement producers are exploring the use of industrial and municipal waste, such as tires, plastics, and biomass, to replace traditional fossil fuels and raw materials, reducing their carbon footprint and conserving natural resources.
Another significant trend is the advancement of circular product design and lifecycle management. Cement companies are focusing on designing products that are easier to recycle or reuse at the end of their lifecycle. This includes developing new types of cement and concrete with enhanced durability
and recyclability.
Waste-to-resource initiatives are also gaining traction. Innovations in waste processing technologies enable the conversion of waste materials into valuable resources for cement production, such as incorporating recycled concrete aggregate (RCA) and by-products like fly ash and slag into new cement products.
Digitalisation and data analytics are emerging as crucial tools in advancing circular economy practices. Advanced monitoring and analytics technologies help optimise resource use, track waste streams, and improve overall efficiency in cement production.
Finally, there is a growing emphasis on collaborative partnerships. Cement companies are increasingly collaborating with governments, NGOs, and other industries to drive circular economy initiatives and develop innovative solutions for sustainable development. These trends highlight a transformative shift towards a more circular and sustainable approach in the cement industry, aligning with global efforts to reduce environmental impact and promote resource efficiency.

Conclusion
The adoption of circular economy principles in the cement industry is proving to be a pivotal step towards enhancing sustainability and reducing environmental impact. By embracing alternative and recycled materials, the industry is reducing its reliance on virgin resources and minimising waste. Government policies, such as the National Clean Energy Fund and Solid Waste Management Rules, provide crucial support for these practices, fostering a regulatory environment conducive to circular economy initiatives. Emerging trends, including the use of alternative fuels, circular product design, waste-to-resource innovations, and advanced digital technologies, underscore the industry’s commitment to resource efficiency and sustainability. Collaborative efforts across sectors further drive these advancements, paving the way for a more resilient and environmentally responsible cement industry. As the sector continues to integrate circular economy principles, it not only aligns with global sustainability goals but also sets a benchmark for other industries striving for a circular future.

– Kanika Mathur

Continue Reading

Concrete

Installing a solar system is just the first step

Published

on

By

Shares

Raman Bhatia, Founder and Managing Director, Servotech Power Systems, talks about innovative approaches to advancing energy efficiency in the solar sector, from embracing the ‘Make in India’ initiative to pioneering new technologies.

Can you provide an overview of Servotech Power Systems’ contributions to energy efficiency in the solar sector?
Throughout its journey with a strong motto of providing high-quality solar solutions, Servotech made noteworthy contributions towards energy efficiency in the solar sector, through innovative technologies and solutions. By developing high-efficiency solar solutions that are both sustainable and reliable, Servotech has played its part in making solar energy a household name. The company has expanded its reach across various sectors. Servotech’s residential solar solutions empower homeowners to reduce their carbon footprint and electricity bills. The company provides solar solutions for industries, helping them reduce energy costs, improve their environmental quotient and comply with sustainability regulations. Servotech caters to the commercial sector by offering rooftop and ground-mounted solar power plants helping them reduce electricity costs and enhance their brand image, Lastly, the company has been actively involved in executing solar projects for government institutions, aiding in the country’s renewable energy goals and by providing efficient and reliable solar solutions, we contribute to
the government’s efforts in promoting clean
energy adoption.

What role does the ‘Make in India’ initiative play in your strategy to promote energy efficiency and sustainable solutions?
Make in India, a wonderful initiative by our government, has definitely pushed manufacturers across all sectors, especially our sector, which is the renewable energy sector towards indigenous manufacturing. By manufacturing solar components locally, we significantly reduce the carbon footprint associated with transportation and logistics. Local production often leads to cost reductions in solar products which makes solar energy more affordable for consumers, encouraging wider adoption and contributing to energy efficiency. The Make in India initiative also helps create employment opportunities in the solar sector, leading to skill development and a larger workforce dedicated to renewable energy. Domestic manufacturing reduces reliance on imports and strengthens the supply chain, ensuring uninterrupted production and reducing vulnerabilities to global disruptions.

