Economy & Market

The Best can still get better

Published

8 years ago

April 30, 2018

admin

Having crossed several milestones in energy efficiency and sustainability, Indian cement industry is set to achieve the pinnacle.
Increasing competitive pressures, rising energy prices, coupled with stricter regulations for environmental protection are making energy efficiency and sustainable use of resources a top priority for the manufacturers in the recent years, and the cement industry is no exception.
Indian cement industry has already crossed several milestones on energy efficiency ans sustainability parameters. It has emerged as one of the most energy-efficient industry globally with the lowest carbon footprint in the world and it is among few large scale modern industries that do not produce any hazardous solid or liquid discharge, according to Cement Manufacturers’ Association (CMA).
But the icing on the cake has come from the Cement Sustainability Initiative (CSI) an initiative of the World Business Council for Sustainable Development (WBCSD). In 2015 itself CSI had said, "The member companies from India are more efficient.
They emit less CO2 than the companies in Europe and the US. Their energy consumption is also less." The distinction between Indian firms from those in the US and Europe is technology. Indian companies use the latest technology since many of the cement plants are relatively new, CSI had said. CSI was then a 23-member organisation including nine Indian cement companies, including UltraTech Cement and Dalmia Bharat, and seven global companies with operations in India.
Since then the industry is taking a number of measures aimed at further improving its performance on parameters like specific heat consumption, setting up of waste recovery systems and use of alternate fuels. In fact, all these measures help the companies attain the GreenCo rating, where the core focus is on energy efficiency. For example, the industry has increased the Thermal Substitution Rate (TSR) through use of alternative fuels and raw materials to 4 per cent in 2017, from a meagre 0.6 per cent in 2014. Performance
The cement production process is quite energy intensive, both in terms of electrical and thermal energy consumption (E&TEC). There are plants in India that have achieved energy efficiency figures which are considerable to the world’s best. However, the presence of old plants with high specific energy consumption (SEC) brings down the average figures. Cement production involves the heating, calcining and sintering of blended and ground materials to form clicker. As a result, cement manufacturing is the third largest cause of man-made CO2 emissions due to the production of lime, the key ingredient in cement. Therefore, energy savings during cement production could lead to lower environmental impact.
Improvement in the cement industry’s energy efficiency and reduction of CO2 emissions could be mainly achieved through two procedures:
(i) By changes in the manufacturing and production processes, and
(ii) By adjusting the chemical composition of cement.
Improvement in manufacturing and production processes can be achieved by changing energy management processes and by investing in new equipment and/or upgrades. The same way, changes in the chemical formulation of cement have proved to save energy and reduce CO2 emissions. The same holds good for cement industry, which is a highly capital intensive and competitive sector with long economic lifetimes, making changes in the existing capital stock difficult.
"The average electrical energy consumption in India is around 90-95 kWh/tonne cement (OPC) whereas the best achievement is around 80 kWh/tonne cement (OPC). Similarly, average TEC is around 760 kcal/kg clinker, whereas the best figures achieved are around 680 kcal/ kg clinker. There is scope for reduction in both E&TEC in many of the cement plants in India," says PK Ghosh, Group Managing Director, Ercom Engineers.
The best achievable figures are generally observed for the larger scale plants in India using the state of the art technology when operating at or higher than design levels, Ghosh added.
The contribution of the various departments to power and heat consumption is given in the Table-1.PAT Scheme
Perform, Achieve & Trade (PAT) scheme of the Bureau of Energy Efficiency (BEE), a market-based mechanism focused on reducing specific energy consumption – energy used per unit of production – in large industries, has managed to save a whopping Rs 47,185 crore in three years between 2012 and 2015 in the form of energy savings achieved on the back of robust implementation of energy efficiency measures. The scheme facilitates these large, energy-intensive industries to achieve their legal obligation under the Energy Conservation Act of 2001, while also motivating them with market-based incentives to reduce their energy use and surpass their individual energy saving targets.
A Government of India initiative, PAT’s first cycle covered 478 designated industries from 8 energy-intensive sectors – Aluminium, Cement, Chlor-alkali, Fertilizer, Iron and Steel, Pulp and Paper, Textiles and Thermal power plant. Together, these sectors account for around one-third of India’s primary energy consumption.
"The scheme resulted in saving of energy equivalent to 8.67 million tonnes of oil, exceeding the target of 6.86 million tonnes by about 30 per cent. This also resulted in avoided generation of about 5,635 MW of power, resulting in monetary savings of
Rs 37,685 crore. At the same time Rs 9,500 crore has been saved due to reduction in energy consumption," according to BEE.
The third PAT cycle was also notified from April 1, 2017 for 3 years including 116 new units with a reduction target of 1.06 MTOE. Key processes
The energy efficiency achieved is the result of optimisation between capital expenditure and reducing operating expenses.
Adoption of alternative fuels as a means of increasing cost competitiveness is gaining ground. But the industry has a long way to go before achieving 25% TSR. The Thermal Substitution Rate (TSR) in India has shown a very positive trend year on year, reaching a level of around 4 per cent in 2017. As indicated in the CII approach paper, India plans to achieve 25 per cent TSR by 2025. "In comparison to global standards, we are far behind as in many countries the substitution is in the range of 60-100 per cent," says Milind Murumkar, Advisor AFR, Vicat India.
Another way to reduce energy and process emissions in cement production is to blend cements with increased proportions of alternative (non-clinker) feed stocks, such as volcanic ash, granulated blast furnace slag from iron production, or fly ash from coal-fired power generation. Indian cement plants consume a quarter of the fly ash produced in the country annually, according to CMA. For the long run, cement industry lacks a viable carbon-free alternative, and the IEA suggested scenarios imply a heavy reliance on Carbon Capture and Storage (CCS) cement kilns with xy-fuelling. Waste heat recovery systems are expected to play a much bigger role as more of it gets tapped. "In case of specific heat consumption, approximately 20 per cent losses are through preheater exhaust gases, 12 per cent are through cooler exhaust gases and around 4-5 per cent are radiation losses (for 6 stage preheater – precalciner system with the state-of-the-art cooler), says Ghosh.
The cement grinding department and the raw material grinding are the major consumers of electrical energy. The material transport systems have also to be looked in to ensure that the power consumption is lowered.
Ghosh of Ercom says, "The implementation of MIS (management Information systems) like SAP helps in keeping track of key performance indicators. Management is able to monitor both plant operations and the productivity in a continuous manner for achieving energy efficiency targets."
When comparing the state of the art technologies in terms of sustainability, suitability, performance, robustness, cost-efficiency, patent restrictions (availability), and competence requirements, it can be expected that at least in the short term cement companies are going to be based on pyro processing and grinding mills.
Having tasted the fruits of energy efficiency measures over the recent years, and development of a host of case studies highlighting several achievements and sustainable development, the Indian cement industry is set to reach the pinnacle in energy efficiency in the world.Underutilisation and Energy Efficiency
Consider a Cement manufacturing unit which is designed for clinkerisation capacity of 5000 tpd (tonnes per day) and correspondingly OPC of 5250 tpd for the sake of this discussion.
The specific heat consumption of this precalciner kiln will lie in range of 695-700 kcal/ kg clinker at the design capacity. The operating temperatures for calcination (900-950oC) and clinkerisation (1350-1400oC) will be the same irrespective of the operating level. The gas and material temperatures in the preheater stages will also to be maintained at similar levels. As a result, the total heat loss due to radiation will remain the same at all production levels. This will cause a higher specific heat consumption for lower than design operating levels as depicted in Figure 1.
The specific electrical energy consumption is around 90 kWh/t of Cement (OPC). The electrical drives, the fans and the HT motors are also designed to have maximum efficiency at their design operating levels. As a result, they will have suboptimum energy consumptions at lower than design production levels. This is depicted in Figure 2.
One of the ways to take care of underutilisation is by operating at design capacities and keeping the plant idle for extended periods of time. This may be feasible for those plants with multiple Pyro processing lines. At 80% annual production, the plant can be shut down for a total of 2 more months, and at 70% there are 3 extra months of shut down. However, the clinker storage section will be a constraint for this mode of operation.
Increased number of kiln shutdowns leads to wastage of heat during kiln cool down and start-up. The refractory life also reduced even though these shutdowns are planned. There are maintenance issues if the equipment has extended idle times.
Hence most plants settle for a production level which helps them meet the demands of the market while continuing to keep the kiln under operation for extended levels of time. However, it is important to note that there is a minimum turndown level, below which gas velocities in cyclones will reduce to a value which will not support the efficient heat transfer in the preheater and affect the gas-solid reaction in the calciner.– P. K. Ghosh, Group Managing Director,
Ercom Engineers

– BS Srinivasalu Reddy

Concrete

Our strategy is to establish reliable local partnerships

Published

3 hours ago

February 19, 2026

admin

Jean-Jacques Bois, President, Nanolike, discusses how real-time data is reshaping cement delivery planning and fleet performance.

