Environment

At Dalmia, we have been fulfilling our social responsibility for over eight decades now

Published

5 years ago

January 8, 2020

admin

– Vishal Bhardwaj, CEO, Dalmia Bharat Foundation

What are the activities you are involved under CSR commitment and how the government mandate is prescribing various benchmarks?
We work closely with communities around our manufacturing locations and our CSR is sharply focused on livelihoods, climate action and building social infrastructure. Under our livelihoods vertical, we work both in the farm and non-farm sectors. We impart skill training to youth, making them employable and that’s our flagship program. Currently, we can train 5,000 youth every year at 11 centres of Dalmia Institute of Knowledge and Skill Harnessing (DIKSHA), spread across the countryand also run three Industrial Training Institutes (ITIs). We assist farmers by helping them increase their income through improved agricultural practices as well as by helping them develop the social and natural capital.

Under Climate Action, our major focus is on water harvesting and water conservation with rough various projects including Integrated Watershed Development. In the last five years, we have created the harvesting potential of more than 17 million cubic metres of water annually. We also help tribal households enhance their income through horticulture plantations. Furthermore, we promote access to solar energy for domestic and agricultural purposes as well asthat to cleaner fuels like biogas and LPG for cooking.

Working mainly in remote rural areas, we also assist the local administrations and communities to fill the existing infrastructural gaps. This improves the quality of life of communities adjacent to our Plants.

At Dalmia, we have been fulfilling our social responsibility for over eight decades now. We have always believed in giving back to the society that has created an opportunity for us to run our business. We consider that the growth and development of all stakeholders-most importantly the communities around us-has to be an essential by-product of our business. That is why we engage with them in a very structured manner to bring about a positive and material change in their lives. To achieve that, we do not restrict ourselves to the mandate given to us under the law but go way beyond that to fulfil our objectives.

How are the actual and prescribed budgets for the last three years? Please give details of allocations for various activities. How long it will take for you to complete the mission you have undertaken in that particular region?
Having set the mid to long-term CSR goals, there’s a clear roadmap with a predetermined clutch of targets to be achieved by 2020 and another by 2030. Meanwhile, each project we pick has a unique start and close dates and we plan adequate exit protocols to ensure the long-term sustainability of our initiatives.

What has been the impact of various CSR activities in various geographies? What is the criterion adopted in choosing the target group or community for CSR initiatives?
There have been encouraging outcomes and impacts of our program in various geographies. For example, there is a significant rise in the water table in our watershed development project areas that we have noticed. Increased irrigation opportunities and moisture retention in the soil results in to higher income for farmers. In the last couple of years, there has been an average of 20 per cent increase in farmers’ income through these projects.

This helps the communities cultivate fallow lands while the availability of water allows them to grow more remunerative cash crops such as vegetables. Similarly, through the skill training initiatives, we help more than 5,000 youth get jobs each year at an average starting salary of Rs 10,000 per month. Thousands of members of the Self-help Groups and Farmer-Producers’ Companies promoted by us gain access to institutional finance. All this has ensured sustainable human development in these regions.

Generally, we choose to work with neighbourhood communities near our manufacturing locations.

Can you give us the best case study that has yielded highest/ best results?
One of our best cases is a public-private-people s partnership project for water harvesting in the drought-prone Mylavaram Tehsil in District Kadapa of Andhra Pradesh to mitigate the impact of drought on livelihoods.

In the past few years, District Kadapa has been declared drought-hit twice. In these uncertain times, the vagaries of water availability create a crisis for agriculture as well as for humans and cattle. With groundwater out of reach for most villagers, agriculture is primarily rain-fed. Cattle rearing is also challenging, including their survival, which impacts milk yield and productivity.

To address such challenges, we explored opportunities for creating large number of farm-ponds to harvest rainwater for effective use in agriculture, to meet drinking water needs of milch animals and for recharging the groundwater table. To accelerate work in this sphere, we sought partnerships. Therefore, we met local Government and District Officials and developed a plan for creating the farm-ponds leveraging MNREGA programme.

