Economy & Market

Cement Machinery – Eyeing on the green potential

Published

3 years ago

October 14, 2021

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Increasing focus on savings in energy consumption, stringent emission and pollution control norms, thinning bottom lines on one hand, and thanks to the Perform-Achieve-Trade Scheme, launched by Bureau of Energy Eficeny (BEE), most of the cement majors been inspired to innovate for ways and means, not only to reduce the energy consumption and the carbon footprint, but also to better cost efficiency. This has resulted in plant optimisation where energy and fuel efficient equipment and components play a pivotal role. INDIAN CEMENT REVIEW trains its thoughts on the latest developments.

EVEN THOUGH THE economic slowdown has adversely impacted the off take of cement, and to an extent, has dented the confidence of the equipment vendors, the long term growth potential is really tremendous. The per capita consumption of cement in India tells no other tale. Indian per capita consumption of cement is much less compared to the world average. As per reports, compared to the world average of over 350 kg, the Indian per capita consumption of cement was around 150 kg in 2011. The corresponding figure is 660 kg per capita in China, 631 kg per capita in Japan and 447 kg per capita in France. This very fact has been one of the main reasons that brought in global players into the Indian shore.

The Indian cement industry is globally competitive with lowest energy consumption and CO2 emissions. As per inputs from Cement Manufacturers Association during 2009-10, the Indian cement industry grew at a robust rate of 12.7 per cent. With the government promoting construction activities across the country through various stimulus packages for building roads, bridges, houses, etc., the Indian cement industry added a capacity of 37 million tonne in 2009-10, which is the highest capacity ever added in any single year so far. The government’s focus on building infrastructure is likely to continue in the near future and the Indian cement industry is expected to sustain an even higher growth rate of 15 per cent over the coming years.

According to G Jayaraman, Associate Director, Price Waterhouse, Chennai, the Indian cement industry has been very proactive in adopting various technological advancements taking place all over the world. This was particularly triggered by the partial decontrol of cement industry in 1982 followed by full decontrol in 1989 giving the resultant free market competition an opportunity for growth in production and productivity. Jayaraman points out, "The share of energy inefficient wet process plants had slowly decreased from 94.4 per cent in 1960 to 61.6 per cent in 1980. Thereafter, as a result of quantum jump in production capacities through installation of modern dry process plants as well as conversion of some of the wet process plants, the share of wet process has reduced to less than 5 per cent today. During the last two decades (80’s and 90’s), major technological advancements took place in design of cement plant equipment/systems basically in the following major areas – a) pre-calcination b) high pressure grinding c) automation in process control d) high efficiency particle separation and e) clinker cooling.

Technology Roadmap

These innovation resulted in sea change developments globally and the Indian cement industry followed the international trend."

Recently, a low-carbon technology roadmap for the Indian cement industry has been launched in response to the sector’s need to cut its carbon footprint whilst meeting the growing demand for building materials in the country. It follows the launch of the global cement technology roadmap published in 2009. Enhancing energy efficiency and investing in newer technologies is one of the major objectives in the India-specific roadmap that aims to reduce the industry’s carbon emissions by 45 per cent by 2050. In an exclusive interview with Indian Cement Review, Philip Fonta, Managing Director, World Business Council for Sustainable Development says, "The Indian cement industry’s efforts to reduce its carbon footprint by adopting the best available technologies and environmental practices are reflected in the achievement of reducing total CO2 emissions to an industrial average of 0.719 tonne COf per tonne cement in 2010 from a substantially higher level of 1.12 tonne CO2 per tonne cement in 1996. The Indian roadmap outlines a low-carbon growth pathway for the Indian cement industry that could lead to carbon intensity reductions of 45 per cent by 2050. It proposes that these reductions could come from increased clinker substitution and alternative fuel use; further improvements to energy efficiency, and the development and widespread implementation of newer technologies."

Fonta further adds, "The vision laid out in the roadmap is ambitious but achievable. Wide stakeholder consultation took place throughout the process to bring in varied perspectives, and to reiterate that decisive action by all stakeholders is critical to realise the vision laid out in the roadmap. To achieve the proposed levels of efficiency improvements and emissions reduction, government and industry must join hands to take decisive and collaborative actions in creating an investment climate that will stimulate the scale-up of financing required."

