Product development
Unlocking India’s mining potential
Published
7 years agoon
By
adminThe mining sector, in many countries, has been resilient despite the global financial crisis, and has contributed substantially towards the recovery of their economies. Can India now follow the footsteps of other countries? Explores ICR cover story.
Exploration of minerals must keep pace with the growth of the industry but India’s story is completely different. As is the case globally, there are challenges in bringing the mineral resources to market, but these are surmountable. For decades, the story of India’s mining industry has been one of vast potential that is yet to be truly unlocked.
India shares a geological history with resource-rich regions that is comparable to South America, Canada, Australia and South Africa. Jharkhand, Odisha, Rajasthan, Madhya Pradesh and Bihar can be regarded as major contributing mining States, yet its domestic mining industry has struggled to achieve momentum. In the last decade or so, mining contribution to India’s GDP fell from 1.2 per cent to 1 per cent as on December 2014, a report by McKinsey & Company suggested.
Given the present globally competitive environment, the mining industry must work on new financial strategies, aggressive exploration development programmes, investment-friendly policies and regulatory framework, value addition of minerals and the use of productivity enhancing techniques. The domestic mining industry is facing a galore of challenges when it comes to mineral exploration. It has further led to a severe lack of participation from the private sector and lack of investment, with a large majority of exploration work carried out by public sector companies.
H Noor Ahmed, Ex President, the Federation of Indian Mineral Industries (FIMI), states that India’s figures is nowhere in the global exploration budget. He says, ‘When Canada makes up 14 per cent of the global exploration spend and Australia sits just behind at 12 per cent, India is languishing at just 0.4 per cent. India’s exploration expenditure works out at just $17 per square km, comparing unfavourably with China’s $67 and Brazil’s $51, and not to mention the much higher figures in Chile, Australia and North America.’
Amending the MMDR Act
As our Chairman, Editorial Advisory Board, Sumit Banerjee rightly says ?It is a work still in progress.’ (Refer the editorial column of the current issue) The Act replaces India’s discretionary licensing and approvals system, which was highly vulnerable to corruption at various levels, with a competitive bidding system.
Mining lease periods have been standardised to 50 years in an effort to ensure security for investors. While implementing various provisions to expedite the decision-making process, which could potentially, allow the reopening of mines that had closed while waiting for lease renewal decisions from the Government.
The Act also makes provisions for the creation of the National Mineral Exploration Trust (NMET) to encourage exploration, and the establishment of District Mineral Foundations (DMFs), regional bodies, which will take a third of local mining royalties to spread benefits to people and environments in mining-affected areas. Tackling corruption and environmental concerns, while auctions are currently ongoing for dozens of mines across the country, the prospects appear to be looking up. The biggest of these problems is corruption, which was allowed to flourish under the old discretionary permitting system.
Government-launched NMEP
We have been repeatedly saying that the vast mineral potential possessed by our country remains highly underutilised. The investment decisions are based on the potential of the mineral and policy perception. There is something called ‘Fraser’s annual policy perception index.’ A composition of survey responses to policy factors that affect investment decisions ranks India at 81 out of 109 mining provinces surveyed in 2015. It has to certainly change if we want to attract investment in mining.
In July 2016, the Indian Government has continued to take steps to transform the Indian mining sector. A well-drafted New Mineral Exploration Policy (NMEP) with robust execution can improve India’s ranking in the policy perception index and become an attractive destination for mineral exploration.
In India, exploration activity so far has been carried out largely by the State-run Geological Survey of India (GSI) and Mineral Exploration Corp Ltd (MECL). NMEP envisages increased involvement of GSI. State-run companies can form joint ventures with private companies to undertake exploration projects. NMEP recognises the need to incentivise private sector participation and has various provisions for that. For example, revenue sharing with private explorers in case exploration efforts lead to auction able resources and cost reimbursement to explorers if the exploration agency is unsuccessful in discovering any economic reserves.
Private sector, the largest contributor
All across the globe, exploration is largely funded by private players as they have the technology and the expertise to carry out such a risky and capital-intensive activities. In 2015, private enterprises accounted for more than 90 per cent of the global exploration budget, whereas Government and other institutions accounted for only around 8.8 per cent of the budget.
FDI in mining
During most of the last decade, FDI inflow into the Indian mining industry has been much lower compared to other sectors such as telecommunications, power, machinery and transport equipment. This is despite the Government allowing 100 per cent FDI in the mining sector under the automatic FDI route. FDI in mining increased sharply in the recent past few years, from a very low base. Despite this significant rise, it is still only around 0.8 per cent of the total FDI. Furthermore, the news of Rio Tinto exiting the Bunder diamond project, since it did not reportedly get timely permits for concessions and environment approvals, may again hurt sentiments of foreign investors.