How has Servotech adapted its solar solutions to meet the evolving energy efficiency standards?
Well, it has been more than two decades now. During this long journey, we have constantly worked on ourselves, renovated, and innovated ourselves to keep up with the evolving energy efficiency standards in terms of product development, innovation and R&D. We have consistently incorporated the latest advancements in solar technology that includes the use of higher efficiency solar cells, advanced inverters, and optimised system components. We introduced innovative solar products and solutions that meet the evolving energy efficiency standards. This involves continuous research and development to create more efficient and sustainable products. We prioritise product performance and rigorous testing and quality control measures ensure that our products meet or exceed industry benchmarks and this relentless pursuit of excellence has positioned us as a leader and has helped us in delivering efficient and sustainable
solar solutions.

Could you elaborate on the significance of the engineering and design process in achieving energy efficiency in your solar EPC projects?
The engineering and design phase in solar EPC projects lays the foundation for optimal performance. It involves a careful analysis of site conditions, including solar radiation, shading and environmental factors. By carefully selecting high-performance components and designing the system for optimal orientation and tilt, engineers maximise energy capture. Additionally, this phase focuses on minimising energy losses through efficient wiring, component placement, and system integration. A well-engineered design ensures the solar system operates at peak performance, delivering substantial energy savings and a strong return on investment.

What measures does Servotech implement during the procurement and project execution phases to ensure optimal energy efficiency in its solar power projects?
Constructing a solar system involves a lot of phases with procurement and project execution being the most important ones. During the procurement phase, we prioritise the development of high-efficiency solar modules, inverters and other components. Rigorous quality assurance processes and performance testing are conducted to verify that all components meet or exceed industry standards and are compatible with project requirements. In the project execution phase, Servotech conducts detailed site assessments to determine the optimal system orientation, tilt angle and shading analysis. Strict adherence to installation guidelines and best practices ensures proper system integration and performance. Post-installation, the system undergoes comprehensive testing to verify energy efficiency and performance. Monitoring systems are often incorporated to track performance and identify areas for improvement.

How does your operation and maintenance service contribute to maintaining and enhancing the energy efficiency of installed systems?
Installing a solar system is just the first step; operating and maintaining it properly is equally important to ensure the system runs efficiently over the long term and for that we conduct regular inspections to detect and address issues like module degradation and inverter malfunctions early, preventing energy losses. Our team ensures optimal performance through routine cleaning and maintenance, which maximises sunlight absorption and energy generation. Continuous performance monitoring using advanced data analytics allows us to optimise system settings, while preventive and corrective maintenance activities minimise downtime and equipment failures. By utilising techniques such as module-level monitoring and inverter tuning, Servotech ensures that solar systems operate at peak efficiency, delivering maximum energy output and long-term cost savings.

In your view, how important is radiation data analytics and project feasibility studies in the planning of energy-efficient solar projects?
Radiation data analytics and project feasibility studies are absolutely critical for the successful planning of energy-efficient solar projects. Accurate radiation data allows for precise predictions of energy generation, system sizing and financial returns. By analysing radiation patterns, engineers can optimise system design, including orientation and tilt angles, to maximise energy capture. Feasibility studies help identify potential risks, such as shading or grid constraints, enabling proactive solutions. These studies also assess financial viability, considering ROI, payback periods, and incentives, ensuring projects are economically sound enabling data-driven decision-making throughout the project lifecycle.

Looking ahead, what are the key trends and innovations in energy efficiency that Servotech Power Systems plans to focus on in the near future?
Energy efficiency is a dynamic realm with constant emergence of trends and innovations. The company recognises the value these trends and innovations will add in the growth of energy efficiency in the solar sector. Our innovative product solar powered EV charging carport integrates solar power with EV charging, which is an innovative take on how we can charge our EVs and also save energy from renewable sources. Additionally, Servotech plans to invest in enhancing the quality of bifacial solar panels to increase energy generation. We are investing in research and development of major solar developments and understand the importance of energy storage in enhancing grid stability and optimising energy utilisation and grid optimisation. In fact, we are developing an energy storage system that will accelerate the adoption of renewable energy in low electricity areas.
Exploring digitisation of energy efficiency, we are focused on developing advanced monitoring and control systems to optimise system performance, predict maintenance needs. Lastly, to meet the growing demand for clean energy, we are exploring the integration of solar power with other renewable energy sources like wind and hydro to create hybrid power systems.

– Kanika Mathur

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds