Environment
Safety first
Published
7 years agoon
By
adminCement and RMC are industrial activities that are equally vulnerable to any lapses that may occur in any other industrial activity. The cover story focuses on some of the past workplace incidents that are significant.
Workplace safety is of paramount importance. Just a month ago, the news of a blast at NTPC Limited’s Unchahar power plant in Raebareli, Uttar Pradesh, claimed lives of 43 employees. It is a well-accepted fact that we take safety very lightly and are not doing enough collectively. Incidentally, this plant supplies fly ash to several cement units. ICR decides to take a deep dive into the past few incidents on workplace safety.
The NTPC Limited’s Unchahar power plant blast claimed lives of 43 persons and 85 were treated at hospitals in Raebareli, Lucknow and New Delhi. The blast took place in the boiler of Unit no 6 (500MW) on November 1, 2017. The blast occurred in the boiler area of the recently commissioned 500 MW unit. The equipment for the plant was supplied by Bharat Heavy Electricals Ltd. "There was clinker formation that choked the bottom ash outlet," as informed by NTPC executive. Blockages in the flue gas pipe in a unit led to the blast. Hot fuel gases and steam let out by the blast severely injured several workers and other employees While boiler cleaning operations in thermal plants are automated, there are instances when it needs manual cleaning in the case of clinker formation. Clinkers are lumps formed after burning of coal at high temperature in the furnace. With the clinkers choking the bottom ash outlet, the pressure in the boiler went up thereby melting the water valves surrounding the boiler. This created a vent, with hot flue gases and steam at high temperature escaping. This got mixed with ash (around 200?C) present and injured and killed the personnel present. It is a very uncommon incident. The economizer duct blew releasing flue gas and steam. There was a pressure build-up. Due to the impact, people who were working there were thrown back a distance of 10-20 m.
NTPC as an organisation has very good safety records and we have not heard of any major accidents in over the last 20 years. It is very difficult to draw any specific conclusions since the matter is still under investigation. The severity of disaster clearly indicates that the incident will throw a lot much learning to the fraternity.
Korba Chimney Collapse, 2009
The chimney collapse occurred in the town of Korba in the State of Chhattisgarh on September 23, 2009. It was under construction for the Bharat Aluminium Co Ltd (BALCO). Construction had reached 240 m (790 ft) when the chimney collapsed on top of more than 100 workers who had been taking shelter from a thunder storm.
Plans specify a 275-m chimney for the construction of a thermal power plant by BALCO, which is owned by Vedanta Resources. The incident happened during extreme weather conditions involving lightning and torrential rainfall. Workers sought shelter from the rain in a nearby store room, and a lightning strike at approximately 4 PM brought the chimney down on top of them. A rescue attempt was initiated following the collapse. Ongoing rain obstructed effort to retrieve the trapped workers. At least seven of the wounded were hospitalised. BALCO initially did not discuss the incident at length, strange only that "there is an accident and some people are injured"; claiming to be too busy with the rescue effort to make a longer statement. The state government believes that BALCO had been overlooking security aspects. In November 2009, the project manager from GDC Ltd was arrested, as well as three officials from Vedanta Resources which manages BALCO.
Key learnings: The National Institute of Technology (NIT), Raipur observed that the materials used were of substandard quality and technically faulty in design. NIT also concluded that there was improper water curing and that soil at the site was not up to code. Additionally, supervision and monitoring was found to be negligent. There was no preparedness to face thunderstorm or any kind of extreme weather conditions.
Jaipur Oil Depot Fire, 2009
The fire broke out on October 29, 2009 at 7:30 PM at the Indian Oil Corporation (IOC) oil depot’s giant tank holding 8,000 kilolitres (2.80,000 cu) of oil, in Sitapura Industrial Area on the outskirts of Jaipur, Rajasthan, killing 12 people and injuring over 200. The blaze continued to rage out of control for over a week after it started and during the period half a million people were evacuated from the area. The oil depot is about 16 km south of the city of Jaipur.