Accessibility of geological data
The Government will make available pre-competitive baseline geoscience data for open dissemination free of charge, since it has now also obtained relaxation in restrictions from the Ministry of Defence (MoD) on sharing of data. This data will be continuously updated and benchmarked with those of other leading countries like Australia. The Government will implement a National Aero-geophysical programme to acquire state-of-the-art baseline data for targeting concealed mineral deposits.
NMEP has proposed to set up a National Geoscientific Data Repository (NGDR) to collate all baseline and mineral exploration information generated by various Central and State Government agencies as well as mineral concession holders to maintain these on geospatial database. There is one flipside of the story, India ranks low in the quality of its geological database, which includes quality and scale of maps, ease-of-access to information. One of the reasons could be that the information so far was non-digitised and was not available freely in the public domain. Moreover, most of the exploration in the country has so far been near the surface (50 to 100 m) with little or no information on deep-seated minerals. However, geological mapping needs to be updated on a continuous basis, since technology advancement in geophysical surveys are likely to make older reports look insufficient or sub-standard. The real test of these reports will come once exploration companies bid for permits on the basis of these reports.
Contractual mining
We need more focused attention in this area. Today; the outsourcing of services in the mining industry is done in a very fragmented way, which needs a complete overhaul. The outsourcing is primarily limited to either labour or equipment. But no other service is attempted to be outsourced. Ideally what should happen is entire job of operations of mine should be left to a professional company, which will improve the efficiencies of operations. However there are issues mainly that of safety which many experts feel may be compromised since the present regulation will not be effective in addressing the concern. However the contractual mining is yet to take off in our country. We expect many more developments to come in the coming years.
Forest regulations
The Ministry of Environment and Forests is considering a proposal to relax regulations for forest clearing for exploration, allowing automatic approval if the tree canopy covers less than 40 per cent of the affected area. Canopy coverage of 40 to 70 per cent will require a permit, and areas with more than 70 per cent coverage would automatically be disqualified from consideration. The hard limits will once again be helpful for companies that need better understanding of their regulatory obligations, but with more than 250,000 ha of forest already threatened by coal mining operations alone according to a recent report by Dutch environmental group Fern, a more relaxed stance to forest conservation could have an unforeseen knock-on effect for jungle habitats.
The Government has plans to intensify geochemical mapping (target to cover entire OGP [Obvious Geological Potential] by 2018?19) and geophysical mapping (target to cover entire OGP by 2020?21), which are important milestones for exploration of minerals.
Only after a few years, we will be assess whether the country is heading towards the right direction or not. Let us wait and watch.
Source: Ernst & Young LLP India Report
Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.
Concrete
Indian cement industry is well known for its energy and natural resource efficiency
Published
2 years agoon
November 18, 2022By
adminDr Hitesh Sukhwal, Deputy General Manager – Environment, Udaipur Cement Works Limited (UCWL) takes us through the multifaceted efforts that the company has undertaken to keep emissions in check with the use of alternative sources of energy and carbon capture technology.
Tell us about the policies of your organisation for the betterment of the environment.
Caring for people is one of the core values of our JK Lakshmi Cement Limited. We strongly believe that we all together can make a difference. In all our units, we have taken measures to reduce carbon footprint, emissions and minimise the use of natural resources. Climate change and sustainable development are major global concerns. As a responsible corporate, we are committed with and doing consistent effort small or big to preserve and enrich the environment in and around our area of operations.
As far as environmental policies are concerned, we are committed to comply with all applicable laws, standards and regulations of regulatory bodies pertaining to the environment. We are consistently making efforts to integrate the environmental concerns into the mainstream of the operations. We are giving thrust upon natural resource conservation like limestone, gypsum, water and energy. We are utilising different kinds of alternative fuels and raw materials. Awareness among the employees and local people on environmental concerns is an integral part of our company. We are adopting best environmental practices aligned with sustainable development goals.
Udaipur Cement Works Limited is a subsidiary of the JK Lakshmi Cement Limited. Since its inception, the company is committed towards boosting sustainability through adopting the latest art of technology designs, resource efficient equipment and various in-house innovations. We are giving thrust upon renewable and clean energy sources for our cement manufacturing. Solar Power and Waste Heat Recovery based power are our key ingredients for total power mix.
What impact does cement production have on the environment? Elaborate the major areas affected.
The major environmental concern areas during cement production are air emissions through point and nonpoint sources due to plant operation and emissions from mining operation, from material transport, carbon emissions through process, transit, noise pollution, vibration during mining, natural resource depletion, loss of biodiversity and change in landscape.
India is the second largest cement producer in the world. The Indian cement industry is well known for its energy and natural resource efficiency worldwide. The Indian cement industry is a frontrunner for implementing significant technology measures to ensure a greener future.
