Connect with us

Concrete

Cementing social upliftment

Published

on

Shares

After dilly-dallying for a couple of years after the government?? mandate that proposed to spend two per cent of the profits of specified corporate entities came into effect on April 1, 2014, Corporate Social Responsibility (CSR) has taken firm roots by fiscal 2020. This has also come in handy for their involvement when COVID-19 pandemic hit the country in February 2020, pitching their mite to help the communities in the vicinity of their operations, to fight the virus based disease.

Out of four cement companies, who have provided us data on their CSR contributions, we have seen three of them witnessing their CSR commitments going up over the last three years. Mandated by the government, CSR is a transformational practice by the business corporations in India, for socio-economic upliftment of the poor and the deserving, leading to overall development.

It is not that Indian cement companies have woken up to the mandated CSR, suddenly. For example, Ambuja Cements Ltd, a part of the global conglomerate LafargeHolcim, had set up its own implementation agency, Ambuja Cement Foundation (ACF), in 1993. Even as Dalmia Bharat Foundation (DBF) was set up only 2009 to implement the CSR initiatives of Dalmia Bharat group of industries, the group had been undertaking CSR activities for eight decades now.

HeidelbergCement India, part of a cement multinational, has been engaged in community development projects for the last 30 years, while The Ramco Cements said its CSR initiatives had a long history, much before it was made mandatory.

However, the mandated CSR implementation was delayed by a couple of years due to expectations in the industry

that the mandate will be relaxed by the new government at the Centre that came to power in a few months of the mandate coming into force in 2014. But the expectations were belied.

The government?? CSR mandate has led to various companies taking up the social development projects around their business facilities, creating a ??in-win??for the business as well as various stakeholders.

??he companies are bringing business core competencies and learning to the solution of social issues and problems, and that is resulting in high level of social entrepreneurship and innovations,??says Vinita Singhania, Vice Chairman and Managing Director, JK Lakshmi Cement Limited (JKLC). The CSR mandate has also brought ??roject Management benchmarks??to social and community development projects, which were not there earlier, along with company?? financial commitment to them.

Though many companies were involved in CSR activities for several decades before the CSR law came into effect, there was no structured model of implementation and reporting standards set for these companies.

Budgets

CSR commitments of ACF, HeidelbergCement and Ramco have seen a consistent growth in the last three years. ACF, with a large focus on water, agro-based livelihood, skill and health, has seen its CSR budget going up from Rs 42.25 crore in FY18 (2017-18) to Rs 44 crore next year, which level it had maintained its budget of FY20. On the spending side, it went up from Rs 41.96 crore to Rs 44 crore in FY19 and down to Rs 41,45 crore in FY20, perhaps because of initial precautions and social distancing norms coming into force in the wake of COVID-19, during the last quarter.

Against the mandate of spending 2 per cent of profits for CSR activities, ??mbuja Cement has been dedicating 3-4 per cent of their profits for the last many years,??says Pearl Tiwari, Director and CEO, Ambuja Cement Foundation (ACF).

JK Lakshmi Cement has seen its CSR budgets going up from Rs 89 lakh to Rs 172.04 lakh in three years, while expenditure went up from Rs 130.78 lakh to Rs 181.48 lakh.

The budget of Ramco Cements also went up from Rs 12.56 lakh to Rs 15.60 lakh. Though its real commitment also went up from Rs 10.93 lakh to Rs 14.99 lakh, the FY20 figures lagged that of FY19, which was at Rs 17.97 lakh.

The CSR budget of The KCP Limited went up from Rs 95 lakh for FY18 to Rs 160 lakh in FY19, but in FY20 it has come down to Rs 92.12 lakh and its CSR expenses also mimicked budgeted pattern with Rs 54 lakh, Rs 108.90 lakh and Rs 63.68 lakh respectively.

DBF of Dalmai group, and HeidelbergCement have not provided their yearly data of budgets and expenditure under CSR activities. However, Jamshed N Cooper, Managing Director, HeidelbergCement India says that as per the mandate for CSR ??or FY 2020 translated close to Rs 69.7 million (Rs 6.97 crore) for our Group?? operations in India, against which we spent Rs 72.2 million (Rs 7.22 crore).

Meanwhile, DBF?? Annual Report shows that their total expenditure amounted to over Rs 40 crore in FY18 and FY 19 each,

but it was yet to upload its FY20 annual report on the website by the time ICR was going to the press.

However, the outcome of the CSR interventions may not confine to the budgets provided and spent by the companies as mostly they join hands with several agencies for yielding enhanced benefits for the communities they cater to. ??CF also harnesses the power of partnerships ??etween communities, government and other like-minded corporates and NGOs ??to help solve pressing community problems and to foster prosperity. We are also matching funds from external sources both government and other funds available helping us expand our outreach substantially,??says Tiwari.

