Connect with us

Environment

Energy conservation depends more on the compressed air system

Published

on

Shares

Kuntan Panchal, Joint Managing Director of Indo Air Compressors.

Indo Air Compressors manufactures reciprocating air and water cooled compressors. It has a very modern factory, spanning across an area of 6300 sq m. The company has been continually adopting best engineering practices to lift the product quality to new heights. Young and dynamic Kuntan Panchal, Joint Managing Director of Indo Air Compressors, has pushed the turnover growth of Indo Air by 25 per cent in just three years of his association with the firm. He has also been instrumental in orienting the company to develop advanced compressors to meet the market demands. The company has harnessed its state- of- the- art R&D facility to develop highly energy efficient systems. Here he talks about what to look for in compressors and how to get the best out of them. Excerpts from the interview.

Tell us about the range of compressors offered by your company.

We manufacture both piston type reciprocating compressors and rotary screw compressors. The piston type reciprocating compressors includes single-stage for low pressure application, two-stage models for medium pressure application and the high pressure models of multi stage models. The connected load of the compressors range from 1 HP to 30 HP. The state-of-the-art rotary screw compressor manufactured by us emits very little noise, making it ideally suitable for installation within the factory area. Our screw compressors range from 7.5 HP to 100 HP now and plans are afoot to manufacture up to 300 HP systems.

Reciprocating type compressors in the oil-free version from 0.5 HP to 15 HP are also available for the industry where completely oil-free air is required. This has special application in hospitals.

Other products from Indo Air include vacuum pumps from 2 HP to 10 HP and heavy-duty water cooled vertical compressor from 25 to 60 HP.

The latest addition to our range is the high pressure water- cooled, oil-free IAH series compressor, from 40 HP to 150 HP models.

Which are your latest breakthrough products?

To ensure the product quality in the production of PET bottles, containers for home care/cosmetic products, food products, pharmaceutical products, aeronautics, turbine and hydraulic circuit pressurising and pharmaceutical industries, Indo Air has developed its new IAH hundred per cent oil-free high pressure series compressors.

Catering to the need of hospital for clean oil-free air systems has been a focus of Indo Air for many years. Indo Air’s NL type compressors were well received in the market. Indo Air Vacuum pumps have satisfied the demands of hospitals to the fullest.

How can one rationalise the use of compressed air and improve the efficiency of compressor?

There are various steps that could be taken to improve the efficiency of compressors and can help in using compressed air effectively.

  • Use of high efficient and higher pull-out torque electrical motors has been found to give power savings in different plants; power savings of around 5 to 8 per cent was recorded at many plants.
  • Variable Speed Drives (VSD) for the compressors improves the power consumption pattern of the compressors. Of course, this depends on the usage and air output linked to the air pressure requirements. The savings VSDs provide vary between 10 to 40 per cent depending on the flow pattern.
  • Proper sizing of the pipe diameter contributes significantly to lower the power consumption; increasing the pipe diameter typically reduces annual energy consumption by 3-4 per cent.
  • When the compressor works, it produces heat and it is simple physics that compressing air gives off heat. The heat energy gets stored in the decreasing volume of air. To maintain proper operating temperatures, the compressor must transfer excess heat to a cooling media before the air goes out into the pipe system. As much as 90 per cent of that heat can be recovered for use in your operation. If you can supplement or replace the electricity, gas or oil needed to create hot water for washrooms or direct warm air into a workspace, warehouse or for any other use, the savings can add up significantly. The possibilities to recover this waste heat via hot air or hot water are very good. The return on the investment for energy recovery is usually as short as one to three years. In addition, energy recovered by means of a closed loop cooling system (for water cooled compressors) is advantageous to the compressor’s operating conditions, reliability and service life.
  • If the input temperature to the compressor is reduced by placing the compressor inlet strategically, the energy consumption of the compressor can be reduced to the extent of 1-2 per cent for every 3-4 degree drop in inlet temperature.
  • Often, the air-cooled compressors are relegated to boiler rooms that do not have proper ventilation. These centralised compressors can experience elevated operating temperatures that reduce equipment life, increase maintenance and repair cost, and ultimately can yield an unreliable air system. The initial cost of a good ventilation system is usually far less than the ongoing increased maintenance costs of a hot operating environment.
  • System operators should also examine if a reduced system pressure could be used. Use of a central control system can run the existing air compressors to cyclical demand more effectively.
  • Increased storage capacity can also reduce the unnecessary high cycling demand of compressors.

Which features in your equipment help in the energy conservation?

With regard to the rationalisation of the use of compressed air, energy conservation depends more on the compressed air system than the elements built into the compressor. However, there are a few which are already available or can be built into Indo Air compressors.

Indo Air has been incorporating innovative ideas in the design of its reciprocating compressors. One such instance is to change the cylinder diameter combination, resulting in reduced speed of the compressor leading to drop in temperature built up. The Automatic Start-Stop control can be modified to have a solenoid valve system to have a pressure free start up of the compressor thus reducing the starting current demand of the electric motor. The water-cooled, inter-cooler can be provided as an option to reduce the input temperature of air at the subsequent stages. Variable speed drives is offered with the screw compressors to reduce energy consumption.

What kind of testing and quality checks does your equipment go through?

All internal assemblies are carried out in a dust-free closed assembly room to protect the internal moving parts. This room is adequately furbished to have the necessary tools, test benches, air lines and inspection facilities. The quality plan for the assembly is displayed at every stage of the compressor assembly to ensure a repetitive set performance of the compressors. All critical parts are inspected one hundred per cent for dimensional as well as geometrical accuracy. All castings and raw material purchases are accompanied by chemical and physical property reports. All compressors leaving the premises of Indo Air are tested for its performance, efficiency and the quality. Every model of the compressor is tested once in two months on a test bed established specially for this purpose, with calibrated instruments and measurement devices, where the nozzle is tested at various parameters as specified in the relevant Indian Standard and sometimes, rechecks are carried out.

There is a monitoring system in place on the compressor at the customer’s place and the feedback is used to update the check list in the assembly. For every deviation noticed, a Quality Assurance Report (QAR) is prepared with the action taken to eliminate the error. We are a certified ISO 9000-2008 company and all quality practices are followed from design, procurement, inspection, assembly and testing, and proper records are maintained.

What are the new developments in compressor operations, design and maintenance processes?

With the advent of microprocessor systems, modern air compressors are now available with user friendly software systems to operate, control and maintain the equipment. All Indo Air screw compressors and high pressure, water-cooled reciprocating compressors come with a Indo-numeric PLC based control system software to control the compressor. Its user-friendly touchscreen MMI allows the operator to modify the parameters.

The system monitors, regulates, does error diagnosis and gives out warning signals, both visual and audible, preventing potential damages to the equipment. It also gives service warning signals to indicate oil filter/air filter change and such other service requirements.

The provision of an auto shutdown ensures shutting down of the compressors in case of abnormal parameters, to avert system damage. In the high pressure, water-cooled compressor control, there is a port available in the controller for a computer connection. Using this facility, remote sensing of the compressor can be performed via the internet for troubleshooting, from the Indo Air factory.

Double-acting cylinders have been incorporated into the new design, instead of single acting cylinders; this gives two compressor strokes for every revolution of the crank, thus doubling the output. Now booster compressors are developed where high output and high pressure of air is required. These designs use the advantage of both reciprocating and rotary screw compressors, compressors with a smaller footprint.

How have you incorporated safety into your design?

The air compressor is fitted with several safety components.

The first is an unloading valve. The unloading valve allows the air to escape from the compression chamber when there is a strain on the electrical motor.

The pressure inside the air receiver must never exceed the manufacturer’s recommendations. If the pressure is greater than the recommended level, it may cause an explosion. The pressure in the air receiver is controlled by the pressure switch. To adjust the pressure, simply turn the switch in the desired direction.

Pressure relief valves are also installed on the compressor system. These valves allow air to escape from the system when the pressure goes beyond the desired level. The valves operate automatically.

The air intake valve is fitted with an air filter. The filter prevents dust from being drawn into the compression cylinder. If dust enters the compressor, the heat inside the cylinder can cause the dust to catch fire. Fire inside the cylinder may cause damage to the air compressor. For this reason, it is important to make sure that the air filter is clean and securely connected to the compressor.

Moisture too, can cause problems and so another filter must be installed to take out the moisture out of the compressed air. The moisture is usually removed using a filter and moisture separator assembly which is installed between the air compressor and the air receiver. It removes the moisture and dust from the compressed air before it enters the air receiver.

An automatic control device is attached to the air receiver. It controls the starting and stopping of the air compressor. It shuts down the compressor when the air pressure in the air receiver is adequate. It restarts the air compressor when there is a need for more pressure.

A cooling system is installed in each air compression unit. The compression chamber and the compressed air must be cooled. Small compressors are usually air-cooled. The air is circulated around the compressor by a fan. Large air compressors are usually water-cooled. Cold water is pumped throughout the compressor. Both the air and water cooling systems prevent the compressors from overheating and causing serious damage. The air compressor is also fitted with a low oil level indicator switch. This indicator switch automatically shuts down the air compressor if the oil level is low. The compressor should not be operated if the oil is low as this can cause serious damage to the compressor. Do not attempt to run the air compressor until the oil is replaced.