The incident occurred when petrol was being transferred from IOC’s oil depot to a pipeline. There were at least 40 IOC employees at the terminal, situated close to the Jaipur International Airport when it caught fire with an explosion. The MET department recorded a tremor measuring 2.3 on the Richter scale around the time of the first explosion at 7:36 PM, which resulted in shattering of glass windows nearly 3 km from the accident site.
The fire was a major disaster in terms of deaths, injury, loss of business, property and man-days, displacement of people, environmental impact in Jaipur. As per eyewitnesses, having factories and hotels around IOC’s Sitapura (Jaipur) Oil Terminal they felt presence of petrol vapour in the atmosphere around 4:00 PM on October 29, 2009. Within the next few hours the concentration of petrol vapours intensified making it difficult to breathe. The Ayush Hotel in the vicinity of the terminal asked all its guests to vacate the Hotel to avert any tragedy. Adjacent to the Terminal wall was the workshop of Morani Motors (P) Limited whereas per eyewitnesses the cars parked on the roof top were thrown up in Air to about 10 feet and 35 new Hyundai brand cars were completely damaged. The police, civil administration and fire emergency services were oblivious of the situation developing in Indian Oil terminal.
The staff in the terminal had contained the leak and flow of petrol panicked and reported the matter to nearby Sanganer Sadar Police Station. Within the next 30 minutes the local police chief and District Collector were on the spot along with Indian Oil general manager, but with no plan to deal with the situation. The nearby industries, which were running second shift, were cautioned to vacate the area. At 7:35 PM, a huge ball of fire with loud explosion broke out engulfing the leaking petrol tank and other nearby petrol tanks with continuous fire with flames rising 30-35 m (98-115) and visible from a 30 km radius. The traffic on adjacent National Highway No. 12 was stopped leading to a 20 km long traffic jam.
The Jaipur International Airport is just 5 km away from the accident site. Both the Army and experts from Mumbai were employed on October 30, 2009 to contain the fire, which started when an oil tanker caught fire at the depot in the Sitapura Industrial Area. The district administration disconnected electricity and evacuated nearby areas to limit the damage. The fire still raged on October 31, 2009, in the IOC depot, at Jaipur, after a defective pipeline leak that set fire to 50,000 kilolitres (1,800,000 cu) of diesel and petrol out of the storage tanks at the IOC depot. By then, the accident had already claimed 11 lives and seriously injured more than 150.
Key learnings: The District Administration and IOC had no disaster management plan to deal with this kind of calamity. The local fire officers were ill equipped to deal with fire accidents of this magnitude. They remained onlookers and no efforts were made to breach the terminal wall to get closer to kerosene and diesel tanks to cool them with water jets.
Industrial accidents
Industrial accidents are caused by chemical, mechanical, civil, electrical, or other process failures due to mishap, negligence or incompetence, in an industrial plant which may spill over to the areas outside the plant causing damage to life and property. Major threats encountered in industrial accidents are fire, explosion, toxic release, poisoning and or combination of any of these. It is important to check the probable causes of accidents which are process deviations i.e pressure, temperature and flow, parameters with regard to the state of the substance, i.e., solid, liquid or gas, proximity to other toxic substances.
Probable causes: Boiling liquid expanding vapour explosion (BLEVE) on the chemicals during transportation, electrical failure, cutting and welding, open flame, carelessness, poor housekeeping, smoking, sabotage, etc.
Effects of accidents
Meteorology of the area, wind speed and direction, rate of precipitation, toxicity/quantity of chemical released, population in the reach of release, probability of formation of lethal mixtures and other industrial activities in vicinity.
We have narrated three industrial disasters only to provoke the thought process of our readers. Cement industry and RMC business are no exception to any of the incidents narrated above. An industrial disaster of this kind leaves a stigma behind and we as professionals have to take learnings from it so as to avoid similar occurrences in future.
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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.
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
Concrete
Installing a solar system is just the first step
Published
3 weeks agoon
September 23, 2024By
adminRaman 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