Economy & Market

Manpower Development for Indian Cement Industry

Published

7 years ago

October 31, 2018

admin

Indian cement industry is among the best in the world when it comes to energy efficiency. However, specialised training is essential to face and overcome certain unique challenges of the Indian cement industry.

The Indian cement industry is poised for a big growth considering the various infrastructural developments planned by the Government of India and the demand for housing all over the country. The Government of India has planned to invest Rs 5.94 lakh crore in the infrastructural sector with an additional allocation of Rs 2.04 crore for smart cities in the Union Budget of 2017-18. GST, demonetisation and some other factors have affected the growth of the industry temporarily but things are expected to stabilise soon. The Central Government has an ambitious plan to provide housing for all citizens by 2022. Increased allocation to rural housing under Pradhan Mantri Awas Yojna-Gramin scheme and developing smart cities will boost demand. Additional efforts in development of ports under "Sagarmala" and nation-wide road network development under "Bharatmala" will give impetus to cement demand. Nine new airports are on the anvil.

From the chart (next page) it is pertinent that housing sector will play a major role in boosting growth of Indian cement industry. The consumption of cement in agricultural sector is negligible today but as announced in the union budget of 2017-18, this sector is being given due importance.This will contribute to a substantial demand for cement for building warehouses and other logistics in the rural sector. International Monetary Fund (IMF) in its latest update has forecasted a GDP growth of 7.4 per cent next year. If all goes well CLSA expects a volume growth in new home construction to a compounded annual growth rate to about 8 per cent over the next seven years. Cement is a cyclical commodity with good correlation with GDP. With the projected GDP growth of 7.5 to 8.0 per cent in the next few years, cement demand will also increase. The present installed capacity of cement manufacturing is around 435 MT/year. It is estimated that India would need 550 to 600 MT/ annum by 2025. This means an additional capacity of 100 to 150 MTs/ annum need to be installed by 2025. In spite of being the second largest cement producer in the world the per capita consumption in India is only 225 kg, which is much lower than the world average of 500 kg and far behind China where it is more than 1,000 kg. These figures indicate that India has a long way to go to be called a developed nation. However Indian economy is the fifth largest economy as of now and is expected to become third largest very soon. This gives the possibility of huge expansion of the Indian cement industry.

Future technical manpower requirement
Getting skilled manpower for the industry is a challenge. There is a big gap between availability and demand. With the anticipated addition of another 150 MT/annum by 2025, it is estimated that the cement industry will require around 66,000 skilled technical manpower for greenfield projects, brownfield expansion and captive power plant operations.

Need for specialised manpower
Indian cement industry is among the best in the world when it comes to energy efficiency. However specialised training is essential to face and overcome certain unique challenges of the Indian cement industry. The major ones are listed as follows:

Depletion of high-grade limestone. We need to add more capacity with marginal and sub marginal grades of limestone. Also depletion of good quality mineral gypsum and finding large volumes of alternative material is also concerning.
Non availability of good quality cheaper fuel. The plants have to balance their fuel cost without diluting product quality. A rapid stride has to be taken to use alternate fuels and raw materials (AFR). This requires specialised skills.
Further improvements in energy efficiency is necessary by installing WHR systems and retrofitting with energy efficient equipment.
Compliances with stricter environmental and safety norms.
Implementing innovative ideas and methods to keep production cost low in view of the ever increasing cost of inputs like raw materials, fuels, logistics, taxes, etc.

There is shortage of skilled manpower in the industry who can handle such burning issues. There is hue and cry in the country saying that people are not getting employment. On the other hand the manufacturers complain that they do not get the rightly skilled manpower. There is a serious gap between what is wanted and what is available. To address all these issues it is necessary to:

Design training programmes which are practical in nature and completely wedded to the requirement of the construction industry. In this respect, a close co-ordination of industry and academics is the need of the hour.
Enhance skills of the semi-skilled workers to enable them to do their jobs in a scientific manner for better quality and productivity
Make a pool of people ready for the future growth of the cement and construction industry

Initiatives taken by organisations
It is worthwhile to mention that the National Council for Cement and Building Materials (NCCBM) has considerable contribution in this area. They are conducting various programmes to train fresh graduates. They are also regularly conducting short term, customised and contract programmes for improving skills of technical personnel of plants. Few universities and colleges have implemented diploma courses in cement technology but are not doing that well perhaps because their courses are not designed as per industry needs and limitations of cement plant experience in their faculties.With the anticipated rapid growth of the industry all these efforts may not be sufficient.