These measures are a must for the safety of the equipment and also for the people working in the factory. We at Indo Air take additional precautions with all compressor parts under air pressure. All the air receivers, inter-coolers and after -coolers, pressure pipes, are tested hydraulically at 2.5 times the designed pressure.

Selecting The Right Compressor

An air compressor is a valuable piece of equipment for operating power equipment or tools. The type you need depends on the equipments you will be using.

  • Consider how often you will use an air compressor and how it will be used. What tools will you be using and how much power will be needed to operate them? Some tools like nail guns use low volume of compressed air whereas other equipment, such as drills or sanders needs high volumes because they require a steady air flow.
  • Consider the power of the compressor; consider both the horsepower and pound per square inch (PSI) pressure. Make sure it is more powerful than the most powerful equipment you will be using.
  • The type of the compressor depends on the volume of air required and the air pressure. Normally in a cement plant, the compressor is located in a room far away from the equipment to be operated. There will be a significant pressure drop and this should be taken in to account while selecting the compressor.
  • With the availability of screw compressors with high volume outputs, with a closed canopy, it is possible to install these types of compressors in the shop floor itself, close to the equipment, resulting in minimum pressure loss.
  • The tank size is another important factor. The more you use the equipment, the larger the tank you will need. Always go a little larger than you think you will need, this will ensure that you can get the optimum use from the compressor and reduced power consumption.
  • List out the accessories you may need with the compressor and include them in the buying order.

Continue Reading
Click to comment

Leave a Reply

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

Concrete

Sustainable Procurement Practices

Published

on

By

Shares

Partha Dash, Managing Director, Moglix, discusses how India’s cement industry, a key player in the country’s construction growth, is at a critical juncture as it faces the challenge of balancing expansion with sustainable practices.

According to research by construction blog Bimhow, the construction sector contributes to 23 per cent of air pollution, 50 per cent of the climatic change, 40 per cent of drinking water pollution, and 50 per cent of landfill wastes. Over the last decade cement has been one ubiquitous element in India’s construction growth story. As the world’s second-largest producer, we are seeing an impressive growth trajectory. Major players like Birla, Adani, Dalmia Bharat, JK Cement and Shree Cement are expanding fast, with plans to add 150-160 million tonnes of capacity over the next five years. This follows a substantial increase of 120 million tonnes in the past five years, pushing India’s total capacity to around 600 million tonnes. But with all this expansion, we have got a big question – How do we ensure sustainable procurement practices, in such an energy dependent industry?

Energy-intensive nature of cement production
Making cement takes a lot of energy. Process starts with limestone being mined, crushed, and grounded, using about 5-6 per cent of the total energy. The biggest energy use happens during clinker production, where around 94-95 per cent of the energy is used. Here is where limestone is heated to very high temperatures in a kiln, which needs a lot of energy from fossil fuels like coal and pet coke. Electricity is also used to run equipment like fans and kiln drives.
Once the clinker is made, it’s ground into cement. This grinding process uses another 5-6 per cent of the energy and usually happens at facilities close to where the cement is needed. Facilities that handle both clinker production and grinding in one place are generally more energy-efficient. Many of these places use coal-powered plants to supply the heat needed for the kilns, keeping production steady.

Transitioning to bulk cement
Making cement use more efficient is key to reducing the industry’s carbon footprint. In India, as per research by World Economic Forum around 75-80 per cent of cement is sold in 50kg bags to small-scale builders and individuals. But there’s often little insight into how this bagged cement is used. Research from the World Economic Forum also shows that about 40 per cent of this cement is mixed by hand. Builders sometimes use more cement than needed, thinking it will make the structure stronger, which increases emissions.
It’s crucial to educate these small-scale users about using cement efficiently. Builders need accurate information on mixing ratios and should be encouraged to adopt design techniques that use less cement. One idea suggested in the report is to put embodied carbon labels on cement bags to provide this information, helping to promote more sustainable practices at the grassroots level.
On the flip side, bulk cement, which now makes up 20-25 per cent of India’s cement use, has its own set of challenges and opportunities. Bulk cement is often used for large-scale projects that need high-strength concrete, which tends to be more carbon-intensive. However, it also makes it easier to mix in supplementary cementitious materials (SCM), which can reduce the carbon intensity of the cement. As bulk cement use grows, especially in big infrastructure projects, balancing structural needs with lower-carbon solutions will be crucial.