Areas of activity

Among the focus areas of activity that could be undertaken under the act, education, healthcare, skills training, environment protection activities like water conservation, tree plantation etc., and rural development and infrastructure figured prominently among the companies, with at least five of the six respondents involved in each of these activities. (See table for more details)

Cement companies such as Ramco, JK Lakshmi, Ambuja, Heidelberg, Dalmia and KCP have responded to our queries on CSR activities. Four companies are involved in livelihood enhancement, while two companies each are involved in gender equality and women empowerment and disaster management and relief. I fact, gender equality and women empowerment can be part of a broader set of livelihood enhancement projects.

Other activities like support to social enterprise projects, hunger and poverty alleviation, community development, promotion of rural and national sports, restoration of buildings and benefit to armed forces also figures in the activities these companies have undertaken.

Education: Almost every company is promoting education in its own way. Ensuring quality of education even in government schools is the priority for Ambuja Cement and HeidelbergCement, while providing infrastructure in government schools is the focus of by JK Lakshmi Cement and Ramco Cement.

??e also run many non-formal education centres for out-of-school children,??says Tiwari of ACF. On the other hand, Cooper of HeidelbergCement India, says, ??e have been involved in improving the infrastructure of schools in rural areas and offering scholarships to meritorious students at Anganwadi centers.??/p>

Besides setting up its own schools at their integrated plant locations, ??amco has adopted government schools for holistic improvement by implementing 5S concept, which has won accolades in many CSR forums,??says AV Dharmakrishnan, CEO, The Ramco Cements. It has also set up a Vocational training centre for rural youth.

JK Lakshmi Cement?? Project Aarambh focuses on bring tribal children back to school in the Pindwara block of Sirohi district in Rajasthan. Since the beginning, numerous tribal children – ??rop-outs and Never-been-to-school??- have been enrolled in various government schools.

Skill development: JK Lakshmi Cement is leading the pack in terms of providing skill development in non-industrial trades like stitching, beautician, embroidery and two-wheeler repairing. ??nder thematic area of livelihoods and skills development, the Company implements various activities for the purpose of creating employability for unemployed youth, women and girls,??says Singhania. JKLC also has ??idya Scholarship??project for the purpose of supporting education of children of masons and petty contractors.

JKLC is also implementing additional income generating projects for women like stitching & embroidery, broom, paper plate/dona, phenyl making, pickle/ papad making, cotton bags, sanitary napkins, by imparting training to over 3,000 young women.

Under skill training programme, ??urrently DBF can train 5,000 youth every year at 11 centres of Dalmia Institute of Knowledge and Skill Harnessing (DIKSHA), spread across the country, and also runs three Industrial Training Institutes (ITIs),??says Vishal Bhardwaj, CEO, Dalmia Bharat Foundation (DBF).

The skill programme implemented through Skill and Entrepreneurship Development Institute (SEDI) centres, ACF is also offering basic computer skills, where knowledge of functional English and soft skills are compulsory components of all training programmes.

Many cement companies are also working in improving livelihoods in the farm and dairy sectors, by training farmers in improved farming techniques and livestock development, supporting farmers through scientific inputs, promotion of sustainable farming practices, as well as through capacity building programmes.

Healthcare: As part of promotion of health, cement manufacturer KCP had set up a sophisticated Hydraulic Operation theatre table, theatre lights, false ceiling and partition and a community health centre at Macherla in Guntur District of Andhra Pradesh. ??n an average 500 – 600 surgeries are conducted yearly in this operation theatre,??says V Madhusudana Rao, Vice President ??Operations (Cement Unit -II), The KCP Limited. KCP also supports Lepra Society for eradication and screening of leprosy, filaria, HIV, T.B., Malaria and awareness camps.

Around its three plants, KCP also conducts mega health camps, where tests like ECG, 2D ECHO, PFT, SUGA, B.P., are conducted for women by lady doctors etc., besides conducting eye surgeries, distribution of free medicines and spectacles to the needy, with the support of reputed and multi-speciality hospitals.

ACF is providing ??omprehensive Healthcare??intervention to address clinical, preventive and promotive aspects of health across communities. The program is led by a cadre of ACF-trained, village-based health workers called Sakhis, ensuring basic health care at the village level, and referring patients for timely medical intervention whenever needed.

Under its healthcare commitment HeidelbergCement organises mobile health check-up camps, multi-specialty health camps and provide support to government hospitals and health centres by way of enhancing their facilities for communities around its plants, while JKLC?? NayaSavera – a family integrated welfare program – focuses on reducing maternal and infant mortality.