Initiatives taken by AKS University
Keeping all these requirements in mind it is worthwhile to mention an innovative University called AKS University in Satna, Madhya Pradesh. This university had the foresight of this future demand of India and started conducting degree anddiploma courses in cement technology from the year 2012 after getting UGC approval. The visionary of AKS University is Er Anant Kumar Soni who started this humble journey to impart quality education at affordable price to the rural masses. He sensed long back that being located in a cement hub, it will be a great service to the rural poor if they are trained to take up employment in cement plants in this limestone rich belt of Satna. He vowed to make education affordablewithout any capitation fees. His objective is to raise the level of rural education and bring it at par with urban levels and trainthe poor students for employment.

AKS University is spread over an area of more than 100 acres of land in the Satna town of Madhya Pradesh, adjacent to NH-7. It has developed 4.5 lakh sqft of lecture rooms, workshops, state of the art laboratories, agriculture research farms, incubation center etc. At present the AKS University is offering 52 courses under 12 faculties and more than 7,500 students are enrolled for the session 2017-18.

AKS University credentials Within a short duration of five years, AKS University has been awarded various credentials for its achievements, this are listed below.

Best University in IT infrastructure for the year 2018 awarded by ASSOCHAM.
Best Private Innovative University for the Year 2017.
Excellent Private University in rural sector awarded by ASSOCHAM in 2016
Excellent Private University in Rural sector for the year 2015, awarded by Dr. RS Katheriya, Hon?ble State Higher Education Minister, Ministry of HRD, Govt of India.
Excellent Private University in Madhya Pradesh by CMAI, Madhya Pradesh Technical Excellence Education Summit Bhopal in the year 2014.
Indo Nepal Sadbhavna award in the year 2014 from Govt of Nepal, Kathmandu, Nepal.
Best University in IT infrastructure for the year 2014 by CCI Technology Excellency Award, Bhopal.

AKS University, in addition to cement technology, offers various Diploma, B. Tech., M. Tech andPh. D programmes in most of the courses. While many private universities are reporting shortfall in the intake of students in the engineering streams, AKS University is experiencing higher intakes especially in the agriculture and mining departments. Mention must be made of the innovative approaches carried out in the mining department which is bringing laurels to the university. Students are sent to present technical papers in internationals seminars. The department organises various seminars in the country where well known persons from the Indian mining industry are felicitated and givenlife time achievement awards. This department has eight professors who are ex general managers from Coal India Limited.

Considerable efforts are taken to ensure good attendance among students as well as professors. The administration ensures that all courses are actually taken and completed in time inclusive of revision classes. Industry academic coordination and networking is given the topmost priority.

Why Cement Technology (CT) from AKS University?

It is the first university in the country offering both Diploma and B.Tech courses in cement technology recognised by MP Board of Technical Education and UGC respectively.
Being an autonomous institution, technical courses are designed and constantly upgraded keeping in view the latest technological developments in Indian cement industry. Frontier areas relevant to Indian cement industry like alternate fuels and raw materials (AFR), waste heat recovery systems (WHR), energy efficiency, composite and geo-polymeric cements, belitic cements, etc. A great thrust is given on concrete technology with emphasis on application aspects. Management aspects like marketing, operations management, safety and environment management etc. from an integral part of the course. Mechanical, electrical, instrumentation, mining, geology, chemical engineering aspects are covered extensively with examples and case studies from Indian cement industry.
Industrial training and doing project work on frontier areas which challenges the Indian cement Industry is compulsory for all students.
Experienced industry faculty is a special feature at AKS and so in CT Department.There is blend of 50 per cent full time professors from industry with more than 35-year experience and remaining 50 per cent comprising of seasoned academicians specialising in chemical, mining, electrical and instrumentation, mechanical engineering, geology etc.Most of them are from IITs, NITs, and other reputed universities.
State of the art infrastructure and laboratories for hands on training and research.
Group discussions, role plays, mock interview sessions, Saturday departmental seminars are regularly conducted to improve the personality aspects of students
Research opportunities including real-time industry projects.
With the approval of Board of Apprenticeship Training (BOAT) Mumbai, the B.Tech students undergo a Sandwich Apprenticeship (in plant training) for 150 days in VIII Semester.
Simulator based training at National Council for Cement and Building Materials(NCCBM), Ballabgarh, Haryana is compulsory in semester VI in B. Tech programme. These full time degree courses have a practical component of 40% and theoretical component of 60 per cent.
AKS University is connected with many cement plants through Cement Manufacturing Association of India (CMA)
AKS University is a "University with difference" where the courses are modified on a regular basis involving industry professionals. Management is deeply inclined to establish strong relationship with industry. Most of the senior staff in Engineering and Technology departments’ are stalwards in their own fields from institutions like ACC, NCCBM, Lafarge, Coal India, Indian Oil etc. Quite a few of them have foreign degrees and one professor in Cement Technology department is a Canadian national. This helps the students to network with professionals of industry right from early stages of their courses.
A good number of students have been placed and are workingwith Star Cement, Sanghi Cement, Amrit Cement, Ultratech Cement, Gorahi Cement(Nepal), Prism cement, KJS cement, etc.