Challenges in sustainable procurement
The cement industry finds it hard to adopt sustainable procurement because many companies aren’t fully on board with it. Sometimes, sustainability isn’t a big focus for the company, which means top management doesn’t fully support it. This lack of support slows down collaboration with environmental experts and limits the adoption of green practices. Additionally, many clients still prefer traditional materials, which means there’s less demand for sustainable options.
In terms of knowledge and innovation, there’s a gap in understanding how to incorporate green procurement into existing practices. Many companies aren’t fully aware of the benefits of adopting green strategies or getting environmental certifications. This lack of knowledge also affects the public sector, where innovation in sustainable practices is often held back due to a shortage of technical support and experts.
There’s also a common belief that green procurement is more expensive, which can be a significant barrier, especially when resources for sustainable products are limited. Awareness and readiness for green practices are still low. Many people don’t fully understand the importance of sustainable procurement in construction, and there’s a lack of information about the market for green materials. Without adequate training and a clear structure for green purchasing, it’s difficult for companies to fully commit to sustainability. Moreover, existing policies and regulations aren’t strong enough to drive real change and without enforcement and incentives, the availability of green materials remains limited.

Opportunities in sustainable procurement
To fully understand the opportunities in sustainable procurement, Indian construction companies need to make it a key part of their business approach. This requires strong support from top leadership, including CEOs and boards of directors. When sustainability is a central focus in a company’s goals, it not only improves environmental impact but also sets the company apart in the market. Firms that focus on green practices can attract clients who value sustainability.
Working together with industry, academic institutions and government bodies is crucial for advancing green procurement. Top institutions in India like IIMs and IITs should collaborate with agencies like the Central Pollution Control Board and the Ministry of Environment. These partnerships can help develop shared goals and standards, like ISO 14000 for Environmental Management Systems, and offer training programs across the country.
It’s crucial to help clients understand how green buildings can save money over time. These sustainable structures not only cut down on running costs but also enhance the quality of life for those who live or work in them. Organisations such as the Construction Federation of India and the Builders Association of India should promote green products, which can drive demand and reduce costs by boosting production.
The government’s role is also vital. Programmes like the Pradhan Mantri Awas Yojana should focus on using green materials to show that sustainable construction can be affordable. To encourage use of sustainable materials, giving incentives like tax breaks, just like the ones for electric vehicles, could make a big difference.
Establishing a national certification for green procurement professionals, backed by organisations like the Indian Green Building Council, can help create a skilled workforce that can lead sustainable practices in the construction industry. By seizing these opportunities, India can move toward a more sustainable future in construction.

India’s leadership in sustainable cement production
India has made impressive strides in sustainable cement production. As per a research report by JMK research and analytics in 2022, the global cement industry accounted for 26.8 per cent of industrial emissions, but Indian manufacturers have been proactive in reducing their carbon footprint. The same report also states that between 2017 and 2022, the industry cut its emissions intensity by 19.4 per cent, thanks to a rise in alternative materials like fly ash and slag Blended cements, which now make up 81 per cent of India’s output, are a big part of this progress.
Leading cement producers in India, including Ultratech Cement, Shree Cement and Dalmia Cement, have committed to reducing emissions by 20 per cent by 2030, with a long-term goal of achieving net-zero emissions by 2050. Recently, the industry introduced 150 electric trucks to reduce carbon footprints, though challenges like limited charging infrastructure and high costs remain. Still, this move is expected to cut logistics expenses by 25-40 per cent. The industry is also pushing for policy support to accelerate the adoption of electric trucks and further its sustainability goals. According to report published by India Brand and Equity Foundation, some of the major investments in renewable energy and energy storage solutions include:

  • UltraTech Cement plans to deploy 500 electric trucks and 1,000 LNG/CNG vehicles by June 2025, cutting transport emissions by 680 tonnes annually. They aim to reach 85 per cent green energy use by 2030 and boost production capacity to 200 million tonnes.
  • Shree Cement completed a 6.7 MW solar project in Haryana in September 2022.
  • Dalmia Cement aims to produce 100 per cent low-carbon cement by 2031, supported by a $405 million carbon capture investment.
  • JK Cement signed an agreement with PRESPL in October 2021 to increase the use of biomass and alternative fuels, reducing reliance on coal.

Is the impossible possible?
The Indian construction and cement industries are making prudent strides toward sustainability. Recent research shows a strong link between the use of renewable energy and economic growth, highlighting the importance of reducing reliance on traditional energy sources. The construction industry, which has a large environmental impact, must adopt greener practices to help reduce pollution and waste.
The Indian cement industry is leading the way, with plans to significantly increase its use of renewable energy by 2026. This shift not only helps reduce costs but also sets a positive example for other sectors. The focus on renewable energy, like solar and wind, and efforts to avoid new thermal power plants show a clear commitment to a more sustainable future.
As the cement industry continues to push for net-zero emissions by 2050, its proactive approach is setting a new standard. These efforts not only benefit the industry itself but also provide a roadmap for others to follow. By embracing greener practices, the cement industry is helping to pave the way for more sustainable and environmentally friendly procurement practices in India.