"Energy efficiency index of Indian cement industries is better than the world average. This has been achieved by judicious selection of plant/equipments for greenfield projects/plant upgradation and adopting outstanding processes/practices. Installing latest equipments has resulted into incremental saving in terms of energy consumption, innovative efforts that lead towards quantum jump in terms of energy saving to be pursued," says Ratan K Shaw, Group Executive President & Chief Manufacturing Officer, UltraTech Cement Limited. He further adds, "Enhancement of blended cement share and fly ash/slag absorption will contribute not only towards energy reduction but will also help in reducing carbon footprint and thus paving the road to green solution."

According to him, the criteria for selection of equipment for new plants are as follows: input material properties viz. grindability, abrasiveness, moisture, presence of free silica, minor constituents, versatility in terms of grinding viz. OPC/PPC/Slag, output material properties-product fineness, PSD etc, investment and operating cost, scope for capacity enhancement and layout constraints in application of the technology. The operative norms desired are specific fuel and power consumption, environmental considerations, equipment reliability-easy to maintain equipment/proven performance.

The focus on energy efficiency for upcoming new plants as well as operating plants will contribute towards reduced energy demand and CO2 abatement, and he stresses on the selection of state-of-art energy efficient equipments /auxiliaries, latest automation systems/optimal systems/layout, integrated design with WHR power plants.

SN Subrahmanyan, Member of the Board and Sr. EVP, L&T Construction says, "The current focus is on savings in energy consumption and emission control methods, with stringent pollution control norms which are tightened day by day and the introduction of the PAT (Perform, Achieve and Trade) scheme. Cement manufacturers are expected to operate their plant in optimised conditions all the time. Power availability is also a key factor that affects cement plant operations. Clients are looking for equipment which reduces energy, fuel consumption, and effective utilisation of waste heat. Due to this trend, waste heat recovery systems and alternate fuel firing systems have become common requirements in cement plant tenders."

"Fuel efficient technologies have been adopted by majority of cement manufacturers," says Jayesh Somwanshi, Proprietor, Shreeyash Engineering. He adds, "A lot of affordable technology is now coming into the market. Also, there is a shift in focus of the manufacturers on the fuel efficient products which are really important for our industry."

Talking about the latest trends in technology, B Seenaiah, National President, Builder’s Association of India and Managing Director, BSCPL says, "The cement machinery manufacturers are obviously now focusing more on fuel efficient equipment. The manufacturers are now more keen on complying this latest emmission norm which helps save fuel and increases durability of the machinery." Explaining the same further, Martin Gierse, Managing Director, KHD Humboldt Wedag India Pvt Limited "We see that the trend is towards environmentally friendly and energy efficient products and services. As such, KHD has established themselves as one of the industry leaders in low NOx calcining technology, power efficient grinding technology and highly efficient pyro processing equipment requiring less heat and energy consumption, and thus avoids producing additional unnecessary CO2."

According to R Bhargava, Chief Climate & Sustainability Officer Shree Cement, periodic review of performance of various parameters of equipment with operating condition of plant at time of commissioning, year on year basis, checking of all parts of equipment at suppliers site, evaluation of energy efficiency for new equipment, determination of measuring points for evaluating the performance of plant are important factors while selecting plant and machinery with an approach towards energy reduction. Training on energy policy to vendors/contractors to design and construct energy efficient plant, efficient purchasing strategies, and incorporating specific energy consumption for every equipment in purchase order/contract etc, will also help moving towards the higher goal making an energy-efficient plant.

K Karunakara Rao, Dalmia Cement (Bharat) says, "The life cycle cost is a very important factor while selecting equipment. Deployment of higher capacity equipment bring added advantages of higher reliability, and easier supervision of operation apart from lowering overall cost per tonne, and will also reduce manpower. The higher capacity equipment also helps reduce the traffic on the haul roads, reduce the exposure of humans to the safety risk, and minimise the fugitive emissions. He also stressed the use of Vehicle Health Monitoring System (VHMS) that could help avoid unexpected machine downtime by a prognostic look at data changes over time, helps faster troubleshooting due to readily identified situations and causes. Another advantage is the in-advance arrangement for certified rebuilt parts for replacement, resulting in downtime reduction, which also helps achieve extended service life of the machine through proper operating method and maintenance work."