Environment protection: Most of the cement companies are involved in water harvesting and conservation. Ambuja?? Water Programme works to enhance water and land resources. The programme promotes rainwater harvesting through indigenous and new technologies, promotes micro irrigation methods and constructs check dams, percolation wells and rooftop rain water harvesting structures.

During the last five years, DBF has created harvesting potential of more than 17 million cubic metres of water annually. ??e also help tribal households enhance their income through horticulture plantations. Furthermore, we promote access to solar energy for domestic and agricultural purposes as well as that to cleaner fuels like biogas and LPG for cooking,??says Bhardwaj.

Rural development & infrastructure: The main focus of many cement companies is building rural roads and making movement easer in remote rural areas. Besides undertaking road repairs, The KCP Ltd has constructed additional class rooms and new buildings for schools, compound walls for schools, flooring in the school premises, veterinary hospital building, ladies dress-changing rooms near Krishna river bank, rural community halls and rest places near its facilities.

DBF is working mainly in remote rural areas, where it also assists the local administrations and communities to fill the existing infrastructural gaps, improving the quality of life of such communities. Ramco has also helped families of 8 CRPF Jawans martyred in Phulwama attack in Jammu and Kashmir with fixed deposit of Rs 5 lakh each. More than 42 Jawans were killed in the gruesome attack.

Challenges

The CSR veterans are in unison in identifying educated unemployment as the biggest concern stalking the country that too when India is growing younger, stating that it should be tackled with and re-skilling and upskilling of youth through CSR activities, particularly in rural areas. ??s the growing pace of technology will generate a new era of employment opportunities as a nation, we would still have to address the aspirations of those who would not be fortunate enough to make it there and would require earning a living. Rural India will be a home for them and the farm sector their source of livelihood,??says Cooper.

Highlighting the need to bridge disparities, Rao says, ??ocio-economic disparity is one of the biggest challenges, main reason being the rural-urban divide among a host of factors, which increase the intensity of this disparity.??/p>

ACF?? Pearl Tiwari?? heart goes out for the lower income group, who don?? even have decent or dignified living conditions, sometimes scraping through life with no basic facilities like healthcare and infrastructure, and such issues needs to be addressed and fulfilled on an urgent basis.

To address challenges on rural front on a priority basis, Cooper suggests, ??ater harvesting, drip irrigation and advanced farming techniques should be made available to the farmers at subsidized and affordable prices. To supplement farmers??income, livestock management needs to be promoted.??Besides women empowerment, CSR activities directed at this front will add towards reinforcing the economy at the ground level, he added.

Bhardwaj says CSR initiatives should address supply chain issues in agriculture by facilitating backward and forward linkages. Helping build e-platforms and institutions like farmers-producers??companies is what these companies should do.

Stating that the Indian healthcare scenario presents a spectrum of contrasting landscapes – At one end of the spectrum are the glitzy steel and glass structures delivering high tech Medicare and on the other end with fragile infrastructure and lack of basic health care facilities in rural areas ??Dharmakrishnan suggests that CSR activities should support primary health centres with medical infrastructure, organise special medical camps in association with speciality hospitals, and support traditional streams of medicine like Siddha and Ayurveda.

Looking ahead

When World Bank and International Monetary Fund (IMF) are forecasting a fall in gross domestic product (GDP or economic activity) of our country due to COVID-19, our CSR veterans are taking a hunch that it will have an impact on the business revenue and profitability of CSR mandated companies for at least a couple of years.

??here are estimates that there would be about 30-35 reduction in the CSR spent this year because of the expenditure that has been incurred on COVID-related activities,??says Bhardwaj of DBF.

However, JK Lakshmi Cement, ACF, DBF and KCP were in the affirmative to the query on whether they will continue to affirm their commitment to CSR activities in these difficult times.

The board of Dalmia Cement Bharat has already resolved to keep their CSR commitments unaffected by COVID. ??ike I mentioned, our contribution for COVID has been more than the 2 per cent mandate,??Bhardwaj of DBF pointed out.

??part from the growing concern for COVID-19, India still needs to focus on water, health and vaccination… We as CSR spenders need to now integrate COVID-19 with our current programmes to maintain balance,??suggests Tiwari of ACF.

KCP reminded us of the saying, ??f there is a will there is a way?? while affirming their commitment to CSR. ??f course, every company will adapt to the situation relevant to the ecosystem it is operating in. COVID-19 has given an opportunity to expedite some of the changes vis-a-vis integration of technology, finding most cost-effective methods of implementation, working closely with stakeholders as resources are getting scarce,??says Rao. There are a few lessons that the pandemic has taught us. For instance, due to imperative of maintaining social distancing, the CSR agencies have already changed the content and methods of dissemination of various development and behavioral-change communications.