About the author:
Partha Dash, Managing Director, Moglix, is a sales and marketing professional with 15+ years of hands-on experience in shaping businesses especially in the emerging markets.

Continue Reading

Concrete

The Circle of Life

Published

on

By

Shares

The circular economy offers a transformative approach for the cement industry, focusing on resource efficiency, waste minimisation, and sustainable practices. ICR finds out why integrating alternative materials, reducing carbon emissions and embracing innovative technologies, is crucial for the cement sector.

The circular economy is an innovative model aimed at minimising waste and maximising the use of resources by closing the loop of product life cycles through greater resource efficiency, recycling, and reusing. Unlike the traditional linear economy, which follows a ‘take-make-dispose’ pattern, the circular economy emphasises a restorative approach that seeks to maintain the value of products, materials and resources in the economy for as long as possible.
In the context of the cement industry, which is known for its resource-intensive processes and substantial environmental footprint, embracing circular economy principles is crucial. Cement production typically involves high energy consumption and generates significant greenhouse gas emissions. By adopting circular practices, the industry can reduce its reliance on virgin raw materials, lower waste and emissions and enhance overall sustainability.
The relevance of the circular economy in cement production is evident in several key areas:
• Resource efficiency: Utilising alternative and recycled materials, such as industrial by-products or waste, can significantly reduce the demand for raw materials and lower the environmental impact of cement production.
“Utilisation of alternative raw materials in the cement industry is a key strategy for enhancing sustainability and resource efficiency. Wonder Cement has substituted traditional raw materials like limestone with industrial by-products such as fly ash, marble slurry, chemical gypsum, red mud, mine telling reject, alumina slat, iron sludge, etc. Wonder Cement not only reduces its reliance on natural resources but also mitigates environmental impacts,” says Nitin Jain, Unit Head – Integrated Plant, Nimbahera, Wonder Cement.
“Low-carbon cement production is an innovative approach by Wonder Cement aimed to reduce the carbon footprint associated with traditional cement manufacturing. This process involves several strategies to minimise CO2 emissions, which are typically high due to the energy intensive nature of clinker production. The production of blended cement, Portland Pozzolana Cement (PPC) involves mixing clinker with supplementary materials like fly ash. This not only reduces CO2 emissions but also enhances the durability and performance of the cement,” he adds.

  • Waste management: Implementing strategies to manage and repurpose waste products not only helps in minimising landfill use but also creates valuable resources for reuse in cement manufacturing.
  • Energy optimisation: Circular economy practices promote energy-efficient technologies and the use of renewable energy sources, contributing to a reduction in carbon emissions associated with cement production.
  • Product lifecycle: By focusing on the entire lifecycle of cement products, from production to disposal, the industry can develop more sustainable practices and innovative solutions for recycling and reusing cement-based materials.

Adopting a circular economy approach is not only essential for reducing the environmental impact of cement production but also for driving innovation, enhancing resource security, and fostering long-term economic resilience in the industry.

Use of Alternative and Recycled Materials
The cement industry is undergoing a transformative shift with the increasing adoption of alternative and recycled materials. This shift is driven by the
need to reduce environmental impact, conserve natural resources, and enhance the sustainability of cement production.
Alternative materials: Alternative materials, such as industrial by-products and waste materials, are increasingly being used as partial replacements for traditional raw materials like clinker.

Common examples include fly ash, slag, natural pozzolans, etc.
Recycling plays a crucial role in minimising waste and promoting a circular economy within the cement industry. Key recycled materials include:

  • Recycled concrete aggregate (RCA): Reclaimed from demolished concrete structures, RCA can be used as a partial replacement for natural aggregates in new concrete, reducing the need for virgin resources.
  • Construction and demolition waste: Incorporating materials from construction and demolition activities not only diverts waste from landfills but also provides valuable resources for cement production.