Highlighting the latest technologies in raw material grinding, Jayaraman says, "Selection of the type of grinding mill depends on the raw materials’ several physical characteristics, most important amongst them are hardness of the material and moisture content. Availability of the major grinding equipment in appropriate capacity decides complexity or otherwise of layout, auxiliary equipment sizing etc which ultimately decide the plant’s pyro-processing capacity. Vertical roller mills have been widely accepted for combined grinding and drying of moist raw materials in view of their excellent drying capacity and low energy consumption.

Although the principle of the vertical roller mill did not change over the years, many improvements have been made in design of the mill and other equipments in the grinding circuit resulting in less energy consumption and improved reliability. Introduction of external re-circulation of material, adjustable louvre ring and modification of mill body to improve the air and material trajectories are examples of such design changes." He further adds, "Apart from the main equipment viz. mill, classifier and fan, the efforts have been on improving the performance of internals e.g. table liners in case of vertical roller mills and classifying liners in case of ball mills. Use of mechanical conveying systems like bucket elevators are becoming more common in place of pneumatic conveying giving substantial savings in energy."

Market Trends

Gierse says, "The current situation is governed by the low utilisation of the cement production facilities on the one side and low speed in decision making and granting of permits on the other. This has made cement producers focus on reduction of operational cost and increasing efficiency. Some are working on optimisation of their product offerings to serve more specific needs of their respective clients. Only the very strategic players planned to expand their production base, following the good rule that makes you win market shares during low seasons. However, cement consumption grew in 2012 by 8 per cent, which is more than the GDP growth and proves the importance of this core sector."

However, KHD is not planning to launch any new equipment in the market but the focus remains on the further optimisation of, as well the systems for pyro and grinding sections with cost and performance. Talking about the requirements of the clients, Gierse said, "We do believe that our clients’ business cases can best be supported by offering services in achieving the maximum performance for their manufacturing plant."

Commenting on the situation, Gaurav Khanna, Managing Director, Ashoka Group says, "Currently the industry is going through a bad phase since the infrastructure projects are not happening and there is no business. However, we expect the industry to improve in the year 2014 due to elections otherwise to be honest; I do not expect much right now. The year 2013 will be similar to the previous year."

Somwanshi says, "Right now, our industry is not in a satisfactory phase. The projects have not been happening since a long time. Due to which, we are on the receiving end. Though, the announcement made by the government for the construction of 3,000 km road project has brought a huge relief, you actually do not know if they are implementing the same in six months time." Feeling the heat of slowness in the markets, Shreeyash Engineering, does not plan to launch any new equipment currently.

But Seenaiah was on a positive refrain. "I do agree that the cement equipment manufacturers are facing a tough time but by the end of the year, the cement companies will expand their capacity by 25 per cent, especially in the southern parts of India." He further adds, "The construction sector is divided into two parts, one is the building construction and the other is infrastructure projects. The building construction is picking up, but the infrastructure part is stagnant. The year 2013 will be marginal as the government is still taking a stock of the situation and change needs time." Manish Kumar, Head of Plant and Machinery, Supreme Infra, also supports the view. According to him, the industry is gradually coming back to the earlier pace. "I would say that the industry is going well, since there are projects that have been coming up which has reflected in the sale of equipment. We have recently purchased equipments, despite the government not doing enough for the industry."

The China Factor

Contributing nearly 15 per cent globally, Chinese equipment players have taken a significant share of Indian demand. But for some, the only advantage of the China brand is low price. Despite, the users combating several issues like bad quality and after sales services, the Chinese equipment continues to make inroads into the Indian markets.

"There are few plants in India which are running on equipment supplied by Chinese suppliers but the lifecycle of such plants are questionable. Some investors only see the initial cost of the project rather than the performance and efficiency of the plant. This trend is threatening the Indian suppliers who offer quality products at a moderate price. Dumping from China has affected not only the Indian market but industries globally. Most of the customers who purchased Chinese equipment for their plants are facing issues in operation as well as in maintenance areas like frequent breakdowns of core equipment, increased plant downtime and increased equipment replacement cost. This trend can only be arrested if our government takes concrete steps to curb dumping from China," says Subrahmanyan.

