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Being Proactive about Sustainability

Hard-hitting facts such as scarcity and price hike of fossil fuels and challenges of waste management warn of difficult times ahead for the Indian cement industry, unless the players increase their efforts at increasing the capacity of Waste Heat Recovery Systems to meet their energy requirements.

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Waste heat recovery has long been the base standard for setting up cement manufacturing units. In China, a cement kiln will not get an official sign-off unless it has waste heat recovery systems. In Europe, any industry requiring large quantities of heat input for manufacturing must have waste heat recovery as a natural corollary, and sometimes its use could be extended to providing heat input to the neighbourhood and community for simple needs such as room and water heating systems.

The economics of Waste Heat Recovery Systems (WHRS) is preceded by sustainability concerns, as cement manufacturing in kilns continues to produce 8 per cent of the global greenhouse gas (GHG) emissions. The conversion of limestone to clinker is where the bulk of the heat energy is expended. However, this bulk of heat energy that is generated in six-stage preheater kilns by burning of any fossil fuel input actually gets wasted as shown in the pie-chart Fig 1, and only 58 per cent is used in the conversion process yielding clinker.

Theoretically 710 Kcal needs to be generated to convert 1 kg of clinker, out of which actual conversion process would need 410 Kcal, the rest ending up as losses, which can be recovered. In reality, the Indian cement industry average is 744 Kcal of heat input for producing 1 kg of clinker, which means the actual losses are even more than the theoretical possibility.

Out of the total generated heat there are some unavoidable losses, that include radiation loss, loss for evaporation of residual moisture in fine coal and raw meal and some part of heat going with clinker from cooler. The balance loss in pre-heater exhaust gases and the cooler exhaust gases are completely recoverable through WHRS.

Let us look at some statistics from the Indian cement industry. On an average, Indian cement plants require electrical power of 20 billion kWh per year. The coal needed for generating this much power accounts to 32 million tonnes per year. A significant portion of this power could be replaced by the WHRS that will use waste heat from the kilns to generate electricity.

In sustainability terms, this is equivalent to replacing a large component of the 32 million tonnes of coal to be otherwise burnt for producing electricity. WHRS are also very stable systems that operate on the Rankine cycle and it provides an avenue for utilising waste water from the process as well.

Balancing the investments

Let us now see the economics of putting up a captive power generating unit versus putting up a WHRS. The capital investment for WHRS is high at Rs 8 cr per MW going by the current costs, whereas the CPP units can come at Rs 4.5 cr per MW. However, the project Internal Rate of Return (IRR) would be very different as the cost of generation would be as low as Rs 0.40 per unit for the former while Rs 4.5 per unit for the latter, which given the current trajectory of fossil fuel prices is already under severe stress of upward correction. It is only the initial cost that continues to act as a deterrent for putting up a waste heat recovery unit.

The Indian cement industry must act responsibly and move quickly to put in investments that could raise the waste heat recovery installed capacity to cross the minimum threshold of 25 per cent of electricity consumption. That will still be far from the 20 billion KWhr of total electricity consumption by the industry.
The other area of concern is the price trajectory of fossil fuels, which would continue to move northwards. WHRS is one of the simpler ways of insulating the industry from the vagaries of future price increases.

Thus WHRS could be the natural hedge to fossil fuel price increases for a substantial portion of the electrical consumption. As matters stand today most WHRS would be the highest IRR projects that the industry as an ensemble can think of.

-Procyon Mukherjee

Concrete

India’s Cement Sector Cuts Energy Use, but Worker Safety Worsens

iFOREST finds efficiency gains alongside water and safety concerns

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India’s cement sector has improved its energy and carbon efficiency, but rising groundwater use in water-stressed regions and deteriorating worker safety remain significant concerns, according to a report by the International Forum for Environment, Sustainability & Technology (iFOREST). The findings also highlighted weak policy implementation and gaps in sustainability reporting.

India, the world’s second-largest cement producer, uses about 2.54 gigajoules of energy per tonne (GJ/t), below the global average of 2.88 GJ/t. However, renewable sources accounted for only 5.1 per cent of the sector’s energy mix, indicating continued dependence on conventional sources.

The report assessed 18 cement companies against 107 Business Responsibility and Sustainability Reporting indicators for FY24 and FY25. The companies covered 87 per cent of India’s cement production. Carbon emissions intensity declined from 0.58 to 0.57 tonnes of carbon dioxide per tonne, but total emissions increased 4 per cent to 224.3 mn t, equivalent to about 6 to 7 per cent of India’s overall emissions.