The cement industry is an energy intensive and significant contributor to climate change. Cement production contributes greenhouse gases directly and indirectly into the atmosphere through calcination and use of fossil fuels in an energy form. The industry believes in a circular economy by utilising alternative fuels for making cement. Cement companies are focusing on major areas of energy efficiency by adoption of technology measures, clinker substitution by alternative raw material for cement making, alternative fuels and green and clean energy resources. These all efforts are being done towards environment protection and sustainable future.
Nowadays, almost all cement units have a dry manufacturing process for cement production, only a few exceptions where wet manufacturing processes are in operation. In the dry manufacturing process, water is used only for the purpose of machinery cooling, which is recirculated in a closed loop, thus, no polluted water is generated during the dry manufacturing process.
We should also accept the fact that modern life is impossible without cement. However, through state-of-the-art technology and innovations, it is possible to mitigate all kinds of pollution without harm to the environment and human beings.
Tell us about the impact blended cement creates on the environment and emission rate.
Our country started cement production in 1914. However, it was introduced in the year 1904 at a small scale, earlier. Initially, the manufacturing of cement was only for Ordinary Portland Cement (OPC). In the 1980s, the production of blended cement was introduced by replacing fly ash and blast furnace slag. The production of blended cement increased in the growth period and crossed the 50 per cent in the year 2004.
The manufacturing of blended cement results in substantial savings in the thermal and electrical energy consumption as well as saving of natural resources. The overall consumption of raw materials, fossil fuel such as coal, efficient burning and state-of-the-art technology in cement plants have resulted in the gradual reduction of emission of carbon dioxide (CO2). Later, the production of blended cement was increased in manifolds.
If we think about the growth of blended cement in the past few decades, we can understand how much quantity of , (fly ash and slag) consumed and saved natural resources like limestone and fossil fuel, which were anyhow disposed of and harmed the environment. This is the reason it is called green cement. Reduction in the clinker to cement ratio has the second highest emission reduction potential i.e., 37 per cent. The low carbon roadmap for cement industries can be achieved from blended cement. Portland Pozzolana Cement (PPC), Portland Slag Cement (PSC) and Composite Cement are already approved by the National Agency BIS.
As far as kilogram CO2 per ton of cement emission concerns, Portland Slag Cement (PSC) has a larger potential, other than PPC, Composite Cement etc. for carbon emission reduction. BIS approved 60 per cent slag and 35 per cent clinker in composition of PSC. Thus, clinker per centage is quite less in PSC composition compared to other blended cement. The manufacturing of blended cement directly reduces thermal and process emissions, which contribute high in overall emissions from the cement industry, and this cannot be addressed through adoption of energy efficiency measures.
In the coming times, the cement industry must relook for other blended cement options to achieve a low carbon emissions road map. In near future, availability of fly ash and slag in terms of quality and quantity will be reduced due to various government schemes for low carbon initiatives viz. enhance renewable energy sources, waste to energy plants etc.
Further, it is required to increase awareness among consumers, like individual home builders or large infrastructure projects, to adopt greener alternatives viz. PPC and PSC for more sustainable
resource utilisation.
What are the decarbonising efforts taken by your organisation?
India is the world’s second largest cement producer. Rapid growth of big infrastructure, low-cost housing (Pradhan Mantri Awas Yojna), smart cities project and urbanisation will create cement demand in future. Being an energy intensive industry, we are also focusing upon alternative and renewable energy sources for long-term sustainable business growth for cement production.
Presently, our focus is to improve efficiency of zero carbon electricity generation technology such as waste heat recovery power through process optimisation and by adopting technological innovations in WHR power systems. We are also increasing our capacity for WHR based power and solar power in the near future. Right now, we are sourcing about 50 per cent of our power requirement from clean and renewable energy sources i.e., zero carbon electricity generation technology. Usage of alternative fuel during co-processing in the cement manufacturing process is a viable and sustainable option. In our unit, we are utilising alternative raw material and fuel for reducing carbon emissions. We are also looking forward to green logistics for our product transport in nearby areas.
By reducing clinker – cement ratio, increasing production of PPC and PSC cement, utilisation of alternative raw materials like synthetic gypsum/chemical gypsum, Jarosite generated from other process industries, we can reduce carbon emissions from cement manufacturing process. Further, we are looking forward to generating onsite fossil free electricity generation facilities by increasing the capacity of WHR based power and ground mounted solar energy plants.
We can say energy is the prime requirement of the cement industry and renewable energy is one of the major sources, which provides an opportunity to make a clean, safe and infinite source of power which is affordable for the cement industry.
What are the current programmes run by your organisation for re-building the environment and reducing pollution?
We are working in different ways for environmental aspects. As I said, we strongly believe that we all together can make a difference. We focus on every environmental aspect directly / indirectly related to our operation and surroundings.