HeidelbergCement?? Cooper exudes confidence that the humanity would rise on the other side and the privileged would

come forward to contribute and serve those who served them once, thereby reinstating the balance.

This also holds good for corporate entities. As such, the post-COVID-19 scenario is set to create ??ew Champions of Humanity??and earn the goodwill and loyalty of their stakeholders and society at large, at a time when India faces enormous development challenges. The solution lies in the government, civil society and corporations working together to fulfil the basic requirements of the poor and underprivileged.

– BS SRINIVASALU REDDY

The CSR mandate

  • Governing law: Section 135 (1) of Companies Act, 2013

  • Mandate criteria:

a. Every company having net worth of Rs 500 crore or more, or

b. Turnover of Rs 1000 crore or more or

c. Net profit of Rs 5 crore or more, during the immediately preceding financial year

  • Minimum commitment to CSR: 2 per cent of profits.

  • Date of commencement: April 1, 2014

  • Overseeing body: CSR Committee of the Board

  • Mode of execution: ??roject/ Programme??model

  • Designated activities: Broad spectrum of activities specified

Benefits of Mandate:

i. Companies bringing business core competencies and learning to resolve social issues and problems

ii. Leading to high level of social entrepreneurship and innovations

iii. Brought ??roject Management benchmarks??to social and community development project-5

Continue Reading
Click to comment

Leave a Reply

Your email address will not be published. Required fields are marked *

Concrete

The use of AFR plays a critical role in our strategy

Published

on

By

Shares

Rajesh Kumar Nayma, Assistant General Manager – Environment, Wonder Cement, shares the company’s ambitious commitment to reducing emissions through advanced technology and alternative fuel use, thereby driving significant change in the cement industry.

How does your company address the environmental impact of cement production, particularly in terms of reducing emissions?
Wonder Cement Limited (WCL) has played a vital role in Indian infrastructure development and focuses towards a more sustainable future, including environment protection, clean energy and water positivity. The organisation is a firm believer in putting a positive impact on the environment. Environment and sustainability is a core value that drives our operations. We are committed to minimising the environmental impact from cement production, particularly when it comes to emissions. We do the impact analysis due to operation of the units being carried out at design stage level to ensure minimum impact on the environment i.e. air, water and land. Equipment selection is done accordingly taking various measures to ensure no fugitive emission, stack emission, water pollution and soil degradation such as installation of best-in-class air pollution control equipment (ESP’s Reverse Air Baghouse); bag filters at all the material transfer points; provided covered storage facilities/storage silos to maintain ambient air quality; fugitive emission and stack emission well within the prescribed emission Norms, Selective Non Catalytic Reactor (SNCR) for control of NOx Emission; and preventive routine maintenance of air pollution control equipment are carried out. By taking these measures, WCL ensures emissions are well below the stipulated norms for particulate matter, SO2 and NOx.

We are focusing on reducing the GreenHouse Gases (GHG) emissions, too. Due to our operations, we have done GHG Invertisation, which aims to achieve Net Zero by 2060, in line with the nation’s commitment in COP-26.
We have Zero Liquid Discharges facilities across all our units. Being dry process cement manufacturing units, the wastewater generation in our units is very low in quantum and the implemented closed-loop systems help to reuse process water and minimise fresh water consumption. WCL is reusing 100 per cent STP/ETP water in its process, greenbelt development and dust suppression at its integrated cement plant and split grinding units.

What measures have been implemented to monitor and control emissions of CO2, NOx, and particulate matter during the cement manufacturing process?
We have installed an Online Continuous Stack Monitoring System (OCEMS) in all the process stacks along with PTZ cameras and Continuous Ambient Air Quality Monitoring Systems (CAAQMS) in all our operating units. Real time data of OCEMS/CAAQMS is transmitted to SPCB/CPCB servers, and also to our control systems, which enables us to take corrective action on priority.
The major pollutants through air are particulate matter and gaseous emissions. The emissions of particulate matters from all the stacks are maintained within the prescribed norms by installing bag house, bag filters and electorstatic precipitator (ESP) at all major sources of air pollution i.e. raw mill, kiln, clinker cooler and coal mill cement mills and captive power plant (CPP).
We have also installed SNCR technology along with a low NOx burner to reduce NOx emissions effectively to keep the same in the prescribed norms and lime dosing systems have been installed in the power plants to ensure SO2 emission within the prescribed norms.
We use alternative fuels and raw materials (AFR) in order to increase our green energy portfolio, to reduce the clinker factor and to reduce the power/energy consumption per tonne of clinker/cement. The installation of WHRB in all the operating kilns has further helped in cutting down the CO2 emissions.