Achievements of AKS University

1.First batch of B.Tech students passed out in 2015
2.More the 50per cent students placed in cement plants
3.Carrying out short term courses (three to six months) for enhancing skills of plant personnel (workers and staff) on cement technology. Completed two programmes for Prism Cement Ltd. Satna and further programmes are in offing.

Negotiation with UltraTech are on to train masons on a regular basis. These masons will be picked out by them.
4.Established a name in imparting high quality training programmes for techno-marketing professionals of cement industry. This is a well established popular training programme highly appreciated by industry.
Application engineering is an area that needs a lot of manpower. Now-a-days, this has emerged as a necessary activity of cement marketing. These engineers are responsible for technical marketing of cement and assist the customers throughout the construction process. They also handle quality complaints. TheAKS three-year diploma course, which is being renamed as diploma in cement and concrete technology, is perhaps the best fit degree for techno marketing personnel in rural areas as they know both sides of the game (cement and concrete ). They can do all the dirty work better as compared to a B.Tech/Diploma in civil engineering.

AKS University has conducted numerous short-term courses for techno marketing professionals for companies like UltraTech, KJS Cement, etc. with grand success. These are residential programmes with certification from Centre of Continuing Education, Department of Cement Technology, AKS University, Satna.

Training scheme
The department can train fresh personnel selected by cement manufacturers and make them industry ready either with the Diploma or B.Tech programme in cement technology which are on campus programmes. Short term customised courses are also feasible.New cement companies who have started their greenfield projects can send their entire team of fresh recruits to AKS so that they get professionally trained by the time the plant is ready for commissioning. Good hostel facilities are available in Satna town. Local people from surroundings of Cement plants located in rural areas have been found to be assets for the industry both in the past and present. These people show lot of dedication and loyalty compared to people from urban areas Moreover creating local employment is also compulsory as part of CSR schemes. AKS University has all the expertise to nurture these poor people from rural areas and make them industry ready.

Summary
With the expected spurt in demand for technical personnel in cement industry, which is imminent, it is worthwhile to have a serious thought on manpower development and skill enhancement of existing manpower. Actions need to be taken right now so that the industry is not starved of skilled personnel. It is worthwhile if cement manufacturers recruit cement technologists who are already trained by institutes like AKS University. Such trained personnel with degree or diploma in cement technology are industry ready and only need to be customised to the working of individual cement manufacturers who recruit them. This will reduce the gestation period to take up independent supervisory and other roles. There are very few institutions in India imparting quality cement technology programmes in India. AKS University, Satna is already in this field for past five years and has matured enough to be a partner to generate competent manpower for the Indian cement industry at affordable cost. Customised short-term courses are also feasible as per requirement of individual cement manufacturers.

About the authors:
Prof KN Bhattacharjee and Prof GC Mishra of Department of Cement Technology AKS University Satna. Prof KN Bhattacharjee is the corresponding author. He can be contacted on: Email: karuna.bhattacharjee3@gmail.com| Mob: 91-9340898824.

Concrete

The primary high-power applications are fans and mills

Published

3 weeks ago

October 10, 2025

admin

Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

Concrete

We conduct regular internal energy audits

Published

3 weeks ago

October 10, 2025

admin

Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

Concrete

Digitalisation is pivotal in driving energy efficiency

Published

3 weeks ago

October 10, 2025

admin

As energy costs continue to dominate the cement industry, efficiency and sustainability are proving to be vital components. MM Rathi, Joint President, Power Management, Shree Cement, explains the company’s long-term strategy is focused on cutting emissions while powering growth with renewable energy solutions.