If we talk about air pollution in operation, every section of the operational unit is well equipped with state-of-the-art technology-based air pollution control equipment (BagHouse and ESP) to mitigate the dust pollution beyond the compliance standard. We use high class standard PTFE glass fibre filter bags in our bag houses. UCWL has installed the DeNOx system (SNCR) for abatement of NOx pollution within norms. The company has installed a 6 MW capacity Waste Heat Recovery based power plant that utilises waste heat of kiln i.e., green and clean energy source. Also, installed a 14.6 MW capacity solar power system in the form of a renewable energy source.
All material transfer points are equipped with a dust extraction system. Material is stored under a covered shed to avoid secondary fugitive dust emission sources. Finished product is stored in silos. Water spraying system are mounted with material handling point. Road vacuum sweeping machine deployed for housekeeping of paved area.
In mining, have deployed wet drill machine for drilling bore holes. Controlled blasting is carried out with optimum charge using Air Decking Technique with wooden spacers and non-electric detonator (NONEL) for control of noise, fly rock, vibration, and dust emission. No secondary blasting is being done. The boulders are broken by hydraulic rock breaker. Moreover, instead of road transport, we installed Overland Belt Conveying system for crushed limestone transport from mine lease area to cement plant. Thus omit an insignificant amount of greenhouse gas emissions due to material transport, which is otherwise emitted from combustion of fossil fuel in the transport system. All point emission sources (stacks) are well equipped with online continuous emission monitoring system (OCEMS) for measuring parameters like PM, SO2 and NOx for 24×7. OCEMS data are interfaced with SPCB and CPCB servers.
The company has done considerable work upon water conservation and certified at 2.76 times water positive. We installed a digital water flow metre for each abstraction point and digital ground water level recorder for measuring ground water level 24×7. All digital metres and level recorders are monitored by an in-house designed IoT based dashboard. Through this live dashboard, we can assess the impact of rainwater harvesting (RWH) and ground water monitoring.
All points of domestic sewage are well connected with Sewage Treatment Plant (STP) and treated water is being utilised in industrial cooling purposes, green belt development and in dust suppression. Effluent Treatment Plant (ETP) installed for mine’s workshop. Treated water is reused in washing activity. The unit maintains Zero Liquid Discharge (ZLD).
Our unit has done extensive plantations of native and pollution tolerant species in industrial premises and mine lease areas. Moreover, we are not confined to our industrial boundary for plantation. We organised seedling distribution camps in our surrounding areas. We involve our stakeholders, too, for our plantation drive. UCWL has also extended its services under Corporate Social Responsibility for betterment of the environment in its surrounding. We conduct awareness programs for employees and stakeholders. We have banned Single Use Plastic (SUP) in our premises. In our industrial township, we have implemented a solid waste management system for our all households, guest house and bachelor hostel. A complete process of segregated waste (dry and wet) door to door collection systems is well established.
Tell us about the efforts taken by your organisation to better the environment in and around the manufacturing unit.
UCWL has invested capital in various environmental management and protection projects like installed DeNOx (SNCR) system, strengthening green belt development in and out of industrial premises, installed high class pollution control equipment, ground-mounted solar power plant etc.
The company has taken up various energy conservation projects like, installed VFD to reduce power consumption, improve efficiency of WHR power generation by installing additional economiser tubes and AI-based process optimisation systems. Further, we are going to increase WHR power generation capacity under our upcoming expansion project. UCWL promotes rainwater harvesting for augmentation of the ground water resource. Various scientifically based WHR structures are installed in plant premises and mine lease areas. About 80 per cent of present water requirement is being fulfilled by harvested rainwater sourced from Mine’s Pit. We are also looking forward towards green transport (CNG/LNG based), which will drastically reduce carbon footprint.
We are proud to say that JK Lakshmi Cement Limited has a strong leadership and vision for developing an eco-conscious and sustainable role model of our cement business. The company was a pioneer among cement industries of India, which had installed the DeNOx (SNCR) system in its cement plant.
Concrete
NTPC selects Carbon Clean and Green Power for carbon capture facility
Published
2 years agoon
October 12, 2022By
adminCarbon Clean and Green Power International Pvt. Ltd has been chosen by NTPC Energy Technology Research Alliance (NETRA) to establish the carbon capture facility at NTPC Vindhyachal. This facility, which will use a modified tertiary amine to absorb CO2 from the power plant’s flue gas, is intended to capture 20 tonnes of CO2) per day. A catalytic hydrogenation method will eventually be used to mix the CO2 with hydrogen to create 10 tonnes of methanol each day. For NTPC, capturing CO2 from coal-fired power plant flue gas and turning it into methanol is a key area that has the potential to open up new business prospects and revenue streams.