The major outputs of the project that was executed in a participatory form were:

175 ponds with a total capacity of 1.85 lakh m3 created
One check dam and one causeway constructed, with a total capacity of 50,000 m3
Employment opportunities provided for local communities by generating over
77,000 workdays worth Rs 155 lakh

Consequently, we have achieved the following outcomes:

Increase in annual income of Rs 6,000 to Rs 7,000 per family
50 acres of land is now irrigated for fodder cultivation
An increase of two to three litres of milk reported by Dairy Farmer-Producers’ Company members per day
No depletion in the water table in the area of influence of these structures has been reported recently

What are the crushing challenges the country is facing in the socio-economic sphere and what CSR activities can contribute towards fulfilling these needs?
While we were facing several socio-economic challenges like many other developing economies, I think the scenario is likely to change because of Covid. While we already had employment as a big challenge, the lockdowns and reverse migration is likely to aggravate that. Reskilling and up-skilling will need to get the attention in the current situation. That’s where companies through their CSR could play an important role.

Disruption in supply chain is likely to affect the sowing in the ensuing Kharif season as well as post-harvest services of the just concluded Rabi season. That is likely to affect the Government’s effort to double the farmers’ income. CSR’s can address this issue by facilitating backward and forward linkages. Helping build e-platforms and institutions like the Farmers-producers’ companies is what is expected of the Companies at this point in time.

Sectoral and spatial gaps in the healthcare and education system continue to bother us. And now we see different kind of challenges in these two sectors amidst Covid. Digital access to healthcare and education is the need of the hour and that’s also where the CSR interventions could be very effective.

Overall, what is very important for the Companies to do at this point in time is to work in close coordination with the Government and build strong partnerships in order to collectively meet whatever challenges exist.

What are the CSR activities you have undertaken on outbreak of Covid-19 and what are the challenges you faced?
Besides adhering to all regulatory guidelines and precautionary norms against Covid-19, we ensured a pan-India workplace compliance audit. Firstly, we contributed Rs 25 crore to PM Cares Fund to fight the pandemic. Apart from that, employee contributions (Rs 1.65 crore) and contributions from Dalmia Cement Bharat (totalling Rs 5 crore) to various state relief funds for combating the pandemic were undertaken as well.

We also partnered with International Association for Human Values and the Art of Living, distributing cooked food packets, essential groceries and supplies to immigrant workers, slum dwellers and villagers in and around Delhi-NCR. In Odisha, our teams distributed 2,250 relief packets to periphery tribal hamlets as well as around 16,000 face masks, 3,000 nose masks and sanitisers to local villagers.

Similar activities were undertaken in numerous places where we have a presence, benefitting local communities. Likewise, contributions were made by our sugar business to the #PMCARESFund as well as NGOs, Trusts and Gurudwaras implementing relief work. Furthermore, there were other measures too numerous to outline here.

The only challenge was to ensure the safety of every stakeholder of our activities, the communities that we were assisting and our volunteers. However, with very robust sops that we had put in place, we were able to reach out to the underserved communities timely and safely.

How do you think the CSR scenario will pan out in general in the next two to three years, in the wake of Covid-19 impact on business revenues and profitability?
I think we will have to wait for the situation to emerge. There are estimates that there would be about 30 to 35 reduction in the CSR spent this year because of the expenditure that has been incurred on Covid related activities. Besides, as Covid is expected to make an impact on the bottom-line of businesses, the mandate based on 2 per cent of the profits is likely to see a downward movement. We should, however, wait for a while to know how the situation would emerge. At Dalmia, for instance, our Board has resolved to keep our CSR commitments unaffected by Covid. Like I mentioned, our contribution for Covid has been more than the 2 per cent mandate. With more companies following suit, there could actually be a lesser impact than what is being widely expected.

Concrete

Solving AF Processing Challenge with Advanced Combustion

Published

2 days ago

April 18, 2025

Roshna

Alternative fuels reduce cement plants’ carbon footprint, but infrastructure challenges limit adoption. Technologies like the HOTDISC® Reactor help overcome these barriers.