As cement producers look to extract efficiency gains beyond the plant gate, real-time visibility and data-driven logistics are becoming critical levers of competitiveness. In this interview with Jean-Jacques Bois, President, Nanolike, we discover how the company is helping cement brands optimise delivery planning by digitally connecting RMC silos, improving fleet utilisation and reducing overall logistics costs.

How does SiloConnect enable cement plants to optimise delivery planning and logistics in real time?
In simple terms, SiloConnect is a solution developed to help cement suppliers optimise their logistics by connecting RMC silos in real time, ensuring that the right cement is delivered at the right time and to the right location. The core objective is to provide real-time visibility of silo levels at RMC plants, allowing cement producers to better plan deliveries.
SiloConnect connects all the silos of RMC plants in real time and transmits this data remotely to the logistics teams of cement suppliers. With this information, they can decide when to dispatch trucks, how to prioritise customers, and how to optimise fleet utilisation. The biggest savings we see today are in logistics efficiency. Our customers are able to sell and ship more cement using the same fleet. This is achieved by increasing truck rotation, optimising delivery routes, and ultimately delivering the same volumes at a lower overall logistics cost.
Additionally, SiloConnect is designed as an open platform. It offers multiple connectors that allow data to be transmitted directly to third-party ERP systems. For example, it can integrate seamlessly with SAP or other major ERP platforms, enabling automatic order creation whenever replenishment is required.

How does your non-exclusive sensor design perform in the dusty, high-temperature, and harsh operating conditions typical of cement plants?
Harsh operating conditions such as high temperatures, heavy dust, extreme cold in some regions, and even heavy rainfall are all factored into the product design. These environmental challenges are considered from the very beginning of the development process.
Today, we have thousands of sensors operating reliably across a wide range of geographies, from northern Canada to Latin America, as well as in regions with heavy rainfall and extremely high temperatures, such as southern Europe. This extensive field experience demonstrates that, by design, the SiloConnect solution is highly robust and well-suited for demanding cement plant environments.

Have you initiated any pilot projects in India, and what outcomes do you expect from them?
We are at the very early stages of introducing SiloConnect in India. Recently, we installed our
first sensor at an RMC plant in collaboration with FDC Concrete, marking our initial entry into the Indian market.
In parallel, we are in discussions with a leading cement producer in India to potentially launch a pilot project within the next three months. The goal of these pilots is to demonstrate real-time visibility, logistics optimisation and measurable efficiency gains, paving the way for broader adoption across the industry.

What are your long-term plans and strategic approach for working with Indian cement manufacturers?
For India, our strategy is to establish strong and reliable local partnerships, which will allow us to scale the technology effectively. We believe that on-site service, local presence, and customer support are critical to delivering long-term value to cement producers.
Ideally, our plan is to establish an Indian entity within the next 24 months. This will enable us to serve customers more closely, provide faster support and contribute meaningfully to the digital transformation of logistics and supply chain management in the Indian cement industry.

Economy & Market

Power Build’s Core Gear Series

Published

3 hours ago

February 19, 2026

admin

A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

Concrete

Compliance and growth go hand in h and

Published

3 hours ago

February 19, 2026

admin

Pankaj Kejriwal, Whole Time Director and COO, Star Cement, on driving efficiency today and designing sustainability for tomorrow.

In an era where the cement industry is under growing pressure to decarbonise while scaling capacity, Star Cement is charting a pragmatic yet forward-looking path. In this conversation, Pankaj Kejriwal, Whole Time Director and COO, Star Cement, shares how the company is leveraging waste heat recovery, alternative fuels, low-carbon products and clean energy innovations to balance operational efficiency with long-term sustainability.

