Concrete

Utilisation of Alternative Fuels and Raw Materials in Indian Cement Industry: The Current Scenario and Future Prospects

Published

4 years ago

January 15, 2022

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With the net zero target confirmed for India, the Indian cement sector needs to optimise its efforts in utilising alternative fuels and raw materials, as these two factors are instrumental in determining the industry’s contribution in the nation’s carbon neutral future

Climate Change, fast depleting natural resources like limestone, increased cost of conventional fuels like petcoke and coal, have become a matter of great concern for cement industry all over the world. Recently, our Hon’ble Prime Minister of India Shri Narendra Modi has committed to cut the CO2 emissions in the COP 26 summit at Glasgow in November 2021 and has set a Net Zero Carbon target for India by the year 2070. Cement industry, generating 7 per cent of anthropogenic CO2 emissions will also have to move towards the path of decarbonisation. The process emissions from calcination are hard to abate, however, the emissions from fuel combustion can be avoided by replacing fossil fuels with alternative fuels.
Cement industry is making enormous efforts to enhance the utilisation of alternative fuels by co-processing of hazardous and non-hazardous wastes/by-products from various industries like pharma industry, paint industry, processed municipal solid waste from local bodies, etc. However, one of the pressing issues is to enhance the utilisation of alternative fuels to achieve TSR of 25 per cent by 2030 without impacting the productivity, product quality and environment emissions.
Niti Aayog has also focused on implementation of a circular economy in India by preparing comprehensive action plans for different wastes available in our country. Implementation of Circular Economy will not only help in reducing the dependence on natural resources but also help in gaining economic advantage to the industry. Rapid industrialisation has resulted in generation of large quantities of industrial wastes such as fly ash in thermal power plants, slag from steel industry, red mud from aluminium industry, copper slag from copper industry, dolochar from sponge iron industry, lime sludge from paper industry. Some of these wastes have high potential for utilization as raw mix / blending components in cement manufacturing and are being gainfully utilised in the cement industry. Cement industry plays a central role in the Circular Economy framework and is a key component of industrial waste management in India.
Utilisation of Alternative Fuels and Raw Materials (AFR) in cement industry, therefore, helps in reduction in carbon footprint, increased sustainability, avoiding consumption of fossil fuel and its associated higher cost as well as implementation of a circular economy in India.
Status of Alternative Fuel Utilisation in Indian Cement Industry
The utilisation of alternative fuels in cement kilns started in Year 2000 with the active support of the Central Pollution Control Board. With persistent efforts of the cement industry, Government of India and other stakeholders, the Thermal Substitution Rate (TSR) has now increased to ~5 per cent as compared to 0.6 per cent in 2010. The Indian cement industry has been using large quantities of wastes such as non-recyclable hazardous and other wastes, segregated combustible fractions from Municipal Solid Wastes (MSW), plastics wastes, tyre wastes, surplus biomass etc. as alternative fuel in cement plants. Some of the hazardous and non-hazardous wastes presently used in cement plants are:
Hazardous waste: textile ETP sludge, tannery ETP sludge, TDI tar, paint sludge, process waste, waste residue, chemical sludge, process sludge, phosphate sludge, chemical sludge from ETP, insulation waste, mixed salt, organic residue, liquid organic residue, spent solvent, benzofuran and waste lubricant oil.
Non-hazardous waste: Tyre chips, RDF, plastic waste, FMCG expired products, wood/bamboo chips, carbon black, biomass like rice husk, groundnut husk, cashew nut husk, poppy straw, opium marc etc.
The availability and characterisation of some of the non-hazardous waste and hazardous waste are given in Tables 1 and 2 respectively.
The leading cement companies in India have achieved Thermal substitution rate (%TSR) in the range of 3 – 7 per cent on an average annually as shown in Table 3. However, some cement plants in India have achieved high %TSR up to 15 – 25 per cent.

Thermal substitution rate of India is comparable with other countries such as 100 per cent TSR in Australia, 100 per cent TSR in France and South Korea is equivalent to 4 per cent, 8 per cent and 25 per cent TSR in India respectively. This indicates that TSR in India is still reasonably good considering high cement production capacity but still has huge potential to achieve high TSR.

Status of Alternative Raw Materials Utilisation in Indian Cement Industry
Cement industry uses a number of wastes and by-products as supplementary raw materials in cement raw mix which are referred to as alternative raw materials. Industrial and mineral wastes from mineral processing industries, such as metallurgy, petrochemicals, chemicals, paper and pulp account for nearly 275 million tonnes per annum. The more important wastes are fly ash from thermal power plants, slag from steel industry, metallurgical slags from non-ferrous industry, press mud from sugar industry, paper sludge from pulp and paper industry, phospho- chalk and phosphogypsum from fertilizer industry, red mud from aluminium industry, wollastonite mineral and ore tailings, catalyst fines, foundry sand and leather sludge from tannery effluent treatment plants. It is essential that the composition of the alternative raw materials considered for the cement raw mix be compatible with the materials they intend to replace or supplement. Marble slurry/dust, waste generated by the marble processing industries, particularly in the state of Rajasthan. Physical, chemical and mineralogical evaluation of these wastes showed their similarity with conventional limestone and could be used in cement and construction industry. Due to their compatibility with cement system, marble waste materials could be used in cement manufacture (i) as raw material in Portland clinker making (ii) in blended cement (iii) in the development of various building products such as marble coating, tiles and bricks (iv) as fine aggregate in concrete etc. High moisture content and inconsistent quality of marble wastes are the main factors for their limited use in cement manufacturing units.
Waste generated by different industries and their characteristics, which has the potential to be used in the Indian cement industry is shown in Tables 4 and 5 respectively.

ISSUES AND CHALLENGES IN
INCREASING %TSR IN CEMENT INDUSTRY
The major issues faced by cement plants in enhancing AF utilization up to 25% TSR and above are:

Non homogeneity of MSW based RDF is one of the prominent issues faced by the industry. Although the quality of RDF has improved in recent years due to initiatives taken by the Government of India and local bodies. Some other alternatives to utilize MSW like MSW/RDF gasification to produce synthesis gas of consistent quality can be explored. Countries like China are already using gasification techniques to produce homogeneous synthesis gas.
High chloride content in the alternative fuel or raw material creates problems of coating/jamming. In order to achieve TSR of 25 per cent, cement plants will have to install kiln by-pass systems which needs substantial investment and adverse impact on unit cost of cement production. Handling of by-pass dust with high chlorine concentration will also be a critical task.
Lack of database on inventory of alternative fuels as well as district and sector wise break up is a major hurdle in sourcing the waste and eventually in increasing TSR.
Efficient shredding system is important to have proper output size of AF and avoid jamming issues. Pre-processing and handling of wastes bring the overall cost close to the price of conventional fuel in India and sometimes even higher in cement plants.
Plants need to upgrade their present testing laboratories which requires investment and skilled manpower. Upgradation of lab facilities includes sample preparation, testing of characterisation of hazardous waste like calorific value, proximate analysis, ultimate analysis, chlorine, fluorine and phosphorus, heavy metals, flash point, mixing compatibility, reactive sulphide, cyanide or halides.
Skill development of CCR operators to handle several types of waste in their calciners/kilns is also required.

NCB’s EXPERIENCE

NCB has vast experience of analytical studies, trial runs and system design for AFR utilization. Recently, NCB has carried out studies for feasibility of utilization of Tyre Derived Fuel (TDF) and system design to handle multi fuels for various cement plants in India. Recently, a detailed project report has been prepared to achieve 25 per cent TSR through RDF in kiln main burner for a cement plant in Southern India. Feasibility studies for liquid alternative fuels were also carried out in the recent past.
Presently, NCB is carrying out Project Management Consultancy project for Installation of Tyre Chips Storage, Feeding and Dosing System as well as enhancing AFR utilisation at cement plants. NCB has also undertaken a research project on design and development of Transfer Chute, which will be able to handle variation in characteristics of different kinds of solid wastes like RDF without any issues of chute jamming. NCB has also carried out studies on utilisation scenarios of 15 inorganic industrial wastes including lime sludge, wolstanite, leather sludge, jarosite, LD slag, red mud and marble slurry in cement manufacture as well as aggregate in concrete. NCB is also involved in preparing action plans for Phosphogypsum, FGD gypsum and C&D waste for the concerned ministries.
NCB is fully equipped to undertake any studies related to AFR utilisation owing to its vast experience coupled with state of art testing and evaluation facilities and has been providing its services to the industry in India and abroad.
Utilisation of AFR is a win-win situation for cement industry, society and the Government in India. Uncertainty in availability, higher cost of conventional fuels, and climate change are some of the key drivers to enhance AFR utilisation in India. Improving the quality of potential alternative fuels like RDF at minimal cost and making AF/RDF available to cement industry within their reach will make alternative fuels a lucrative option for cement industry. Waste management models adopted in Kerala and Indore, should be replicated in local bodies of other States. Promoting AFR usage will address the menace of the ever-growing problem of waste management, which poses serious environmental and ecological problems in the country.

About the author:
Dr. BN Mohapatra is the Director General of National Council for Cement and Building Materials (NCCBM). He is a Phd in Cement Mineral Chemistry, enriched with 13 years of research and development and over 22 years of industry experience with a strong academic relations with premier institutes. He is the chairman of the Cement Sectoral Committee of the Bureau of Energy Efficiency (BEE).

Images Sources: Google Images

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The primary high-power applications are fans and mills

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2 days ago

October 10, 2025

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

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

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

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

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

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

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

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

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We conduct regular internal energy audits

Published

2 days ago

October 10, 2025

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

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

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

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

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

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

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

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
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Published

2 days ago

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Enlight Metals has implemented technology-driven solutions to strengthen supply chain efficiency, ensuring consistent availability of construction materials for large-scale projects nationwide. Its contribution to the Navi Mumbai International Airport underscores the company’s growing role in supporting India’s infrastructure development initiatives.

This milestone reflects Enlight Metals’ ongoing engagement in delivering quality materials and timely services for major national projects, further cementing its position as a reliable partner in India’s infrastructure sector