Can you elaborate on the role of alternative fuels and raw materials in reducing the environmental footprint of cement production?
The use of AFR plays a critical role in our strategy to reduce the environmental footprint of cement production. By substituting traditional fossil fuels with waste-derived alternatives like biomass, refuse-derived fuel (RDF) and industrial by-products, we significantly lower CO2 emissions and reduce the demand for natural resources.
The utilisation of supplementary cementitious materials (SCMs), such as fly ash, helps in reducing clinker consumption, which is a major source of carbon emissions in cement production. This not only decreases our reliance on energy-intensive processes but also promotes waste recycling and resource efficiency. AFR adoption is an integral part of our commitment to the circular economy, ensuring that we minimise waste and optimise the use of materials throughout the production cycle, ultimately contributing to a more sustainable and eco-friendly cement industry.
WCL is exploring transitioning from fossil fuels to cleaner alternatives like biofuels or hydrogen or RDF/plastic waste/other hazardous waste. Till date, 5 per cent TSR has been achieved, while the intent is to achieve more than 20 per cent TSR. WCL is utilising the hazardous and other waste as an alternative fuel or raw material. We have used more than 3 lakh metric tonne of hydrogen waste and other waste in FY-2023-24.

How does your company approach waste management and recycling to minimise environmental harm?

WCL is focusing on the 3 R’s – Reduce, Reuse and Recycle. We focus on optimum utilisation of natural resources and reuse of said resource as well as recycling of the waste material generated from our operations.
We are contributing to reduce the legacy waste generated in our municipalities and we have co-processed more than 50000 tonnes of RDF/plastic waste. Additionally, we are sending other waste generated at our facilities such as used oil / used lead acid batteries / e-waste to authorised recyclers. We are focused on targeted reduction in waste generation.
We are also utilising alternative raw materials. which are the waste from other industries such as red mud, chemical gypsum, iron sludge and ETP sludge to substitute natural resources.
WCL is also increasing the use of recycled content of plastic in PP bags.
We have met our EPR target for plastic waste introduced in the market for FY 23-24 through co-processing of plastic waste in its kiln. Additional EPR credit will be traded for this in the market.

What are the biggest challenges your company faces in achieving compliance with environmental regulations, both locally and globally?
WCL is committed toward 100 per cent compliances to applicable rules and regulations and having dedicated resources to do so, when we talk about the challenges WCL faces in complying with environmental regulations is the constantly evolving nature of both local and global environmental rules and regulation which further leads to strength. While we are committed to adhering to stringent regulations, keeping up with the rapid changes in environmental laws requires continuous upgradation in technology and processes. Another challenge is the high capital investment needed for adopting cleaner technologies, such as De_Sox System / SNCR / Up-gradation of ESP /bag house and carbon capture systems.
Additionally, the availability of AFR can be inconsistent, making it difficult to achieve consistent reductions in GHG emissions. Despite these challenges, WCL remains committed to sustainability and continuously collaborates with regulatory bodies and industry experts to stay ahead of compliance requirements. We also invest in research and development to innovate our production processes, ensuring that we not only meet but exceed environmental compliances.

What technological innovations or process optimisations has your company adopted to lower greenhouse gas emissions?
WCL has adopted several technological innovations and process optimisations to lower greenhouse gas emissions. One of the key initiatives is the installation of 45 MW waste heat recovery systems, which capture excess heat from the production process and convert it into energy, reducing the overall carbon footprint. We have also introduced advanced burner technology with lower NOx emissions and optimised energy consumption and presently we are less than 47 KWh/tonne of clinker, which is one of the best in the cement industry.
The deployment of energy-efficient vertical roller mills (VRM) for clinker grinding also contributes to reducing energy consumption and emissions. These innovations are part of our broader commitment to sustainability and are continuously enhanced to meet global environmental standards.
WCL is focusing on investing in renewable energy sources like solar or wind power to meet the electricity needs. We have installed a solar power plant at our Nimbahera plant and Jhajjar grinding unit as well as 15 MW windmills at Pratapgarh, for our grinding units located at Aligarh, Uttar Pradesh and Dhule Maharashtra. We have renewable power purchase agreements to source renewable energy, which will replace approximately 50 to 60 per cent of energy demand from the grid, further leading to reducing the GHG emissions.
WCL is taking various operational/capex measures to reduce the energy requirement like installation of VFD, optimisation of differential pressures across bag filters and optimisation of kiln operation to get maximum output.

