Concrete
How Energy-Efficient Are We?
As the cement sector moves towards a sustainable future, energy conservation takes centrestage. ICR looks at the efforts taken and challenges faced in achieving energy-efficient manufacturing processes
The power or energy generation in India is shared between national public utilities (around 40 per cent), state utilities and private companies (around 30 per cent each). This management sector of energy is split between several ministries: the Ministry of Power (MoP) for electricity and the coordination of energy conservation programmes; the Ministry of Petroleum and Natural Gas (MoPNG); the Ministry of Coal; and, finally, the Ministry of New and Renewable Energy (MNRE).
According to the India Energy Report, 2021 by Enerdata, the total energy consumption per capita remained around 0.7 tonne of oil equivalent (toe) in 2021, which was about half of the Asian average consumption. Electricity consumption per capita reached 970 kWh in 2021, about a third of the Asian average. Total energy consumption reached 927 Mtoe in 2021 (+4.7 per cent), which was still 1.2 per cent below the 2019 level. It had increased rapidly over 2010-2019 (4 per cent per year). Coal is the country›s top energy source with a share of 44 per cent in 2021, followed by oil (24 per cent) and biomass (22 per cent). Natural gas covered 6 per cent and primary electricity (hydro, nuclear, solar, and wind) was at 4 per cent.
The energy sector aims to achieve an ambitious target of 450 GW of solar and wind in 2030 as it has pledged to reach carbon neutrality by 2070. What makes this target seem achievable is that the renewable capacity of the Indian energy sector (excluding large hydro) overtook 100 GW in 2021. While three quarters of the energy requirement is still met by fossil fuels, the overall consumption of energy has gone down by 5 per cent in 2021.
Cement plays a vital role in building the economy of a nation. The sector is largely dominated by players with large manufacturing capacities, making the cement industry one of the largest in the country and one that is energy intensive.
The Perform Achieve and Trade (PAT) scheme of the Ministry of Power, Government of India has so far covered 126 numbers of cement plants in India targeting to reduce specific energy consumption since its inception from 2012 onwards.
The Bureau of Energy Efficiency states that based on the threshold defined, 85 numbers of cement plants were included as DCs and their cumulative energy consumption was 15.01 million MTOE in PAT Cycle-1. Based on their specific energy consumption level, these DCs were given SEC target reduction of an average 5.43 per cent resulting in 0.815 million TOE energy consumption reduction in absolute terms. The cement sector constituted 12.19 per cent of the overall energy saving target under PAT Cycle-1.
The total savings achieved by the cement sector covering 75 numbers of designated consumers in PAT Cycle-1 is 1.48 million MTOE which is 0.665 million MTOE in excess of the target. At present, the energy consumption of these cement units as designated consumers is 23.246 million tonnes of oil equivalent. The target given for them from PAT Cycle –II onwards is 0.94 million tonnes of oil equivalent.
The cement sector is highly energy-intensive, consuming approximately 7 per cent of global industrial energy consumption each year. The manufacturing process is carried out in stages. From grinding of raw material in raw mill grinders, to pyroprocessing and clinkerisation and then grinding of clinker in roller press mills, vertical mills, balls mills etc., to obtain the final product, cement. Each stage consumes a significant amount of energy and organisations are constantly looking at solutions, technology, automation and better equipment to optimise the quantum of energy consumed in the process.
Pictorial depiction of cement manufacturing process.
Given the significant impact that the manufacturing industry has on global sustainability and considering the increasing economic pressure introduced by a competitive market and the reduction of available energy resources, optimising the energy efficiency of production systems has become a primary concern.
According to the Technological Energy Efficiency Improvements in Cement Industries Report, 2021 published at MDPI, energy consumption in the cement industry is provided by electricity and fuels.
Over 90 per cent of fuels used are consumed in the production of clinker. Electric energy, on the other hand, is used for about 39 per cent for the finishing process, for around 28 per cent for both processing the raw materials and burning the clinker, and for less than 5 per cent for other operations.