Alternative fuels are a relatively straightforward and readily available means of reducing a cement plant’s carbon footprint. The technology is proven and well used worldwide, and with the right controls in place the switch from fossil fuels to waste-derived fuels does not impact the quality of the end product. In some countries, cement plants are achieving near 100 per cent substitution in the calciner and high levels of substitution in the kiln. However, this trend is not universal, and some countries are struggling to achieve a thermal substitution rate (TSR) of 25 per cent. In this article, we will look at the obstacles to alternative fuels use and the technology that is available to overcome them.

Advantages of alternative fuels
Alternative fuels offer three key environmental advantages.
1) A lower carbon alternative to coal or petcoke.
2) A pathway for waste that might otherwise be landfilled, including hazardous waste.
3) An alternative to waste incineration, which is typically done at lower temperatures where emissions tend to be higher.
In addition, the cost of alternative fuels can often be lower than fossil fuels and is not subject to the fluctuations of the energy market.
The sources of alternative fuels are many and varied – to the extent that the supply chain looks vastly different from one region to the next. For example, whereas India has abundant sources of biomass such as rice husk, in Western Europe there are plentiful supplies of refuse-derived fuel (RDF). This is partly a matter of industry and partly of infrastructure. But given the importance of reducing the cement industry’s reliance on coal, a lack of infrastructure must not prevent greater utilisation of alternative fuels – which is why FLSmidth Cement has for some time been developing alternative fuels solutions that reduce the burden of pre-processing and enable cement plants to more easily and more cost-effectively utilise a wide variety of waste streams.

A solution for all waste
Direct calciner injection may seem like the simplest way to replace fossil fuels with alternatives. However, it’s not always the best. The options for alternative fuels are limited by the necessity to pre-process fuel in preparation for burning, which, as stated, requires established infrastructure, or additional facilities at the plant.
Though the CAPEX cost of direct calciner injection is low, the calciner fuel substitution rate is also low, so this method doesn’t enable cement plants to optimise the potential for fuel replacement. Plant operators must also consider the impact on the process of direct injection, which doesn’t allow the long residence time that can be required to reduce process volatility. No plant wants to contend with greater instability or an increase in emissions from adding alternative fuels to the mix. Fortunately, direct calciner injection is not the only option. There are other ways of extracting energy from waste that require no pre-processing at all.
The HOTDISC® Reactor can handle a wide variety of solid waste in sizes up to 1.2m – from sludge or grains to whole truck tyres. There’s no need for expensive shredding or pre-drying, or any pre-processing, which removes one of the obstacles to adopting alternative fuels. The broad range of accepted fuel types also means cement plants are free to shop the market and not tied into one supplier. This makes it a very cost-effective solution because cement plants can select the lowest cost fuel without worrying about the quality.

How does the HOTDISC® work?
The HOTDISC® is a moving hearth furnace that is integrated into the pyroprocess below the calciner bottom and above the kiln riser. Coarse alternative fuels are fed onto a slowly rotating disc. Hot tertiary air is directed into the HOTDISC to provide an oxidising atmosphere for the alternative fuel to burn. As the alternative fuel slowly travels around approximately 270 degrees on the rotating disc, almost all of it fully combusts. Depending on the nature of the alternative fuel (size, heat content, moisture, etc.), the rotational speed of the HOTDISC can be adjusted to optimise the residence time (up to 45 minutes) and combustion rate. In addition, the temperature inside the HOTDISC is controlled by directing a portion of the preheated raw meal into the HOTDISC. The HOTDISC operation generates a controlled mix of hot gases, combustion residue (ash) and calcined raw meal that exits the HOTDISC. The combustion gases and finer materials are carried with the hot gases into the bottom of the calciner, while the coarser residues meet a scraper at the end of the 270 degrees rotation, where they are directed down into the riser duct. From there, this material falls into the kiln and is incorporated into the clinker.
The HOTDISC is designed to achieve a calciner substitution rate in the range of 50 to 80 per cent – or even higher – of the calciner fuel. Results vary by the specific plant conditions and fuel specification, but based on over 20 years of plant data it is possible to predict the substitution rate in each application.
The HOTDISC was originally designed for use with In-Line Calciners (ILCs), but new models are now available for use with Separate Line Calciners (SLCs), enabling the HOTDISC to be installed under the calciner and still deliver the same benefits. The HOTDISC-S is installed in the bottom part of the SLC calciner on the ground, the reject will be cooled and transported to a container or back into the system, gas flow and AF flow operates counter current.
For cement plants that wanted to utilise a wide range of alternative fuels, the HOTDISC®-S is a cost-saving solution that avoids the expense of changing the SLC to an ILC while enabling a high substitution of alternative fuels. Another model, the HOTDISC®-HMT (Hot Material Transport), enables quicker and easier installation of the HOTDISC in existing plants. Instead of directly integrating the exit of the HOTDISC reactor to the calciner and riser duct, the new layout allows the HOTDISC reactor to be mounted two to five metres away. It is then connected to the calciner and riser duct via a hot material transport chute for gas flows and combustion ashes.