How does your company engage with stakeholders, including local communities and environmental agencies, to ensure transparency and sustainability in your operations?
WCL has a well-defined approach for identification of stakeholders, which is done after considering the material influence each group has on the company’s ability to create value (and vice-versa). The objective of stakeholder engagement is to foster connections, build trust and confidence and buy-in for your company’s key initiatives. This can also help us mitigate potential risks and conflicts with stakeholders.
Stakeholder engagement is done is to understand the needs and expectation of anyone who has a stake in our company, based on which we can develop our strategy and identify our focus areas such as:

  • What long-term goals has the company set in terms of reducing emissions
  • What steps are being taken to achieve them
  • What are the key focus areas to take society along with us

WCL places great emphasis on engaging with stakeholders, including local communities, environmental agencies and industry experts, to ensure transparency and sustainability. We conduct regular environmental audits and share our findings with relevant regulatory bodies to ensure compliance. Our CSR initiatives are closely aligned with community needs, particularly in areas like water conservation, afforestation and waste management, health, education and women empowerment, which directly impact the local environment.
We maintain an open dialogue with local residents to address their concerns about air quality, emissions and resource use and carry out need based assessment and accordingly design our CER/CSR programme and further implement the same.
Additionally, WCL participates in various industry forums and collaborates with environmental agencies to stay ahead of regulatory changes and adopt best practices. Transparency is key to building trust, and we ensure that all stakeholders are kept informed about our sustainability initiatives through periodic reports and community outreach programs. This collaborative approach ensures that we maintain a positive environmental and social impact.

What long-term goals has your company set in terms of reducing emissions, and what steps are being taken to achieve them?
WCL has set ambitious long-term goals to significantly reduce emissions in line with global climate targets. One of our primary objectives is to achieve net-zero carbon emissions by 2060, with interim goals to reduce CO2 intensity by 25 per cent by 2040 through increasing Green Energy Portfolio from present 41 per cent to 70 per cent, AFR and green hydrogen 3 per cent to 40 per cent, reduction in clinker factor from 79 to 60 per cent and CCUS and electrification of the kiln, introduction of LC3 and PLC cements based on techno-economic feasibility.
To achieve these targets, we are investing to develop facilities to feed more AFR, which helps to reduce dependence on fossil fuels and natural resources and lower carbon emissions. We are also exploring carbon capture and storage (CCS) technologies to capture CO2 emissions at their source. WE are committed to achieving its long-term sustainability goals and contributing to the global effort to combat climate change.

– Kanika Mathur

Continue Reading

Concrete

We consistently track air emissions from fuel combustion

Published

on

By

Shares

Raju Ramchandran, SVP Manufacturing (Cluster Head – Central), Nuvoco Vistas, sheds light on the company’s robust commitment to sustainable cement production, achieving low emissions through innovative energy solutions, alternative fuels and circular economy practices.

How does your company address the environmental impact of cement production, particularly in terms of reducing emissions?
As a cement manufacturing company, managing energy consumption and emissions is crucial to achieving sustainable operations. At Nuvoco, we have taken significant measures to address this material issue and use it as a competitive advantage for the company. We are consistently enhancing the integration of green power and alternative fuels within our operations. This ongoing commitment is pivotal to our strategy for reducing Greenhouse Gas (GHG) emissions, highlighting our dedication to sustainable practices.
Nuvoco maintains one of the lowest carbon footprints in the industry, with carbon emissions standing at just 457 kg of CO2 per tonne of cementitious materials. Our solar energy capacity has also grown significantly, increasing from 1.5 MW to 5.3 MW for FY 23-24.

What measures have been implemented to monitor and control emissions of CO2, NOx and particulate matter during the cement manufacturing process?
We consistently track air emissions from fuel combustion in our cement manufacturing and power generation operations. The burning of fossil fuels releases pollutants such as Oxides of Sulphur (SOx), Oxides of Nitrogen (NOx), and Particulate Matter (PM), which require stringent monitoring.
We ensure compliance with regulatory standards by using the Continuous Emission Monitoring System (CEMS) to monitor these emissions. For the FY 23-24, both our stack and fugitive emissions have stayed within the permissible limits set by Pollution Control Boards. Moreover, our ongoing monitoring of fugitive emissions ensures that we meet the prerequisite air quality standards.