“An area where energy is majorly consumed is the grinding stage of cement manufacturing. Here is where there is a large scope of reduction of the same. The industry has worked upon the same and come up with solutions to make that happen. At one point of time, cement grinding used to take up to 50 units to 60 units of power. With the new, energy efficient mills we are able to grind clinker while using 20 units to 25 units of energy and this is a major benefit that the industry has been able to derive of the vertical roller mills or the pre-pressed grinding mills,” says Jamshed Cooper, Managing Director, HeidelbergCement India Ltd. and Zuari Cement Ltd.
“With the use of EFR and alternative fuels also the industry can save on energy. These are not directly energy efficient. Yes, the quantum of heat generation requirement for the clinkerisation process will be the same, but that can be substituted with alternative sources. Also, recycling the waste heat with the Waste Heat Recovery (WHR) unit is also a great way to save energy and use it for further processes,” he adds.
Automation and Technology
The world is moving towards digitalisation. From switching on your home lights to a manufacturing unit, the controls are moving from human to digital across the board. Technological advancement in the area of cement manufacturing has led to a lot of advancement in its functioning and has led towards achieving the goal of energy conservation by reducing its usage in the operations.
“The role of automation in the cement industry is very high. If we look back, the cement plants in the later part of 1970 or early 1980s used to have local substations or local control systems. But today with automation, plants are operated and controlled from a single location (CCR). The control room operator can see the entire plant operation from a single monitor. Functions like start or stop, alarms, process interlocks etc., are major benefits of automation that a cement plant experiences” says Kiran Patil, Managing Director, Wonder Cement.
“Furthermore, industries have used robotics in the plant, and Wonder Cement is one of the cement plants to have robotics for quality control. In this digital world, we cannot be behind and so, we are working towards the implementation of digitalisation in operation and maintenance to get better efficiency” he adds.
The cement industry is realising the importance of process control and automation to achieve their goals of energy efficiency and for a trouble free continuous operation leading to improved productivity at optimal energy levels. Automation also takes care of optimal operation in mining and hence longer life of mines and consistent desired cement quality is assured. Instrumentation and control logic can also be used effectively for taking care of human and equipment safety and to monitor equipment health and implement preventive maintenance in the manufacturing facility.
Organisations are continuously analysing and seeking advanced technical equipment that help streamline their processes and align them with the goals of achieving a similar or higher productivity level with a lower amount of energy input. This not only saves on their costs and enhances profitability for the organisation but also helps achieve their sustainability targets by reducing direct or indirect emissions caused by the cement manufacturing unit’s energy requirement.
While the input of energy is optimised by technology and automation, audits support the need of constant monitoring of the performance of the units individually as well as on a group level. A dedicated professional, certified in the area of energy consumption is stationed at every unit with the key goal of monitoring everyday consumption. Audits play a key role in achieving this goal.
Energy management bodies like Centre for Mining, Environment, Plant Engineering and Operations (CME), under the National Council for Cement and Building Materials (NCCBM), run programmes that offer technical services related to Energy Audits and WHR feasibility studies to cement plants of India.
Their services include energy audit studies in cement plants including captive power plants, management, monitoring and target setting, heat and gas balance studies, identification of potential for thermal and electrical energy savings and recommendations for remedial measures and Techno economic feasibility studies for waste heat recovery system (WHRS) in cement plants.
These audits are conducted by means of site visits and data collection, preliminary data analysis and detailed data analysis. Post which a detailed report and recommendations on economic viability is presented to the organisation in audit.
Hitesh Sukhwal, Dy General Manager – Environment, Udaipur Cement Works, says, “Our company is covered under PAT scheme. We are an ISO 50001 certified company under energy management. We have a dedicated resource under the designation of ‘energy manager,’ who is qualified to keep a check on the energy consumption of the plant and continuously optimise the same.” A periodic energy audit (once in three years) as per EC Act is done. Half yearly internal audits and external audits once a year are performed under energy management. Moreover, power monitoring reports are discussed on an everyday basis during the desktop production meeting” he adds.