Overall water withdrawal declined 9.5 per cent during the study period, while withdrawals in water-stressed areas, mainly in Rajasthan, increased by more than 20 per cent. Groundwater’s share of withdrawals in these areas rose from 27 per cent to 38 per cent, raising concerns about the sector’s impact on vulnerable water resources.

The sector employs about 228,000 people, including 63 per cent contractual workers, 3.1 per cent women and 0.07 per cent persons with disabilities. Women in key managerial roles earned 26.8 per cent less than men, while median pay for women workers fell 11.1 per cent in FY25 as men’s pay increased. Worker injuries rose 36.5 per cent to 359, and fatalities increased from 17 to 22, with workers accounting for more than 90 per cent of deaths.

iFOREST recommended cement-specific reporting guidance, standardised metrics, mandatory production disclosure and third-party verification. It also called for environmental, social and governance policies to be integrated into business strategies and implemented more effectively on the ground.

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Concrete

Ambuja Cements Expects Volume Growth to Outpace Industry in H2

Ambuja Cements sees stronger trade and institutional demand in H2 FY27.

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Ambuja Cements expects its sales volumes to grow faster than the cement industry during the second half of fiscal year 2027, as it seeks a recovery in institutional demand after a weak first half. The Gautam Adani-owned company is aiming to rebuild volumes while protecting profitability.

The company reported a 90 per cent year-on-year decline in consolidated net profit attributable to owners of the parent to Rs. 1.93 bn for the quarter ended 30 September, from Rs. 17.74 bn a year earlier. The previous year’s profit included a reversal of income-tax provisions worth Rs. 16.97 bn. Revenue from operations rose marginally to Rs. 91.66 bn from Rs. 91.3 bn.

Trade volumes increased 8.6 per cent year-on-year in the September quarter, but weaker institutional sales left overall volumes broadly unchanged. Ambuja Cements expects both trade and institutional sales to turn positive in the third and fourth quarters. Trade sales are made through dealers and distributors, while institutional or business-to-business sales involve bulk supplies to infrastructure developers, government projects and real estate companies.

The company had earlier reduced institutional sales that did not generate adequate returns. It now plans to rebuild the business selectively, while continuing to prioritise trade sales and higher-value products. Trade accounted for 74 per cent of sales in the quarter, up six percentage points from a year earlier, while premium products increased to 37 per cent of trade sales from 35 per cent. Blended cement’s share rose to 82 per cent from 77 per cent.

Ambuja Cements commissioned 4.6 mn t of capacity during the quarter. Another 3.2 mn t at Bathinda in Punjab and Jodhpur has stabilised, with the facilities expected to ramp up in the second half. A further 2.4 mn t facility at Varkala in Bihar is scheduled for commissioning during the period. Higher fuel and logistics costs remain a challenge, while the company has realised a cement price increase of about Rs. 10 per bag in October and is targeting operating costs of Rs. 4,250 per t for the full year.

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Concrete

JK Lakshmi Cement Begins Rs 110 Billion Assam Plant Project

The 2.5 MTPA integrated cement plant is expected to be completed by FY2029.

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JK Lakshmi Cement has recently laid the foundation stone for Project Kamakshi, its first integrated cement manufacturing facility in Assam, marking its entry into Northeast India. The groundbreaking ceremony was held at Umrangso village in Dima Hasao district in the presence of Assam Chief Minister Himanta Biswa Sarma.
The project involves an investment of Rs 110 billion, including the mining lease, and will have an annual cement production capacity of 2.5 million tonnes, supported by a 1 million tonne clinkerisation unit. Scheduled for completion by FY2029, the facility is expected to generate employment for over 2,000 people while catering primarily to the growing Northeast market.
The integrated plant will feature dedicated railway sidings to facilitate efficient transportation of raw materials and finished cement, strengthening supply chain reliability and regional distribution.
Vinita Singhania, Chairperson and Managing Director, JK Lakshmi Cement, said, “”Project Kamakshi is the start of a long-term relationship with Assam and the wider North East. This is a region that is building fast, and it deserves quality cement made close to home. With this plant, we want to bring scale, jobs, and dependable supply to the region. At JK Lakshmi Cement, we believe that building a stronger India goes beyond infrastructure. It is also about growing together with the communities we serve.””
The investment aligns with the company’s strategy to expand into high-growth markets beyond its established presence in Northern, Western and Eastern India. The project is also expected to support regional economic development and infrastructure growth.
JK Lakshmi Cement aims to pursue its expansion plans while working towards its long-term target of achieving net-zero emissions by 2047.

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