Further advances in alternative fuels technologies
Low or varying quality alternative fuels can be another inhibitor to substitution, given the requirements of the relatively delicate cement pyro process. FLSmidth Cement has expended considerable R&D effort developing solutions that can accommodate a wide range of fuel types, knowing that this is the easiest path to greater substitution and ultimately the near-elimination of fossil fuels. The FUELFLEX® Pyrolyzer was one result of this effort and offers an exciting prospect for cement plants wishing to achieve near – 100 per cent substitution in the calciner and minimise NOx emissions.

The FUELFLEX® Pyrolyzer utilises hot meal from the lower preheater cyclones (yellow arrows) to dry and pyrolyze RDF or biomass. Either part or the full stream of hot meal from a lower preheater cyclone is admitted to the Pyrolyzer via the U-Lock (controlled by two dividing gates). The U-Lock fluidises the hot meal, forming a U-shaped gas lock that prevents pyrolysis gases from flowing backwards through the process. Subsequently the hot meal stream flows into the Pyrolyzer vessel, which also has a U-shaped lower aerated section to contain the hot fluidised meal. Fuel is pneumatically fed to the pyrolyzer vessel wherein through contact with the hot meal, it is dried, heated and pyrolyzed to form reactive gases and char. The gases push upwards into the main pyrolyzer vessels while the char falls down into the fluidised meal bed, before being reunited and fed as a very reactive stream into the calciner. Aeration panels are used to fluidise the hot meal and drain gates are used to drain out debris and meal from the pyrolyzer to the kiln system in a controlled manner. The reactive stream of pyrolysis products reacts with rotary kiln NO by so-called ‘re-burning’ reactions, utilising pyrolysis gases to convert NO into free N2 in the reduction zone prior to mixing with preheated combustion air in the calciner. In addition, the full fuel pyrolysis preceding the calciner helps limit calciner NOx formation by limiting access to oxygen when burning.

By using the FUELFLEX® Pyrolyzer, cement plants can achieve up to 100 per cent fossil fuel replacement in the calciner, with the following benefits:

Reduced CO2 emissions, as net CO2 emissions from alternative fuels generally are lower than from fossil fuels.
Increased utilisation of local waste streams, avoiding the need to dispose of or store this waste in other ways.
Reduced fuel costs, especially in times of fluctuating energy prices.
Reduced fossil fuel use saves the associated environmental impact of fossil fuel extraction and transport.

Conclusion
The challenge is on: cement plants must reduce carbon emissions now, and continue to do so for the next several decades until the target of net zero is met. While there are some solutions that are not ready yet – i.e. carbon capture – alternative fuels offer a valuable means of reducing the cement industry’s environmental impact immediately, with the added benefit of providing a controlled means of waste disposal. New and proven technologies will help the cement industry to overcome alternative fuel supply chain problems and achieve a dramatic reduction in fossil fuel use.

(Communication by the management of the company)

Concrete

We consistently push the boundaries of technology

Published

2 days ago

April 18, 2025

Roshna

Swapnil Jadhav, Director, SIDSA Environmental, discusses transforming waste into valuable resources through cutting-edge technology and innovative process solutions.

SIDSA Environmental brings decades of experience and expertise to the important niche of waste treatment and process technologies. As a global leader that is at the forefront of sustainable waste management, the company excels in recycling, waste-to-energy solutions and alternative fuel production. In this conversation, Swapnil Jadhav, Director, SIDSA Environmental, shares insights into their advanced shredding technology, its role in RDF production for the cement industry and emerging trends in waste-to-energy solutions.