The use of these alternative and recycled materials helps in reducing the environmental footprint of cement production by lowering greenhouse gas emissions, conserving natural resources, and minimising waste. Furthermore, it supports the industry’s transition towards more sustainable and circular practices, contributing to the overall goal of reducing the sector’s impact on the environment.
According to an article published by McKinsey & Company in March 2023, the cement value chain is well positioned to create closed loops, or automatically regulated systems, for carbon dioxide, materials and minerals, and energy (see sidebar ‘Three categories of circular technologies in cement’). This entails circular economies, which are based on the principles of eliminating waste and pollution, circulating products and materials, and regenerating nature. With these points in mind, circularity can work jointly with reducing carbon emissions in cement production because circular technologies follow the paradigm of three crucial decarbonisation strategies: redesign, reduce and repurpose. According to the organisation’s estimates and expected carbon prices, circularity technologies will be value-positive by 2050, with some already more profitable than today’s business-as-usual solutions.
The report estimates show that an increased adoption of circular technologies could be linked to the emergence of new financial net-value pools worth up to roughly €110 billion by 2050, providing a new growth avenue for cement players that would otherwise face shrinking demand for their core business and significant external costs. Adopting circularity is required to mitigate at least 50 percent of this value at risk. Emerging new technologies and business models will create additional value to mitigate the residual value at risk.

Reducing and Managing Industrial Waste
Efficient waste management is critical for the sustainability of the cement industry. Reducing and managing industrial waste not only minimises environmental impact but also offers opportunities to turn waste into valuable resources. Here are some key strategies of waste-to-resource initiatives:

Waste minimisation at source

  • Process optimisation: Implementing advanced technologies and practices to improve process efficiency can significantly reduce the amount of waste generated. Techniques such as precise control of raw material inputs and process conditions help minimise production losses.
  • Cleaner production techniques: Adopting cleaner production methods, such as the use of less polluting raw materials and more efficient equipment, can reduce waste generation at the source.

Recycling and reuse

  • Alternative fuels: Industrial waste, such as tire-derived fuel or biomass, can be used as alternative fuels in cement kilns. This not only helps in reducing the consumption of traditional fossil fuels but also diverts waste from landfills.
  • By-product utilisation: By-products from other industries, such as fly ash or slag, can be integrated into cement production processes. These materials not only enhance the properties of the final product but also reduce the need for virgin raw materials.

Nitin Sharma, CEO and General Manager, Clariant IGL Specialty Chemicals (CISC), says, “As our climate gives us increasing and alarming signals of change, individuals and industries are looking for ways to reduce their environmental footprints, and the demand for bio-based chemicals is set to grow strongly in the coming years. In several applications, the use of petrochemicals and fossil carbon remains a significant issue. The transition to bio-based carbon chemistry represents a significant challenge for manufacturers.”

Waste-to-resource initiatives

  • Recycled concrete aggregate (RCA): Demolished concrete can be crushed and recycled into aggregate for use in new concrete mixes. This reduces the demand for natural aggregates and decreases the volume of construction waste.
  • Co-processing of waste: The cement industry is increasingly adopting co-processing techniques where various types of industrial and municipal waste are processed in cement kilns. This approach helps in recovering energy and material value from waste streams while simultaneously treating hazardous materials.
  • Zero-waste initiatives: Some cement plants are aiming for zero-waste targets by implementing comprehensive waste management systems that ensure all waste is either recycled, reused or recovered.

Partha Dash, Managing Director, Moglix, says, “There’s also a common belief that green procurement is more expensive, which can be a significant barrier, especially when resources for sustainable products are limited. Awareness and readiness for green practices are still low. Many people don’t fully understand the importance of sustainable procurement in construction, and there’s a lack of information about the market for green materials. Without adequate training and a clear structure for green purchasing, it’s difficult for companies to fully commit to sustainability. Moreover, existing policies and regulations aren’t strong enough to drive real change, and without enforcement and incentives, the availability of green materials remains limited.”
These strategies and initiatives reflect a growing commitment to sustainability within the cement industry. By effectively managing and repurposing industrial waste, cement producers can not only reduce their environmental impact but also contribute to a more circular and resource-efficient economy.
According to the report Indian Cement Industry: A Key Player in the Circular Economy of India published July 2020, the Indian cement industry is playing a key role by enhancing the application of renewable energy for electrical power generation. The renewable energy installed capacity (wind and solar) in cement plants increased by more than 40 per cent to 276 MW from 2010 to 2017. Out of the total, 42 MW is solar power, while off-site wind installations account for 234 MW. A company has undertaken the target of switching over to renewable energy for 100 per cent of all electrical energy needs by 2030. Big players like UltraTech Cement are targeting 25 per cent share of their total power consumption by green energy technologies.
Apart from the solar photovoltaic route, the cement industry is making efforts to tap solar energy through thermal routes.

Government initiatives
The Indian government is actively promoting circular economy principles through various policies and regulations aimed at enhancing sustainability and resource efficiency. The National Clean Energy Fund (NCEF) supports innovative projects in energy efficiency and emission reduction, including those incorporating circular economy practices.
The Swachh Bharat Mission (SBM) and Solid Waste Management Rules, 2016, focus on improving waste management and recycling, encouraging the use of recycled materials in construction and cement production. The Plastic Waste Management Rules, 2016, emphasise recycling and the use of recycled plastic, including as alternative fuel in cement kilns. The National Resource Efficiency Policy (NREP) promotes resource efficiency across sectors, including cement, and the government’s clean technology schemes incentivise the adoption of green technologies.
Additionally, the draft National Circular Economy Policy, currently in development, aims to provide a comprehensive framework for advancing circular economy practices across all industries. These initiatives collectively support the transition towards more sustainable and circular practices in the cement sector.

Emerging trends in circular economy
The cement industry is witnessing several emerging trends in circular economy practices, reflecting a shift towards greater sustainability and resource efficiency. One notable trend is the increased use of alternative fuels and raw materials. Cement producers are exploring the use of industrial and municipal waste, such as tires, plastics, and biomass, to replace traditional fossil fuels and raw materials, reducing their carbon footprint and conserving natural resources.
Another significant trend is the advancement of circular product design and lifecycle management. Cement companies are focusing on designing products that are easier to recycle or reuse at the end of their lifecycle. This includes developing new types of cement and concrete with enhanced durability
and recyclability.
Waste-to-resource initiatives are also gaining traction. Innovations in waste processing technologies enable the conversion of waste materials into valuable resources for cement production, such as incorporating recycled concrete aggregate (RCA) and by-products like fly ash and slag into new cement products.
Digitalisation and data analytics are emerging as crucial tools in advancing circular economy practices. Advanced monitoring and analytics technologies help optimise resource use, track waste streams, and improve overall efficiency in cement production.
Finally, there is a growing emphasis on collaborative partnerships. Cement companies are increasingly collaborating with governments, NGOs, and other industries to drive circular economy initiatives and develop innovative solutions for sustainable development. These trends highlight a transformative shift towards a more circular and sustainable approach in the cement industry, aligning with global efforts to reduce environmental impact and promote resource efficiency.

Conclusion
The adoption of circular economy principles in the cement industry is proving to be a pivotal step towards enhancing sustainability and reducing environmental impact. By embracing alternative and recycled materials, the industry is reducing its reliance on virgin resources and minimising waste. Government policies, such as the National Clean Energy Fund and Solid Waste Management Rules, provide crucial support for these practices, fostering a regulatory environment conducive to circular economy initiatives. Emerging trends, including the use of alternative fuels, circular product design, waste-to-resource innovations, and advanced digital technologies, underscore the industry’s commitment to resource efficiency and sustainability. Collaborative efforts across sectors further drive these advancements, paving the way for a more resilient and environmentally responsible cement industry. As the sector continues to integrate circular economy principles, it not only aligns with global sustainability goals but also sets a benchmark for other industries striving for a circular future.

– Kanika Mathur

Continue Reading

Concrete

Installing a solar system is just the first step

Published

on

By

Shares

Raman Bhatia, Founder and Managing Director, Servotech Power Systems, talks about innovative approaches to advancing energy efficiency in the solar sector, from embracing the ‘Make in India’ initiative to pioneering new technologies.

Can you provide an overview of Servotech Power Systems’ contributions to energy efficiency in the solar sector?
Throughout its journey with a strong motto of providing high-quality solar solutions, Servotech made noteworthy contributions towards energy efficiency in the solar sector, through innovative technologies and solutions. By developing high-efficiency solar solutions that are both sustainable and reliable, Servotech has played its part in making solar energy a household name. The company has expanded its reach across various sectors. Servotech’s residential solar solutions empower homeowners to reduce their carbon footprint and electricity bills. The company provides solar solutions for industries, helping them reduce energy costs, improve their environmental quotient and comply with sustainability regulations. Servotech caters to the commercial sector by offering rooftop and ground-mounted solar power plants helping them reduce electricity costs and enhance their brand image, Lastly, the company has been actively involved in executing solar projects for government institutions, aiding in the country’s renewable energy goals and by providing efficient and reliable solar solutions, we contribute to
the government’s efforts in promoting clean
energy adoption.

What role does the ‘Make in India’ initiative play in your strategy to promote energy efficiency and sustainable solutions?
Make in India, a wonderful initiative by our government, has definitely pushed manufacturers across all sectors, especially our sector, which is the renewable energy sector towards indigenous manufacturing. By manufacturing solar components locally, we significantly reduce the carbon footprint associated with transportation and logistics. Local production often leads to cost reductions in solar products which makes solar energy more affordable for consumers, encouraging wider adoption and contributing to energy efficiency. The Make in India initiative also helps create employment opportunities in the solar sector, leading to skill development and a larger workforce dedicated to renewable energy. Domestic manufacturing reduces reliance on imports and strengthens the supply chain, ensuring uninterrupted production and reducing vulnerabilities to global disruptions.