Many cement producers have lowered energy costs up to 20 per cent by adopting a holistic approach to industrial energy management. The Petroleum Conservation Research Association lists some key areas where cement manufacturing units can work upon for having a more energy efficient plant:
Use improved insulating bricks/blocks in kilns and preheaters.Use energy efficient equipment like high efficiency fans, improved ball mill internals etc.
- Recover waste heat from the preheater and use it for cogeneration of power.
- Prevent idle running of equipment by providing The interlocking arrangement and operating with PLC system. Generate daily reports on idle running of equipment, also in terms of monetary losses.
- Optimise the fuel mix and raw mix by including alternative fuels and supplementary cementitious materials.
- Establish an efficient management information system for identifying various important parameters for efficient operation of the equipment and taking timely remedial measures.
- Regularly monitor and calibrate flow metres.
Carry out regular audits.
Other areas that it focuses on apart from the main manufacturing process are the various overheads and other operations where energy is consumed in smaller quantities but when clubbed together can be a large value of consumption.
“The cement industry affects climate change as it contributes 7 per cent to 8 per cent to the global carbon pool. To curtail this, stakeholders that include members of the United Nations Principal of Responsible Investment and such have begun to reach out to cement industry players across the globe to come up with solutions to cut down on CO2 emissions to see investments flow in.” says Dr Arvind Bodhankar, Executive Director, ESG & CRO, Dalmia Bharat Limited.
“Dalmia Bharat are leading the pack with commitments that encourage the circular economy. Global visionaries such as our honourable Prime Minister, Narendra Modi, have also stated that India will become a carbon-neutral country by 2070 and committed to 520 GW of renewable energy by 2030.
This has helped ease new policies as far as renewable energy is concerned and enabled sector leaders such as us to stay the course to meet our goal of becoming carbon negative by 2040,” he adds.
Alternative sources of energy like solar power plants and Waste Heat Recovery (WHR) are also a key in achieving energy efficiency and sustainability goals for every cement organisation. UltraTech has imbibed Sustainable Development Goals (SDGs) as a business objective and is working towards reducing its energy consumption and carbon emissions. It was one of the first in the Indian cement industry to embrace the technology of WHRS. Waste heat recovery has proved to be an inexpensive energy source in addition to moderating the carbon footprint.
This has enhanced energy security (accounting for 20 per cent of power needs) for the company. UltraTech Cement has an aggregate capacity of about 59 MW in waste heat recovery systems.
In a report published at SAUR Energy International, May 2022, a major issue in the cement industry is the very high particulate matter (PM) emissions from production processes. The pollutants commonly emitted by cement plants are dust or particulate matter, NOx, SOx, carbon oxides and methane and others. Energy consumption is also an issue, with the approximate required per tonne of cement, roughly two thirds of which is used for particle size reduction.
About 65 per cent of the total electrical energy used in a cement plant is utilised for the grinding of coal, raw materials and clinker.
Some of the key players are adaption to alternative sources of energy. Ultratech Cement has a power generation capacity of 156 MW through waste heat recovery systems. The waste heat recovery capacity is expected to reach 302 MW by FY2024. In the area of renewable energy, the firm professes plans to invest in solar power generation for captive usage.
This is in addition to existing contract capacity of 148 MW renewable energy plants. UltraTech is committed to increase the share of green energy in its electricity mix to 34 per cent by 2024 from the current level of 13 per cent.
Utilising its waste heat recovery plants, and solar and wind power plants, Shree Cement boasts a renewable energy portfolio of over 234 MW. Consequently, during FY 2019-20, 45 per cent of the total energy needs of the company was fulfilled by renewable energy. The firm has a 62 kW Solar PV Power Plant at Beawar.