Can you give us an overview of SIDSA Environmental’s role in waste treatment and process technologies?
SIDSA is a leading innovator in the field of waste treatment and process technologies, dedicated to delivering sustainable solutions that address the growing challenges of waste management.
SIDSA is a more than 52-year-old organisation with worldwide presence and has successfully realised over 1100 projects.
Our expertise is in the engineering and development of cutting-edge systems that enable the conversion of waste materials into valuable resources. This includes recycling technologies, waste-to-energy (W2E) systems, and advanced methods for producing alternative fuels such as refuse derived fuel (RDF). The organisation prioritises environmental stewardship by integrating energy-efficient processes and technologies, supporting industrial sectors—including the cement industry—in reducing their carbon footprint. Through our comprehensive approach, we aim to promote a circular economy where waste is no longer a burden but a resource to be harnessed.

How does SIDSA Environmental’s shredding technology contribute to the cement industry, especially in the production of RDF?
SIDSA’s shredding technology is pivotal in transforming diverse waste streams into high-quality RDF. Cement kilns require fuel with specific calorific values and uniform composition to ensure efficient combustion and operational stability, and this is where our shredding systems excel. In India, we are segment leaders with more than 30 projects including over 50 equipment of varied capacity successfully realised. Some of the solutions were supplied as complete turnkey plants for high capacity AFR processing. Our esteemed client list comprises reputed cement manufacturers and chemical industries. Our technology processes various types of waste—such as plastics, textiles and industrial residues—breaking them down into consistent particles suitable for energy recovery.

Key features include:

High efficiency: Ensures optimal throughput for large volumes of waste.
Adaptability: Handles mixed and heterogeneous waste streams, including contaminated or complex materials.
Reliability: Reduces the likelihood of operational disruptions in RDF production. By standardising RDF properties, our shredding technology enables cement plants to achieve greater energy efficiency while adhering to environmental regulations.

What are the key benefits of using alternative fuels like RDF in cement kilns?
The adoption of RDF and other alternative fuels offers significant advantages across environmental, economic and social dimensions:

Environmental benefits: Cement kilns using RDF emit fewer greenhouse gases compared to those reliant on fossil fuels like coal or petroleum coke. RDF also helps mitigate the issue of overflowing landfills by diverting waste toward energy recovery.
Economic savings: Alternative fuels are often more cost-effective than traditional energy sources, allowing cement plants to reduce operational expenses.
Sustainability and resource efficiency: RDF facilitates the circular economy by repurposing waste materials into energy, conserving finite natural resources.
Operational flexibility: Cement kilns designed to use RDF can seamlessly switch between different fuel types, enhancing adaptability to market conditions.

What innovations have been introduced in waste-to-energy (W2E) and recycling solutions?
SIDSA’s machinery is meticulously engineered to handle the complex requirements of processing hazardous and bulky waste.

This includes:

Robust construction: Our equipment is designed to manage heavy loads and challenging waste streams, such as industrial debris, tires and large furniture.
Advanced safety features: Intelligent sensors and automated controls ensure safe operation when dealing with potentially harmful materials, such as chemical waste.
Compliance with standards: Machinery is built to adhere to international environmental and safety regulations, guaranteeing reliability under stringent conditions.
Modular design: Allows for customisation and scalability to meet the unique needs of various waste management facilities.

How does your organisation customised solutions help cement plants improve sustainability and efficiency?
We consistently push the boundaries of technology to enhance waste management outcomes.
General innovations and new product development focus on:

Energy-efficient shredders: These machines consume less power while maintaining high throughput, contributing to lower operational costs.
AI-powered sorting systems: Utilise advanced algorithms to automate waste classification, increasing material recovery rates and minimising errors.
Advanced gasification technologies: Convert waste into syngas (a clean energy source) while minimising emissions and residue.
Closed-loop recycling solutions: Enable the extraction and repurposing of materials from waste streams, maximising resource use while reducing environmental impact.