Seenaiah says, "The quality of machinery is cheap but it is fine for them, since their costs are low and ours are high. But the quality of our machinery is also much better as compared to theirs. For us quality matters and a lot of players have changed their preferences and have now shifted to Indian equipment."

Geirse begs to differ. He says, "I would not call this a threat. As western suppliers, the Chinese suppliers are today players in the global competition. The western suppliers have in the meantime opened up equivalent sourcing strategies to cater the clients’ need for the most favourable balance between technology and cost. India itself offers good opportunities for such sourcing, which lead to the fact that Chinese plant equipment manufacturers have yet to establish a significant presence in the Indian cement industry." Explaining the situation further, he said, "For India as an import destination, equipment manufactured in China loses its competitive edge when pitched against equipment manufactured domestically.

Duties, inadequate transport/handling infrastructure and freight costs are, possibly, the principal deterrents. In addition, the Engineering, Procurement and Construction (EPC) mode of project execution, at which the Chinese are particularly proficient, is yet to establish itself in the Indian context."

According to Somwanshi, the Chinese equipment cannot be labeled as Ã¦cheap quality ones’. Admitting the fact that a few players in the market have been known for its cheap price and substandard quality, he says, "Some companies are really good and their range of products are as competitive as ours. Now, that the Chinese manufacturers know that the customer opts for quality and not price, the companies have now been quality conscious and are adhering to the quality standards." But he quickly adds, "In fact, I suggest that our government should make policies that protect our economy from the Chinese."

Priority List

Voicing their concern over some of the major challenges Khanna, says, "Commencement of the projects which have been pending since long is the one thing that we would like to have. The other would be the reduction in import duty. Since long we have been demanding all this, but even during the budget the government didn’t announce any good policies. So we are stuck where we are and we are not able to move ahead."

According to Seenaiah, the projects worth Rs 40, 000 crore have been pending for a while which need to be cleared quickly.

He says, "The banking policies need to be in place since the companies are now cash-strapped to invest in any of these projects." Says Gierse, "On the policy level, government needs to push investment in infrastructure projects, and with regard to equipment and plant and machinery industry, the government should bring in similar kind of sops given during the 2009 budget, i.e reduction in excise duty for capital equipment. Further, if some changes could be done for abolition of entry tax, and implementation of GST, and bringing in uniform tax structure would lead to positive growth sentiments. According to Kumar, one of the biggest challenges for the industry today is the price rise. He also pointed out that the pending projects are worth crore of rupees resulting in cost escalation. He further adds, "The import duty has also been very high and even the budget hasn’t spelt out any reduction in the same." Valued at US$ 360 billion, India’s construction market accounted for five per cent of the US$ 7.2 trillion global construction market in 2010, and is expected to replace Japan as the third largest, after China and the US, by 2020.

As per India’s 12th Five-Year Plan (2012-17) document, the two segments most important to construction activity are infrastructure and housing. Since, infrastructure spending is expected to go up to nine per cent of gross domestic product (GDP) or US$ 1 trillion for the Plan period (2012-17), this will translate into double-digit growth for the demand of cement.

Concrete

SCMs encourage closed-loop systems

Published

11 minutes ago

November 22, 2024

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As the cement industry prioritises sustainability and performance, Supplementary Cementitious Materials (SCMs) are redefining standards, explains Tushar Khandhadia, General Manager – Production, Udaipur Cement Works.

What role do supplementary cementitious materials (SCMs) play in enhancing the performance and sustainability of cement and concrete?
SCMs play a crucial role in enhancing the performance and sustainability of cement and concrete. These materials are added to concrete to improve its properties such as strength, durability, and workability, as well as to reduce the environmental impact of cement production. The addition of SCMs to cement reduces the amount of Portland cement required to manufacture concrete, reducing the carbon footprint of the concrete. These materials are often industrial waste products or by-products that can be used as a replacement for cement, such as fly ash, slag and silica fume.
SCMs also reduce the amount of water required to produce concrete, which reduces the environmental impact of concrete production. This is achieved through their ability to improve the workability of concrete, allowing the same amount of work to be done with less water.
In addition, SCMs improve the durability of concrete by reducing the risk of cracking and improving resistance to chemical attack and other forms of degradation.

How has your company integrated SCMs into its production process, and what challenges have you encountered?
The integration of SCMs into cement and concrete production may pose certain challenges in the areas of sourcing, handling and production optimisation.