How has your Lumshnong plant implemented the 24.8 MW Waste Heat Recovery System (WHRS), and what impact has it had on thermal substitution and energy costs?
Earlier, the cost of coal in the Northeast was quite reasonable, but over the past few years, global price increases have also impacted the region. We implemented the WHRS project about five years ago, and it has resulted in significant savings by reducing our overall power costs.
That is why we first installed WHRS in our older kilns, and now it has also been incorporated into our new projects. Going forward, WHRS will be essential for any cement plant. We are also working on utilising the waste gases exiting the WHRS, which are still at around 100 degrees Celsius. To harness this residual heat, we are exploring systems based on the Organic Rankine Cycle, which will allow us to extract additional power from the same process.

With the launch of Star Smart Building Solutions and AAC blocks, how are you positioning yourself in the low-carbon construction materials segment?
We are actively working on low-carbon cement products and are currently evaluating LC3 cement. The introduction of autoclaved aerated concrete (AAC) blocks provided us with an effective entry into the consumer-facing segment of the industry. Since we already share a strong dealer network across products, this segment fits well into our overall strategy.
This move is clearly supporting our transition towards products with lower carbon intensity and aligns with our broader sustainability roadmap.

With a diverse product portfolio, what are the key USPs that enable you to support India’s ongoing infrastructure projects across sectors?
Cement requirements vary depending on application. There is OPC, PPC and PSC cement, and each serves different infrastructure needs. We manufacture blended cements as well, which allows us to supply products according to specific project requirements.
For instance, hydroelectric projects, including those with NHPC, have their own technical norms, which we are able to meet. From individual home builders to road infrastructure, dam projects, and regions with heavy monsoon exposure, where weather-shield cement is required, we are equipped to serve all segments. Our ability to tailor cement solutions across diverse climatic and infrastructure conditions is a key strength.

How are you managing biomass usage, circularity, and waste reduction across
your operations?
The Northeast has been fortunate in terms of biomass availability, particularly bamboo. Earlier, much of this bamboo was supplied to paper plants, but many of those facilities have since shut down. As a result, large quantities of bamboo biomass are now available, which we utilise in our thermal power plants, achieving a Thermal Substitution Rate (TSR) of nearly 60 per cent.
We have also started using bamboo as a fuel in our cement kilns, where the TSR is currently around 10 per cent to 12 per cent and is expected to increase further. From a circularity perspective, we extensively use fly ash, which allows us to reuse a major industrial waste product. Additionally, waste generated from HDPE bags is now being processed through our alternative fuel and raw material (AFR) systems. These initiatives collectively support our circular economy objectives.

As Star Cement expands, what are the key logistical and raw material challenges you face in scaling operations?
Fly ash availability in the Northeast is a constraint, as there are no major thermal power plants in the region. We currently source fly ash from Bihar and West Bengal, which adds significant logistics costs. However, supportive railway policies have helped us manage this challenge effectively.
Beyond the Northeast, we are also expanding into other regions, including the western region, to cater to northern markets. We have secured limestone mines through auctions and are now in the process of identifying and securing other critical raw material resources to support this expansion.

With increasing carbon regulations alongside capacity expansion, how do you balance compliance while sustaining growth?
Compliance and growth go hand in hand for us. On the product side, we are working on LC3 cement and other low-carbon formulations. Within our existing product portfolio, we are optimising operations by increasing the use of green fuels and improving energy efficiency to reduce our carbon footprint.
We are also optimising thermal energy consumption and reducing electrical power usage. Notably, we are the first cement company in the Northeast to deploy EV tippers at scale for limestone transportation from mines to plants. Additionally, we have installed belt conveyors for limestone transfer, which further reduces emissions. All these initiatives together help us achieve regulatory compliance while supporting expansion.

Looking ahead to 2030 and 2050, what are the key innovation and sustainability priorities for Star Cement?
Across the cement industry, carbon capture is emerging as a major focus area, and we are also planning to work actively in this space. In parallel, we see strong potential in green hydrogen and are investing in solar power plants to support this transition.
With the rapid adoption of solar energy, power costs have reduced dramatically – from 10–12 per unit to around2.5 per unit. This reduction will enable the production of green hydrogen at scale. Once available, green hydrogen can be used for electricity generation, to power EV fleets, and even as a fuel in cement kilns.
Burning green hydrogen produces only water and oxygen, eliminating carbon emissions from that part of the process. While process-related CO2 emissions from limestone calcination remain a challenge, carbon capture technologies will help address this. Ultimately, while becoming a carbon-negative industry is challenging, it is a goal we must continue to work towards.