Can you elaborate on the role of alternative fuels and raw materials in reducing the environmental footprint of cement production?
The use of alternative fuels and raw materials plays a critical role in reducing the environmental footprint of cement production. At Nuvoco, we are actively embracing this approach to promote sustainability and lower our dependence on traditional fossil fuels and virgin raw materials.
Our manufacturing processes enable the use of waste materials from industries like steel and thermal power generation as alternative fuels. Our mix of alternative fuels includes solid waste, liquid solvent, biomass, refuse derived fuels (RDF) from municipal solid waste, and other substances, with a focus on biomass. By incorporating alternative fuels we not only reduce carbon emissions but also contribute to waste management by diverting materials from landfills. Additionally, in line with our sustainability objectives, we plan to considerably expand our use of alternative fuels in the coming years.
During FY 23-24, the utilisation of Alternative Raw Materials (ARM) in our processes increased to 33.9 per cent in cement production, up from 27.7 per cent in the previous year. Incorporating materials such as chemical gypsum, fly ash and slag into our cement formulations significantly reduced our reliance on virgin raw materials and further promoted circularity in our operations.

How does your company approach waste management and recycling to minimise environmental harm?
The principles of a circular economy are integral to our sustainability initiatives. We engage in a variety of efforts to minimise waste generation, promote resource efficiency, and reduce our environmental footprint. We collaborate with other industries to incorporate their waste into our operations, using it as alternative raw materials. By introducing substitute materials into our cement production, such as blended cement with reduced clinker content, we are able to lower waste disposal volumes and significantly reduce carbon emissions.
In our Ready-Mix Concrete (RMX) plants, we actively integrate recycled aggregates from Construction and Demolition (C&D) waste into our manufacturing process. This practice not only boosts the sustainability of our concrete products but also prevents valuable materials from ending up in landfills, contributing to better resource efficiency.
A notable innovation is the ‘Nu Aqua Zero Debris Recycler System,’ which addresses the challenges of solid concrete waste and slurry disposal at RMX plants. This system significantly reduces debris generation and recycles wastewater for reuse, cutting down on freshwater consumption and solid waste. This initiative underscores Nuvoco’s dedication to promoting sustainability and fostering a circular economy in the building material industry.

What long-term goals has your company set in terms of reducing emissions, and what steps are being taken to achieve them?
Nuvoco has set a long-term vision for reducing emissions, anchored in its ‘Protect Our Planet’ agenda. This agenda aligns with the growing focus on Environmental, Social and Governance (ESG) principles, which have become increasingly important to stakeholders, including customers, employees, partners, investors, regulators and local communities. Sustainability is a core component of our business strategy, driving its commitment to responsible and environmentally conscious operations.
The company’s approach is structured around five key themes: Decarbonisation, Water Management, Circular Economy, Biodiversity and Waste Reduction. As part of its decarbonisation strategy, Nuvoco is committed to reducing carbon emissions by 2 per cent annually. This effort includes a focus on maximising the use of alternative fuels, harnessing waste heat for green energy generation, and incorporating innovative green products such as the ECODURE range.

What technological innovations or process optimisations has your company adopted to lower greenhouse gas emissions?
The company has dedicatedly installed a system that is capable of utilising agricultural waste, refuse derived fuel (RDF), plastic waste, municipal waste, biomass, tyre chips and other hazardous waste sources. We have introduced AFR feeding into the pyro process system for enabling uniform feeding and incorporating all necessary safety interlocks throughout. This system allows us to consume alternate fuels in an efficient and effective way without impacting the environmental standards prescribed and approved by the Pollution Control Board of India. Although this project is primarily focused on environmental sustainability, it also has several other benefits for clinker production and can offer significant cost savings through its alternative fuels program.
The company has also made significant modifications across its plants to improve energy efficiency, specifically targeting SHC (Specific Heat Consumption) and SPC (Specific Power Consumption) during clinker and cement production. Our waste heat recovery systems currently have a combined capacity of 44.7 MW, with plans for further optimisation to increase power generation.

– Kanika Mathur

Continue Reading

Concrete

We are committed to a sustainable low-carbon future

Published

on

By

Shares

Sudhir Pathak, Head – Central Design and Engg (CDE), QA, Green Hydrogen, Hero Future Energies, talks about empowering India’s hard-to-abate industries with innovative renewable energy technology.

How is Hero Future Energies contributing to reducing emissions in hard-to-abate sectors like cement manufacturing, and what role does renewable energy play in this effort?
Today, Hero Future Energies (HFE) is no longer simply a renewable energy (RE) provider but has transformed into an end-to-end Net Zero partner especially for construction and infrastructure clients in the hard-to-abate sectors. In addition to providing Scope 2 based solutions, such as behind the meter RE (rooftop and ground mount solar) and open access-based RE including developing RE-100 roadmaps we also support Scope 1 and 3 emission decarbonisation by providing complete turnkey solutions through the use of green hydrogen and its derivatives. For hard-to-abate sectors like cement, HFE is in advanced discussions with few leading players, regarding enabling decarbonisation of their heating applications such as pre-calciners, rotary kilns etc through green fuels. This supplements our Scope 2 solutions for the cement industry.

