Concrete

We practice zero waste mining as part of our sustainable process

Published

4 years ago

February 1, 2022

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Sushil Kumar Tiwari, Director Technical, Heidelberg Cement India, gives us an in-depth understanding of the limestone mining process and takes us through the innovations in technology, efforts taken to minimise environmental impact and enhance productivity in an exclusive interview.

Tell us about the mining and clinker production process at Heidelberg Cement.

The cement industry is a constantly operating industry and we need limestone for manufacturing of clinker that produces cement. More than 90 per cent of limestone is used for cement manufacturing and this process goes on around the year. This operation includes the development of the mines, drilling, blasting, excavation and finally crushing and transportation of limestone to the plant. Sometimes we make some extra stock to ensure the crushed and uncrushed limestones can be used in case of an emergency.

What is the impact of limestone mining on the environment?

Limestone mining as compared to other mining is the cleanest. It doesn’t generate any harmful chemicals that can contaminate the environment as compared to other minerals. Due to movement of dump or equipment or due to drilling, there is dust generation on the path but we keep on sprinkling water or add it in the injective system to suppress the dust emission.

We practice zero waste mining as part of our sustainable process. The waste generated during the mining (while removing the soil or hard rocks) is used for backfilling. When we move the limestone that is exposed through drilling and mining, a pit is formed, and we use the waste material from the mining process to fill back the pit.

We also make water reservoirs in our pits. In these reservoirs, we harvest water that is later used by the communities surrounding the area or by our organisation for plantation activities. We have put in a conscious effort to develop greenery with plantation activities by our organisation and that is how we also care for the environment.

Tell us about the equipment used for mining.

We use heavy earth moving equipment such as drill machines, excavators and dumpers. These are purchased from Indian suppliers.

What is the technology behind the mining of limestone for the cement making process?

Primarily, we mine with an open cast method. Typically, limestone is overlaid with waste rock and loose top soil. Mining is done in a mechanised way with the help of heavy earth moving equipment. First, we remove the top soil, and then we remove the waste rock by drilling and blasting. Finally the limestone is exposed. And that is how limestone is excavated. The exposed limestone rocks are huge in size, around 1.5 to 2 metres, which cannot be transported easily to the plant. We have installed crushers at the mine site, where we crush the limestone, reduce it to a smaller size of 75 mm and transport it.

How can productivity in mining be enhanced?

The deposit is a very heterogeneous deposit; it is not uniform. The challenge is to maintain the quality. In the cement process, when the fuel changes, the total raw mix changes, which means that we have to accordingly change the limestone quality, too. Thus, maintaining the quality is a major challenge.

For this we work with a software that helps us plan. Then we carry out the drilling. Post that we check the sample and accordingly blend it with various types of deposits of the limestone to get the desired quality. This is where we optimise the limestone processing and even the lower grade limestone is ut ilised. This prevents wastage of the natural resource.

What are the efforts taken by your company to make limestone mining a sustainable process?

Our organisation is a firm believer of sustainable operations. As mentioned earlier, we practice zero waste discharge mining. Whatever waste we generate, we use it for backfilling the pits, thereby ensuring there is no waste. We also ensure zero discharge water, because we use our pits for harvesting water, and this water is used by the community as well as for our own plantation. Pit refilling is very useful. Sometimes when we take the farmers land for mining, then we refill it and return it to the farmers. These lands are then used to crop fields and the farmers have given us feedback that they have seen an increase in the yield as compared to previous times.

On the machinery side, we hold proper maintenance. We use efficient machines and systems ensuring no generation of harmful smoke and emission. We have also installed pollution control equipment like crushers – in case there is a slide generation of dust, these pollution control equipment takes care of it.

How does your organisation address the issue of noise pollution while mining and grinding limestone?

Noise pollution happens when we do blasting or crushing. During blasting, we use non-electrical detonator, which has very low noise and we also use seismometer to monitor the noise and vibration to control it. During crushing, for the crushers we have enclosures so that less noise comes out and there also we provide personal protective equipment (PPE) like earplugs to the operators in case they have to be near the equipment. There is a slight noise when the drill is operated on hard rocks. For this, we provide sound proof cables to the operators, so they are not exposed to the noise pollution.

What are the technological innovations the industry must incorporate to make the mining process more efficient and less harmful for the environment?

In mines, all equipment is kept at certain distances and operators have to travel 3 -4 km to carry out the processes. An on-board monitoring system can be installed in the moving equipment, which can give all the required details of parameters and centralised interface with the communication monitor. This will help the operators carry out their processes more efficiently. Similarly, the latest drill machines provide an efficient water-dust separation system. And for reducing noise pollution, non-electric detonators can be used.

Apart from that the online quality of monitoring systems such as X-ray analyser, online belt analyser, cross-belt analyser, etc., which instantly gives an analysis of the quality should be used. This can help the operators to get information online and then they can blend the limestone properly before shifting it to the machines and get the desired quality. Such improvements can make the mining process more efficient and productive.

What is the future of mining for cement in India?

The per capita consumption of cement in India is something around 225 kg to 250 kg and the world average is more than double. So, there is a lot of scope in India for the cement market, and as mentioned before more than 90 per cent of limestone is used for cement manufacturing. So, there is a good future for limestone mining.

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Concrete

The primary high-power applications are fans and mills

Published

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.

Concrete

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.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

Concrete

Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

The airport is set to become Asia’s largest air connectivity hub.

Published

2 days ago

October 10, 2025

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Enlight Metals has supplied 3,200 metric tonne of steel for the newly inaugurated Navi Mumbai International Airport, marking a major contribution to one of India’s largest infrastructure projects and reinforcing the company’s commitment to supporting national development.

The Navi Mumbai International Airport, developed under a Public-Private Partnership led by the Adani Group, was inaugurated today by Prime Minister Narendra Modi. The airport is set to become Asia’s largest air connectivity hub, enhancing regional connectivity, boosting economic growth, and expanding trade opportunities. Prime Minister Modi described the project as a “glimpse of Viksit Bharat,” highlighting its transformative impact on infrastructure and development in the region.

“The supply of 3,200 metric tonne of steel for this key project aligns with our focus on supporting critical infrastructure development through reliable and timely metal sourcing. Enlight Metals is committed to enhancing transparency and efficiency in the steel supply chain, contributing to projects integral to India’s growth objectives,” said Vedant Goel, Director, Enlight Metals.

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