In 2021, Ambuja Cement and ACC announced investments in Waste Heat Recovery Systems (WHRS) across six sites in India to reduce 5.61 lakhs tons of CO2 emissions per year. ACC committed to reducing scope 1 GHG emissions by 21.3 per cent per tonne of cementitious material and scope 2 GHG emissions by 21.3 per cent per tonne of cementitious material by 2030.
Dalmia Bharat’s carbon footprint is 40 per cent lower than the global average for a cement company which places it at the top, globally in the race of decarbonising the cement sector. Dalmia Cement has been progressively producing cement with ‘greener’ alternatives.
Energy is key to the cement sector, however, the time has come to re-look at the conventional sources and to tap into the more readily available alternative sources of energy. With advancement of technology and automation across the globe, there are various equipment and machinery that make these alternative sources more effective and affordable for the cement manufacturers. It is a conscious choice that the industry shall have to make to safeguard the environment for the future generations to come in terms of availability of energy sources and the quality of surroundings they leave behind.
Fuller Technologies (erstwhile FLSmidth Cement) presents a case study of Shree Cement’s Nawalgarh Plant.
Shree Cement achieved a new milestone and broke a world record in December 2023 when it started its new Nawalgarh plant in Rajasthan. The plant boasts both India’s largest OK® Mill and the world’s largest pyro line, which is rated at 11,500 tpd but achieving at more than 13 500 tpd. It put Shree Cement on track to exceed their target of 80 million tpa cement capacity in India by 2028. Shree Cement chose to partner with Fuller Technologies (then FLSmidth Cement) for the project, since the two groups share such similar values and Fuller offers a portfolio of solutions geared towards reducing the cement industry’s environmental impact.
Cement plays a vital role in India’s development, supporting the country’s ambitions for long-term economic growth. As urbanisation accelerates, infrastructure projects like Smart Cities, Bharat Mala, and metro rail developments are driving steady demand for cement. With per capita consumption increasing however historically lower than global averages, India’s evolving urban landscape and infrastructure needs are expected to significantly boost cement demand in the years ahead.
Shree Cement is well positioned to support India’s growth and is playing a pivotal role in the country’s expansive infrastructure development. The Nawalgarh plant will supply the wider region of north India with cement and clinker, feeding 3/4 grinding plants in the area.
The new Nawalgarh plant
With easy access to a rich supply of raw materials, Nawalgarh was an obvious choice for Shree Cement’s newest cement plant. With abundant reserves of limestone, the region also boasts strategic access to cement markets in northern India.
Though water scarcity is an issue in the region, the plant was committed to using modern, water-efficient technologies, ensuring minimal water consumption and waste. For example, the OK Mill™ can be operated without water, making it an optimal solution in regions where conserving water is particularly important.
Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, says, “We have significantly invested in alternative fuels – including hazardous waste, municipal solid waste (RDF) and biomass – to reduce fossil fuel reliance. Our new state-of-the-art solid waste feeding system for MSW is operational at one site and is being replicated at others, enhancing alternative fuel use and improving thermal substitution in kilns.” The plant also follows Shree Cement’s principal of reducing clinker content in blended cements, which aims to reduce the carbon footprint of Shree Cement products.
The world’s biggest pyro line
The project kicked off with the issuance of the Letter of Intent (LOI) on 15th September 2021 for the Raw Mill. As per the LOI, equipment was expected to be delivered within 8-13 months from the contract’s effective date. The first lot of the raw mill arrived on-site in May 2022, with the major consignment – the Grinding Table – delivered in February 2023. Civil work for the Raw Mill and its building began in May 2022 and was completed by January 2023. Fabrication was wrapped up by June 2023 and erection commenced in January 2023, concluding by September 2023. The final commissioning was successfully completed on 14th December 2023, marking the operational start of the mill.