What future trends do you foresee in waste management and alternative fuel usage in the cement sector?
Looking ahead, several trends are likely to shape the future of waste management and alternative fuels in the cement industry:

AI integration: AI-driven technologies will enhance waste sorting and optimise RDF production, enabling greater efficiency.
Bio-based fuels: Increased use of biofuels derived from organic waste as a renewable and low-carbon energy source.
Collaborative approaches: Strengthened partnerships between governments, private industries and technology providers will facilitate large-scale implementation of sustainable practices.
Circular economy expansion: The cement sector will increasingly adopt closed-loop systems, reducing waste and maximising resource reuse.
Regulatory evolution: More stringent environmental laws and incentives for using alternative fuels will accelerate the transition toward sustainable energy solutions.

(Communication by the management of the company)

Concrete

Technology is critical to our eco-friendly logistics

Published

2 days ago

April 18, 2025

Roshna

Driving sustainable logistics with EV-powered supply chains, Pushpank Kaushik, CEO, Jassper Shipping, explains the correlation between reduced carbon emissions and efficient deliveries.

Jassper Shipping is advancing green logistics by integrating electric vehicles (EVs) into its supply chain and leveraging a transportation management system (TMS) to track and reduce carbon emissions at the shipment level. In this interview, Pushpank Kaushik, CEO, Jassper Shipping, tells us about the gameplan to achieve the goal of net-zero carbon emissions by 2035, and being a pioneer in shaping the future of eco-friendly logistics in India.

How is Jassper Shipping integrating green logistics into its shipping operations?
Jassper Shipping’s green logistics are being integrated by expanding its fleet of EV, with 58 already in operation. Emission-reduction strategies and carbon offset programmes are being implemented in sea logistics to reduce environmental impact. With a strategically mapped network of 380 locations across India, including both major states and smaller towns, sustainable and accessible logistics solutions are being ensured supported by partnerships with FMCG brands and pharmaceutical companies as well as supermarket chains like D-Mart and Big Basket.
A transportation management system is also used to track and measure carbon dioxide emissions on a cargo basis. Jassper Shipping’s efforts remain focused on creating a future-ready, sustainable logistics network.

What sustainable practices are you implementing to reduce carbon emissions?
Jassper Shipping prioritises sustainability, with several measures in place to reduce carbon emissions. The inclusion of electric vehicles (EVs) into the distribution network represents a significant advancement, with 58 EVs currently operational. This change not only decreases the company’s carbon footprint, but it also improves operating efficiency, eliminates fuel cost uncertainty, and helps delivery partners by lowering costs. Collaboration with clients enhances sustainability efforts by producing eco-friendly supply chain solutions with low environmental effect. A transportation management system helps track and measure carbon dioxide emissions at the shipment level, ensuring a data-driven approach to sustainability. Participation in carbon offset programmes further contributes to reducing the environmental impact of shipments.

Are you investing in energy-efficient vessels or alternative fuels?
No, currently we are not investing in energy-efficient vessels or alternative fuels. Instead, our focus at Jassper Shipping is on developing EV fleets and strengthening a sustainable supply chain network in India to support green commerce solutions.

How does technology help Jassper optimise eco-friendly logistics solutions?
Technology is critical to our eco-friendly logistics. Our transportation management system (TMS) monitors and assesses carbon emissions,
allowing for more environmentally responsible operations. The growth of our electric vehicle (EV) fleet decreases environmental impact while assuring efficient transportation.

What challenges do you face in making shipping more environmentally sustainable?
The main challenge in making shipping more environmentally sustainable is the lack of global agreement and consistent efforts. Different countries and organisations have varying levels of commitment and policies, making it difficult to implement uniform sustainable solutions. Without widespread cooperation, progress toward greener shipping practices remains slow.

What are Jassper Shipping’s long-term goals for achieving greener logistics in Asia?
Jassper Shipping is dedicated to reducing carbon footprints, including those of clients. Emission-reduction plans and carbon offset investments aim to achieve net-zero carbon emissions by 2035. Over the next two quarters, the number of EVs in the fleet will increase from 58 to 150. The last-mile delivery supply chain is becoming more sustainable and efficient with EV integration while maintaining high-quality service.