Sourcing: Finding an adequate and reliable supply of SCMs can be a challenge. Some SCMs, such as fly ash and slag, are readily available by-products of other industrial processes, while others such as silica fume or metakaolin may be more difficult to source.
Handling: The storage, handling, and transportation of SCMs require special considerations due to their physical and chemical properties. For instance, some SCMs are stored in moist conditions to prevent them from drying out and becoming airborne, which could pose a safety risk to workers.
Production optimisation: The addition of SCMs into the mix may require adjustments to the production process to achieve the desired properties of cement and concrete. For example, the use of SCMs may affect the setting time, workability, strength gain, and other properties of the final product, which may require reconfiguration of the production process.
Quality control: The addition of SCMs may introduce variability in the properties of cement and concrete, and rigorous quality control measures are necessary to ensure the final product meets the required specifications and standards.

Proper planning, handling and production optimisation are essential in overcoming the challenges encountered during the integration process.

Can you share insights on how SCMs such as fly ash, slag and silica fume impact the durability and strength of concrete in different environmental conditions?

Fly ash is a by-product of coal combustion and is widely used as an SCM in the production of concrete. When added to concrete, fly ash reacts with the calcium hydroxide present in the concrete to form additional cementitious materials, resulting in improved strength and durability. Fly ash increases the durability of concrete by improving its resistance to sulphate and acid attacks, reducing shrinkage and decreasing the permeability of concrete. Fly ash also enhances the workability and pumpability of concrete while reducing the heat of hydration, which reduces the risk of thermal cracking. In cold climates, fly ash helps to reduce the risk of freeze-thaw damage.
Slag is a by-product of steel production and is used as an SCM because of its high silica and alumina content. When added to concrete, slag reacts with the calcium hydroxide present in the concrete to form additional cementitious materials, resulting in improved strength and durability. Slag increases the durability of concrete by improving its resistance to sulphate and acid attacks, reducing shrinkage and improving the strength of concrete over time. Slag also enhances the workability of concrete, reduces the heat of hydration, and improves the resistance of concrete to chloride penetration.
Silica fume is a by-product of the production of silicon and ferrosilicon alloys and is used as an SCM because of its high silica content. When added to concrete, silica fumes react with the calcium hydroxide present in the concrete to form additional cementitious materials, resulting in improved strength and durability. Silica fume increases the durability of concrete by improving its resistance to sulphate and acid attacks, reducing permeability, and improving abrasion resistance. Silica fume also enhances the workability of concrete, reduces the heat of hydration, and improves the resistance of concrete to chloride penetration.

Overall, the use of SCMs such as fly ash, slag and silica fume can significantly improve the durability and strength of concrete in different environmental conditions. Their impact on concrete varies depending on the availability, physical and chemical properties of the specific SCM being used and proper testing and engineering analysis should be done for each mix design in order to optimise the final product.

With the global push for sustainability, how do SCMs contribute to reducing the carbon footprint of cement production?
SCMs provide an environmentally friendly alternative to traditional Portland cement by reducing the amount of clinker required to produce cement. Clinker is the main ingredient in Portland cement and is produced by heating limestone and other raw materials to high temperatures, which releases significant GHG emissions. Thus, by using SCMs, less clinker is required, thereby reducing GHG emissions, energy use and the environmental impact of cement production. Some SCMs such as fly ash and slag are by-products of other industrial processes, meaning that their use in cement production reduces waste and enhances resource efficiency. Moreover, the use of SCMs can enhance the properties of concrete, thereby increasing its durability and service life which helps to further reduce the overall embodied carbon of the structure.
In short, the use of SCMs contributes to reducing the carbon footprint of cement production by improving the efficiency of resource utilisation and reducing greenhouse gas (GHG) emissions during the production process. This has led to an increased demand for SCMs in the construction industry, as environmental concerns and sustainable development goals have become more prominent factors in the selection of building materials.

What strategies or innovations has your company adopted to ensure a consistent and reliable supply of SCMs, given their reliance on industrial by-products?