The world’s largest clinker cooler
The Cross-Bar® Cooler at Nawalgarh is the largest in the world, with a grate area of 325 m2 and a throughput guaranteed at 11 500 tpd, though it has been running at around 13 500 tpd since commissioning. Offering both high throughput and highly stable operation, the cooler also contributes to Shree Cement’s sustainability goals thanks to its hot air recirculation, which generates about 8 MW through the waste heat recovery system.
“With a Cross-Bar Cooler, the bigger you go, the greater your efficiency gains,” says Gowrishankar Ramachandran, Senior Product Specialist, Fuller Technologies. “We were not concerned about the size of the project – we knew we could achieve the performance guarantees with ease. Start-up was paced to get the full pyro system up and running smoothly, starting at 5000 tpd and quickly ramping up to full capacity and then beyond. The combination of features ensures smooth operation whatever’s going on in the kiln and preheater, meaning the cooler is unphased by the introduction of new alternative fuels or variations in throughput.”
Featuring patented ABC Inlet technology, which ensures no build-up in the cooler, Shree Cement also benefit from the cooler’s Heavy Duty Roller Breaker (HRB) and Mechanical Flow Regulators (MFRs) to improve reliability and uptime.
• The ABC™ Inlet uses a patented in-grate design that pushes compressed air up through the grates, blasting agglomerations. Pressure sensors detect when build-up is starting to occur and the automated blast control system reacts accordingly, increasing blast frequency to disperse the clinker and prevent further buildup.
• The HRB can handle clinker boulders up to 1.5 m without blockages. It features a series of transport and crushing rollers that allow right-sized materials to pass through and crush larger materials down to a pre-set size. Its low speed contributes to a long wear life of 3-5 years, while the rollout design enables easy maintenance.
• MFRs control airflow across the whole clinker bed – irrespective of clinker bed height, particle size, distribution or temperature. This optimises heat recuperation and air distribution, reducing both fuel costs and the number of cooling
fans required.
This cooler is a ventless system, with hot air being recirculated back into the cooler instead of bringing in ambient air. This improves the WHR temperature and boosts the power generated through the system. With waste heat recovery from the preheater in addition to the cooler, the total power generated is around 15-18 MW.
Though the operation has the potential for high dust pickup, the cooler casings were enlarged so that dust pickup is less than 4 m/s. This reduces dust to the tertiary air duct and helps reduce the environmental impact of the cooler operation, as well as the wear and safety issues that come with dust settling on equipment and on the local environment.
The cooler is part of the world’s largest pyro system, with a guaranteed capacity of 11 500 tpd (with an achieved production of 13 695 tpd),
that includes:
• Four string pre-heater:
o Cyclone stage I: 7784 mm, Top (HR+)
o Cyclone stage II: 7984 mm
o Cyclone stage III-VI: 8180 mm with Low Nox Calciner
• Dia 6.0m x 88m long & 3 support kiln with forged tyres
• JETFLEX® 2.0 kiln burner (type standard
and plus)
• 2 x 750 tph PFISTER® FRW Rotor Weighfeeder 5.22/13 for Kiln feed and 6 x PFISTER® Smart Linear Feeder
The Fuller® Low NOx Calciner prevents the build-up of raw meal on the calciner walls and maintains a hot core for excellent combustion and NOx reduction. With a design based on extensive research, field tests and CFD modelling, the Low NOx calciner is capable of burning almost any fuel type, giving Shree Cement full flexibility to switch between coal, petcoke and alternative fuels. The calciner has the added advantage of reducing NOx while also minimising the need for ammonia injection, creating a cleaner, greener, more cost-effective process.
The JETFLEX burner was chosen for its high degree of fuel flexibility, further aiding Shree’s green ambitions. The burner can burn a mix of coal, petcoke, oil, natural gas and alternative fuels while maintaining an optimal flame shape. The flame formation is controlled by separate systems for axial and swirl air, ensuring fast ignition and stable flame formation with a shorter and more intense flame. That reduces volatility in the kiln and gives the Nawalgarh plant greater efficiency throughout the pyroprocess.