With HFE’s focus on clean technologies like green hydrogen and energy storage, how do you envision these innovations helping the cement industry reduce its carbon footprint?
The cement industry is one of the largest consumers of grid power (Scope 2) and also a guzzler of in-process fossil CO2 (Scope 1) including process-based CO2 through limekilns. In the case of Scope 2, decarbonisation can be achieved only up to 50 per cent to 60 per cent through plain hybrid solar and wind. However, for achieving balance 40 per cent, storage is essential, be it chemical or mechanical. Today, HFE is ready to provide such bespoke storage solutions as is evident through several complex RTC tenders that we have won in the last 6-8 months floated by agencies like SECI, NTPC and SJVN. These include tenders for FDRE projects, peak power, load following, etc. Further, regarding green hydrogen and its derivatives, we are ready to apply these for decarbonising industrial heating and mobility (Scope 1 and 3).

What are some of the biggest challenges you face when working with the cement sector to integrate renewable energy solutions and reduce emissions?
Deployment of renewable energy for mitigating Scope 2 emissions is relatively easy, except for RE behind the meter, looking at the high dust levels involved in cement production particularly in the crushers. Regarding Scope 1 decarbonisation, there are several challenges. Unlike in Europe, the majority of the Indian cement industry uses coal combustion in heating applications. This being a solid fuel, is suitable for horizontal rotary kilns and needs positive pressures for combustion processes, whereas, green hydrogen, being the lightest of molecules, are good and amenable, when working in vertical combustion shafts. Therefore, existing facilities may be used only partially, and for complete conversion, new installations will be needed. This will entail a significant amount of space inside the plants, which is currently scarce.

HFE has been involved in pioneering projects like hybrid power and energy storage. How do these technologies improve energy efficiency and lower emissions in industries like cement manufacturing?
Cement industry by its nature has a 24×7 duty cycle demand for electricity. Therefore, solar power by itself can’t be a perfect solution, the sector needs round-the-clock RE. While hybrid RE (a right mix of solar and wind), can help to an extent (better than only solar), we will still have to depend on storage to provide predictable supply of electricity, or what is termed as ‘Firm Dispatchable’ RE. In such cases, storage can be provided either through batteries like Li Ion, Sodium Ion, Metal Air or Pumped Hydro and Long Duration Energy Storage (LDES) mechanisms.

How does HFE address the intermittency issues of renewable energy, ensuring a stable and reliable energy supply to cement plants while minimising emissions?
As explained above, this can be resolved through appending storage solutions. However this needs meticulous assessment of RE power every year, every month, every day, every hour and every time block (15 minutes). Further, one needs to carry out an arduous due diligence process for forecasting solar and wind patterns for 25 years. We, at HFE, have the expertise to do this to a great extent, thereby derisking ourselves and offtakers from such vagaries. Our success in winning eight complex FDRE tenders in the recent past testify to this.

Given that cement is one of the largest contributors to industrial emissions, what potential do you see for technologies like green hydrogen to decarbonise cement production in the coming decade?
We believe that emergence of green hydrogen presents a huge opportunity to decarbonise hard to abate sectors such as cement. Not only green hydrogen, but its derivatives like ammonia and methanol also hold huge potential to mitigate industrial carbon footprint. The cement industry sees huge volumes of CO2 being emitted as a result of limestone processing, which is a crucial process. These can be reused and converted to low carbon methanol. With the government promoting M15, M85, MD15 and M100, the same can be used for quick decarbonisation.

What are HFE’s long-term goals regarding environmental sustainability and emission reduction, and how does the company plan to scale these efforts to help heavy industries achieve their sustainability targets?
At HFE, we are committed to a sustainable and low-carbon future through provision of smart, affordable, clean energy and tech solutions. On the utility front, we are focused on complex, high CUF projects that aim to help overcome the intermittency barrier and pave the way for firm, dispatchable, round the clock green power. For our C&I clients, we offer a complete suite of solutions as their Net Zero partner, evolving from being just an RE provider.

If India is to achieve its Net Zero goal, then industrial decarbonisation must take centrestage and this is the space where we believe HFE can be a major player. We see ourselves as an end to end integrated Net Zero partner for businesses, particularly those in hard to abate sectors like cement, steel, chemicals and mobility, charting out a Net Zero roadmap for them and then guiding them to reach the target in a phased manner.

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds