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Sustainable Mining for the Future

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ICR presents a case for responsible reporting across the mining supply chain.

The importance of mining, in times of sustainability reporting, is rising in stature. The rise of mining output is not waning but growing and the share of construction mineral ore in all of this still remains close to 50% of the entire extractive output. 

It is estimated that the global combined extractive output in mining is going to grow to 167gt in 2060, from the 2019 statistics of 92 gt. Out of this 27% is biomass, 15% is fossil fuel, 9% is metal ores and the balance is non-metallic minerals, bulk of which goes to the construction industry. While sustainability considerations would be driving most of the future growth, most notably, metals will be needed for electric storage batteries (eg. for electric cars), which require aluminium, cobalt, iron, lead, lithium, manganese and nickel but also for other relevant technologies, including those used for the production of wind turbines and solar panels; far greater amounts of metals are needed for clean energy production than the traditional energy production from fossil fuels. Thus the growth in metals for sustainability will offset the drop in extraction that would stem from growth in recycling. 

An overview of the mining sector

Mining for non-metallic minerals, from where the construction industry sources all its inputs, perhaps falls under the ASM (artisanal and small-scale mining), which has still remained labour intensive and suffers from safety issues all across, the developed world and developing, all have the similar challenges to grapple with. Efforts to increase automation, mechanisation and digitisation also come with the fair share of demands from the local community, which can hardly be neglected. While Large Scale Mining (LSM) is moving towards mechanisation and automation with minimum labour resources, the focus is increasingly shifting towards partnerships on supply chains that connect local procurement partners and the community at large to the external markets. 

One of the significant developments has been the shift towards battery-electrification of mobile equipment in the mines to the complete automation of all mining equipment with Net zero targets in focus. There are man-less mines in existence already where underground operations are being orchestrated through battery-electric equipment remotely connected through control systems. The partnerships between mining companies and the mining equipment OEMs is ensuring a smooth transition in this area that will take the use of fossil fuels in mines to a negligible proportion (mostly as consumables) in the near future. This however calls for a skills inventory crossover, that would need larger hand holding with the local government and other institutions as well as the local communities.

Sustainability in mining

The goals of sustainable development in mining would include transparency as a key theme between a large pool of actors that constitute and connect the upstream to the downstream supply chain partners (supplier, trader, smelter refiner, component producer, contract manufacturer, end user, intermediaries, agents and transporters). This would also entail collaboration with governments and across the supply chain to support a circular economy to minimise inputs to waste from the mining process and to increase the reuse, recycling and repurposing of raw materials and products to improve sustainable consumption. The traceability systems also ensure that the level of information that is shared and disclosed along the value chain. They illustrate the chain of custody, which is the sequence of stages and custodians the product is transferred to through the supply chain.

The transparency of reporting across the entire supply chain is at the core of this and this has two parts:

  • Minimise resource use and waste (use of water, energy, land and chemicals and minimise production of effluent, waste and chemicals) and also purpose waste rock
  • Incorporate life cycle thinking (extend responsible sourcing to all suppliers and collaborate to connect the consumer with sustainable raw materials).

India-centric big picture

India as a country has progressed well in SDG Reporting and Sustainable Development in the mining sector that accounts for 2.5% of the country’s GDP. Many of the key companies of the sector are SOEs. India is abundant in natural mineral resources and the country is one of the world’s main producers of iron ore and bauxite. India is the third largest producer of coal, behind the US and China. In construction related extractive minerals, India is the world’s second largest producer. Section 135 of India’s Companies Act on CSR and Regulation for large public companies to produce Business Responsibility Reports, makes it imperative for Large Mining companies (both metallic and non-metallic extractive ones) to be part of the SDG reporting, that cover diverse range of sustainability areas including GHG gas emissions, energy use, stakeholder engagement and labour and human rights. 

In 2011, the Indian Ministry of Corporate Affairs issued the National Voluntary Guidelines on the Social, Environmental and Economic Responsibilities of Business (NVGs). Building on the NVGs, a new guidance entitled the National Guidelines on Responsible Business Conduct (NGRBC) was released in 2018. The new guidance integrates the ‘Respect’ pillar of the United Nations Guiding Principles and the UN Sustainable Development Goals. 

Following other countries, India is also on the path of developing sustainability guidelines for the end-to-end supply chains in the mining sector. This will only ensure stakeholder participation for safety and sustainability in all four stages: profiling, reservation, exploration and departure. For future growth in mining, that will entail coal, iron-ore, bauxite and limestone extraction as the top four mining categories, it is an absolute necessity that focus on SDG reporting is carried through beyond the voluntary reporting mandate to encompass the aspirations of the communities and investors who would be the major beneficiaries of such initiatives. Without their blessings, the growth in these sectors would be mired by distrust and lack of transparency, which remains to be one of the dampeners for sustainable growth in mining. 

Procyon Mukherjee

Concrete

PROMECON introduces infrared-based tertiary air measurement system for cement kilns

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The new solution promisescontinuous, real-time tertiary air flow measurement in cement plant operations.

PROMECON GmbH has launched the McON IR Compact, an infrared-based measuring system designed to deliver continuous, real-time tertiary air flow measurement in cement plant operations. The system addresses the longstanding process control challenge of accurate tertiary air monitoring under extreme kiln conditions. It uses patented infrared time-of-flight measurement technology that operates without calibration or maintenance intervention.

Precise tertiary air measurement is a critical requirement for stable rotary kiln operation. The McON IR Compact is engineered to function reliably at temperatures up to 1,200°C and in the presence of abrasive clinker dust. Its vector-based digital measurement architecture ensures that readings remain unaffected by swirl, dust deposits or drift. Due to these conditions conventional measurement systems in pyroprocess environments are often compromised.

The system is fully non-intrusive and requires no K-factors, recalibration or periodic readjustment, enabling years of uninterrupted operation. This design directly supports plant availability and reduces the maintenance overhead typically associated with process instrumentation in high-temperature zones.

PROMECON has deployed the McON IR Compact at multiple cement facilities, including Warta Cement in Poland. Plant operators report that the system has aided in identifying blockages, optimising purging cycles for gas burners, and supplying accurate flow data for AI-based process optimisation programmes. The practical outcomes include more stable kiln operation, improved process control, and earlier detection of process disturbances.

On the energy side, real-time tertiary air data enables reduction in induced draft fan load and helps flatten process oscillations across the pyroprocess. This translates to lower fuel and energy consumption, fewer unplanned shutdowns, and a measurable reduction in NOx peaks. This directly reflects on the downstream cost implications for plants operating SCR or SNCR systems for emissions compliance.

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Adani Group To Set Up Cement Factory In Madhya Pradesh

Chief Minister Mohan Yadav inaugurates plant in Guna

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Adani Group (Adani) will set up a cement factory in Madhya Pradesh, the chief minister of the state announced after an inauguration ceremony in Guna. The chief minister, Mohan Yadav, described the occasion as a historic day for the state and said the project will strengthen industrial capacity. The event was presented as a milestone in efforts to broaden manufacturing and attract large-scale investment. Officials said the facility will add to regional production capability and support related industries.

State officials outlined that the plant will enhance supply chains for construction and infrastructure projects across the region. The company will bring technical expertise and logistical resources to the site, with government agencies coordinating approvals and land allocation. Local suppliers and service providers will benefit from increased demand, and training initiatives will be developed to build workforce readiness. Officials indicated that the project complements broader plans to modernise industrial clusters in the state.

The state administration said it has facilitated clearances and infrastructure support to accelerate implementation. Local officials have coordinated with the company to ensure connectivity and utilities are in place ahead of commissioning. The chief minister emphasised that collaboration between private investors and the government aims to create sustainable economic growth. Community outreach programmes will address local concerns and establish grievance mechanisms as construction proceeds.

Officials said the inauguration in Guna marks a new phase in the state industrial story and will serve as a reference for future investments. Administrators noted that close monitoring and periodic reviews will guide timely execution and adherence to environmental and safety norms. The government affirmed its commitment to facilitating responsible industrial expansion while ensuring benefits reach local communities. Stakeholders will continue discussions on supply chain integration and long term maintenance arrangements.

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Concrete

Railways Boost Cement Movement by 170 Per Cent and Eye Fly Ash

New container wagons cut costs and speed turnaround

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Indian Railways has recorded a 170 per cent rise in cement movement in the last four months after reforms launched in November to promote rail based bulk cement logistics. The Union Railway Minister, Ashwini Vaishnaw, reviewed the container sector reforms and their implementation and described the shift as improving plant to market efficiency. The reforms introduced customised bulk cement tank containers and a bulk cement terminal policy to support multimodal handling and door to door solutions.

The new system has simplified loading and unloading by enabling mechanised operations and by reducing package losses compared with bagged cement transport. Since cement can move directly from manufacturing centres to consumption centres in standardised tank containers compatible with Ready Mix Concrete machines, two stages of handling have been eliminated and material loss has been reduced. The standard shape of the containers facilitates faster turnaround and lowers logistics costs for suppliers and builders.

The improved freight turnaround is helping to lower the delivered cost of cement, which can ease pressure on housing costs for the poor and middle class and support affordable construction. The reform is said to be environment friendly as dust generation during material transfer has fallen and fuel consumption and emissions have reduced due to modal shift from road to rail. The Make in India tank containers are designed for seamless movement between train and trailer and to enable efficient door to door movement while cutting congestion on roads.

Building on the cement reforms, officials were urged to tap the fly ash transportation market to convert industrial waste into national wealth. The minister noted that nearly 300 million metric tonnes (mn t) of fly ash is produced in the country while only about 13 million t is transported by rail and asked officials to substantially increase Railways share to serve brick kilns, cement industries and construction sites. Wider utilisation of fly ash should reduce pollution, promote recycling and lower construction material costs while strengthening sustainable freight movement across infrastructure sectors.

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