How has Servotech adapted its solar solutions to meet the evolving energy efficiency standards?
Well, it has been more than two decades now. During this long journey, we have constantly worked on ourselves, renovated, and innovated ourselves to keep up with the evolving energy efficiency standards in terms of product development, innovation and R&D. We have consistently incorporated the latest advancements in solar technology that includes the use of higher efficiency solar cells, advanced inverters, and optimised system components. We introduced innovative solar products and solutions that meet the evolving energy efficiency standards. This involves continuous research and development to create more efficient and sustainable products. We prioritise product performance and rigorous testing and quality control measures ensure that our products meet or exceed industry benchmarks and this relentless pursuit of excellence has positioned us as a leader and has helped us in delivering efficient and sustainable
solar solutions.

Could you elaborate on the significance of the engineering and design process in achieving energy efficiency in your solar EPC projects?
The engineering and design phase in solar EPC projects lays the foundation for optimal performance. It involves a careful analysis of site conditions, including solar radiation, shading and environmental factors. By carefully selecting high-performance components and designing the system for optimal orientation and tilt, engineers maximise energy capture. Additionally, this phase focuses on minimising energy losses through efficient wiring, component placement, and system integration. A well-engineered design ensures the solar system operates at peak performance, delivering substantial energy savings and a strong return on investment.

What measures does Servotech implement during the procurement and project execution phases to ensure optimal energy efficiency in its solar power projects?
Constructing a solar system involves a lot of phases with procurement and project execution being the most important ones. During the procurement phase, we prioritise the development of high-efficiency solar modules, inverters and other components. Rigorous quality assurance processes and performance testing are conducted to verify that all components meet or exceed industry standards and are compatible with project requirements. In the project execution phase, Servotech conducts detailed site assessments to determine the optimal system orientation, tilt angle and shading analysis. Strict adherence to installation guidelines and best practices ensures proper system integration and performance. Post-installation, the system undergoes comprehensive testing to verify energy efficiency and performance. Monitoring systems are often incorporated to track performance and identify areas for improvement.

How does your operation and maintenance service contribute to maintaining and enhancing the energy efficiency of installed systems?
Installing a solar system is just the first step; operating and maintaining it properly is equally important to ensure the system runs efficiently over the long term and for that we conduct regular inspections to detect and address issues like module degradation and inverter malfunctions early, preventing energy losses. Our team ensures optimal performance through routine cleaning and maintenance, which maximises sunlight absorption and energy generation. Continuous performance monitoring using advanced data analytics allows us to optimise system settings, while preventive and corrective maintenance activities minimise downtime and equipment failures. By utilising techniques such as module-level monitoring and inverter tuning, Servotech ensures that solar systems operate at peak efficiency, delivering maximum energy output and long-term cost savings.

In your view, how important is radiation data analytics and project feasibility studies in the planning of energy-efficient solar projects?
Radiation data analytics and project feasibility studies are absolutely critical for the successful planning of energy-efficient solar projects. Accurate radiation data allows for precise predictions of energy generation, system sizing and financial returns. By analysing radiation patterns, engineers can optimise system design, including orientation and tilt angles, to maximise energy capture. Feasibility studies help identify potential risks, such as shading or grid constraints, enabling proactive solutions. These studies also assess financial viability, considering ROI, payback periods, and incentives, ensuring projects are economically sound enabling data-driven decision-making throughout the project lifecycle.

Looking ahead, what are the key trends and innovations in energy efficiency that Servotech Power Systems plans to focus on in the near future?
Energy efficiency is a dynamic realm with constant emergence of trends and innovations. The company recognises the value these trends and innovations will add in the growth of energy efficiency in the solar sector. Our innovative product solar powered EV charging carport integrates solar power with EV charging, which is an innovative take on how we can charge our EVs and also save energy from renewable sources. Additionally, Servotech plans to invest in enhancing the quality of bifacial solar panels to increase energy generation. We are investing in research and development of major solar developments and understand the importance of energy storage in enhancing grid stability and optimising energy utilisation and grid optimisation. In fact, we are developing an energy storage system that will accelerate the adoption of renewable energy in low electricity areas.
Exploring digitisation of energy efficiency, we are focused on developing advanced monitoring and control systems to optimise system performance, predict maintenance needs. Lastly, to meet the growing demand for clean energy, we are exploring the integration of solar power with other renewable energy sources like wind and hydro to create hybrid power systems.

– Kanika Mathur

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