Energy efficiency has always been a cost-saving lever for the cement industry. Today, it is the backbone of sustainability and competitiveness. Cement manufacturers are under growing pressure to optimise consumption, diversify power sources and align with decarbonisation targets. Shree Cement has been at the forefront of this transformation, significantly scaling up its green power capacity and embedding advanced technologies across operations. In this exclusive conversation, MM Rathi, Joint President – Power Management, Shree Cement, shares insights on the company’s approach to energy efficiency, challenges in brownfield modernisation and long-term strategies for achieving net zero alignment.

What percentage of your total operational cost is attributed to energy consumption?
At Shree Cement, energy is one of the most significant components of production cost, accounting for nearly 30 per cent to 40 per cent of total operational expenses. Within this, thermal energy typically contributes around 20 per cent to 25 per cent, while electrical energy forms about 10 per cent to 15 per cent. The exact share varies depending on factors such as the fuel mix (coal, pet coke or alternative fuels and raw materials), the power source (grid-based or captive like solar, wind or thermal), raw mix quality, and regional fuel and electricity price variations. This makes energy efficiency and the adoption of sustainable power sources a key focus area, both from a cost and sustainability perspective.

How has your company improved energy efficiency over the past five years?
Over the past five years, Shree Cement has consistently invested in enhancing energy efficiency across operations. Our green power capacity, covering wind, solar and Waste Heat Recovery (WHR), has more than doubled from 245 MW in 2020 to 592 MW in 2025. All grinding units are now equipped with biomass firing facilities, reducing dependence on conventional fuels. From the project stage itself, we prioritise efficiency by selecting advanced technologies such as six-stage kilns with integrated WHR, CFD-designed plants, and equipment fitted with VFDs, centrifugal compressors and high-efficiency fans. We also review and upgrade equipment systematically, replacing fans, compressors, blowers, pumps, boilers and turbines with more efficient options. This continuous approach has reduced costs while significantly advancing our sustainability journey.
What technologies or practices have shown the highest energy-saving potential in cement production?
WHR stands out as one of the most effective solutions, offsetting a significant portion of electricity required for clinker production. Hot air recirculation has also proven highly beneficial in reducing heat losses. Additionally, regular energy audits help us identify opportunities for improvement and implement corrective measures in daily operations. Together, these practices play a critical role in optimising energy efficiency and driving sustainable operations.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
The biggest challenge is the significant upfront investment required for upgradation. Retrofitting existing facilities often involves complex civil and structural modifications, which add costs and extend downtime. Integration is another hurdle, as new high-efficiency equipment may not align seamlessly with older kiln systems, fans, mills or automation setups. These factors make the transition in brownfield plants more resource-intensive and time-consuming compared to greenfield projects.

How do you measure and benchmark energy performance across different plants?
We track key performance indicators such as specific heat consumption and specific power consumption for each unit, benchmarking them against internal and external standards. Thermal Substitution Rate (TSR percentage) is another critical metric, measuring the share of alternative fuels in the thermal energy mix. Internally, we benchmark performance across plants to encourage best practice sharing. Externally, we compare against national averages and align with the Bureau of Energy Efficiency’s PAT (Perform, Achieve, Trade) scheme, which sets Specific Energy Consumption (SEC) baselines and targets for cement plants. This multi-layered approach ensures continuous monitoring, improvement, and industry leadership in energy efficiency.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation is pivotal in driving energy efficiency at Shree Cement. IoT sensors integrated with SCADA and DCS systems allow real-time monitoring of parameters like heat consumption and energy use, moving beyond periodic reports. Our digital platforms consolidate plant data, enabling management to compare metrics such as SPC, SHC, kWh per tonne and kcal per kg across units in real time. This visibility supports data-driven decisions, faster corrective actions, and higher operational efficiency.

How do government policies and incentives influence your energy-saving decisions?
Government policies and incentives strongly shape our energy-saving decisions. The Perform, Achieve, Trade (PAT) scheme sets plant-specific SEC targets. Non-compliance incurs penalties, while compliance earns tradable energy-saving certificates. This ensures energy efficiency is both cost-driven and regulatory. Additionally, subsidies and viability gap funding for renewable energy projects in wind, solar and AFR co-processing help reduce payback periods and make energy-saving investments more viable.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
Our long-term strategy aligns energy efficiency with India’s net zero 2070 goals. Key levers include improving efficiency, expanding green electricity, producing more blended cement, and increasing alternative fuel use. Today, more than 60 per cent of our electricity comes from green sources such as solar, wind, and WHR, the highest in India’s cement industry. Our blended cement products, which reduce limestone and fuel consumption, further lower emissions. These products are certified under the GreenPro ecolabel by CII, validating our sustainability practices and environmental standards.