India’s biggest OK Mill
The OK Mill 66.6 selected as the raw mill for this plant is the largest OK raw mill in the country with a guaranteed capacity of 1070 tph, though it has been running at 1080 tph since commissioning. The OK Mill was selected for its proven history of efficiency, low water usage and ease of maintenance. The rollers can be swung out for repair or hard-facing so that operation can continue with the remaining rollers, enabling continuous productivity. The OK-R-66-6 VRM for this plant includes a RARM-1300 separator, known for the simplicity of its design, which reduces wear and maintenance, lowers differential pressure and reduces mill fan power (and thus operational costs) while still providing efficient separation.
This is not the only OK Mill at the Nawalgarh plant. An OK 66-6 finish mill with ROKSH-1100 classifier is employed for cement grinding at 360 tph. In addition, the plant has an ATOX® 32.5 coal mill with RAKM-32.5 classifier for coal grinding, guaranteed at 46 tph but running at 56 tph.
Energy efficiency and saving
“Energy conservation remains a top priority for us, driving innovations from shop-floor experiments to major capital investments,” explains Maheshwari. “These efforts have reduced carbon emissions and production costs. Over 55 per cent of our energy needs across the company are met through green energy sources, including solar and wind power alongside our Waste Heat Recovery Systems. Combined, these systems produce in excess of 520 MW. We consistently exceed PAT Cycle targets and have been honoured as ‘Best Performer’ for the highest number of energy-saving certificates in both PAT Cycle I and II by the Bureau of Energy Efficiency.”
A digital native
Shree Cement is an advocate of the benefits and necessity of digitalisation to improve cement plant performance and efficiency. A few years ago, the company rolled out ECS/PlantDataManagement across 16 plants and 24 lines in a huge digital upgrade to drive efficiency and increase productivity. The new Nawalgarh plant won’t require a digital transformation, however, because it has been built as a digital native.
It is equipped with ECS/PlantDataManagement, which delivers all plant and process data in accessible and practical forms to plant managers and operators, maintenance teams, analysts, and decision-makers, giving them the insights necessary to optimise production lines, minimise equipment downtime, improve productivity and reduce environmental impact. ECS/PlantDataManagement includes important tools like UptimeGo, the downtime analysis solution, and SiteConnect, the mobile app that allows plant operators and managers to view real-time plant data anytime, anywhere from a mobile device.
The plant is also utilising advanced automation solutions across the plant, including in the laboratory where Fuller is enabling clinker substitution while ensuring optimal cement quality. QCX/RoboLab® is a high-tech robotics solution for automated sample preparation, analysis, and automated quality assurance (QA) and quality control (QC) procedures. This advanced automation system ensures fast, accurate, and safe analysis with as few operators as possible. It receives and co-ordinates samples from the QCX®/AutoSampling system and can take on challenging laboratory tasks to ensure optimal quality control in the face of variations in alternative fuels and changes to the cement mix. Again, this was a choice Shree Cement made to ensure the plant has the flexibility to deliver lower carbon cements without compromising on final product quality.
Conclusion
In December 2024, Shree Cement celebrated the first anniversary of the Nawalgarh plant. The plant’s rapid rise as a leading player in cement production aligns with the global position of this impressive company, whose strategic initiatives in alternative fuels, emissions reduction and water management have earned industry-wide recognition, including the acclaimed position of ‘industry mover’ in the construction materials category of the S&P Global Sustainability Yearbook 2025.
Shree Cement’s focus on blended cement production successfully lowered natural resource consumption and CO2 emissions by 7.2 million tonnes in FY23-24, with 73.52 per cent of total production comprising blended cement with an average clinker-to-cement ratio of 64.66 per cent.
“Partnering with a solutions provider like Fuller enables us to turn our sustainability ambitions into reality,” says Maheshwari. “Together we are shaping the future of our industry and our region, and we are very proud of the contributions we are making towards a more sustainable cement industry and greater economic prosperity.”