Developing partnerships with suppliers: Many cement and concrete manufacturers establish long-term partnerships with suppliers of SCMs. These partnerships provide a reliable supply of high-quality SCMs, improve supply chain efficiency, and often provide access to new sources of SCMs.
Advanced SCM processing techniques: Many companies are investing in advanced processing techniques to unlock new sources of high-quality SCMs. Advanced processing techniques include new separation processes, calcination techniques, and chemical activation methods.
Alternative SCM sources: Many companies are exploring alternative SCM sources to supplement or replace traditional SCMs. Examples include agricultural by-products such as rice hull ash or sugar cane bagasse ash, which can be used in place of fly ash.
Quality control measures: Strict quality control measures are necessary to ensure consistent quality of SCMs. Many companies use advanced testing methods, such as particle size analysis, chemical analysis, and performance testing, to validate the quality of SCM materials used in production.
Supply chain diversification: Diversifying suppliers and SCM sources is another way to ensure a reliable supply. This reduces the risk of supply chain disruptions caused by factors such as natural disasters, market changes, or geopolitical risks.

The strategies and innovations adopted to ensure a consistent and reliable supply of SCMs include establishing long-term partnerships with suppliers, investing in advanced processing techniques, exploring alternative SCM sources, implementing strict quality control measures, and diversifying supply chains. By implementing these approaches, we ensure that use of SCMs in cement production is an effective and viable solution for reducing the environmental impact of operations

How does the use of SCMs align with your company’s broader goals around circular economy and resource efficiency?
Here are some ways in which the use of SCMs supports these goals:

Reducing waste: The use of SCMs, such as fly ash and slag, diverts significant quantities of industrial waste from landfills, turning it into a valuable resource that can be used in construction. This helps to reduce waste and conserve natural resources.
Reducing carbon emissions: Cement production is a significant contributor to greenhouse gas emissions, and the use of SCMs can significantly reduce the amount of cement required in concrete mixtures. This helps to reduce the carbon footprint of construction activities and move towards a low-carbon economy.
Enhancing resource efficiency: The use of SCMs can reduce the demand for raw materials, energy, and water in the production of concrete. This not only conserves natural resources but also reduces the costs associated with the extraction, transportation and processing of these materials.
Closing the loop: SCMs encourage closed-loop systems in the construction sector, where waste materials from one process become input materials for another. This can improve the efficiency and sustainability of the construction industry.
Supporting sustainable design practices: The use of SCMs can support sustainable design practices by improving the durability and performance of structures while also reducing their environmental impact. This supports a circular approach to design, construction and operation of buildings and infrastructure
that improves their social, economic and environmental sustainability.

What future trends or developments do you foresee in the use of SCMs within the cement industry?
Future trends in the use of SCMs within the cement industry are likely to focus on: increased utilisation of diverse waste-derived SCMs, development of new SCM sources to address potential shortages, advanced characterisation techniques to optimise SCM blends and data-driven approaches to predict and optimise SCM usage for reduced carbon footprint and improved concrete performance; all driven by the growing need for sustainable cement production and stricter environmental regulations.
Key aspects of this trend include:

Expanding SCM sources: Exploring a wider range of industrial byproducts and waste materials like recycled concrete aggregate, activated clays and certain types of industrial minerals as potential SCMs to reduce reliance on traditional sources like fly ash, which may become increasingly limited.
Advanced material characterisation: Utilising sophisticated techniques to better understand the chemical and physical properties of SCMs, allowing for more precise blending and optimisation of their use in cement mixtures.
Data-driven decision making: Implementing machine learning and big data analysis to predict the performance of different SCM combinations, allowing for real-time adjustments in cement production based on available SCM sources and desired concrete properties.
Focus on local sourcing: Prioritising the use of locally available SCMs to reduce transportation costs and environmental impact.
Development of new SCM processing techniques: Research into methods to enhance the reactivity and performance of less readily usable SCMs through processes like activation or modification.
Life cycle analysis (LCA) integration: Using LCA to assess the full environmental impact of different SCMs and optimise their use to minimise carbon emissions throughout the cement production process.
Regulatory frameworks and standards:Increased adoption of building codes and industry standards that promote the use of SCMs and set targets for reduced carbon emissions in cement production.

– Kanika Mathur

Concrete

The use of AFR plays a critical role in our strategy

Published

23 minutes ago

November 22, 2024

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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

Concrete

We consistently track air emissions from fuel combustion

Published

33 minutes ago

November 22, 2024

admin

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