Connect with us

Concrete

Looking Beyond the Low Hanging Fruits

Published

on

Shares

With the Net Zero targets looming in the near future and an imminent problem of emissions to contend with, the Indian cement manufacturing sector should no longer be satisfied with doing the bare minimum. Looking at innovative solutions, breakthrough technologies, automation and artificial intelligence, and most importantly, a change in mindset, is the need of the hour.

There is no denying the fact that cement being the second most consumed material after water in the world in terms of quantity, and by virtue of its inherent conversion process from limestone to clinker, the amount of CO2 emission from cement alone (7 per cent of all emissions) is one quarter of all industry emissions put together. Even in dollar terms the maximum CO2 per dollar of revenue industry-wide shows cement taking the top spot at 6.9 kg of CO2 per dollar.
The process of cement making has majorly two areas – raw material resources and clinker and cement manufacturing, where the emission needs to be segregated into its constituent elements, both from the point of view of energy consumption and also in terms of CO2 emissions. While two-thirds of the emissions stem from the calcination process, which is where the bulk of the thermal energy is consumed, the raw material extraction to feed generates negligible amounts of emissions and the cement grinding from clinker and logistics makes the bulk of the remaining emissions. The total emissions of 925 kg per tonne of cement production leaves a staggering 4 billion tonnes of CO2 generation each year, as the world produces 4.2 billion tonnes of cement annually.


The pathways through which the industry has progressed so far can be seen in the following areas:

  • Energy Efficiency
  • Alternative Fuel
  • Clinker Substitutes
  • New Technologies
  • Alternative Building Materials

If one goes into the analysis of each of these levers that the cement industry is currently using, the first three have remained the low hanging fruits where most of the attention and energy had been diverted to. These top three levers have so far fetched about 25 per cent of the CO2 emission reduction possibility into 2050, with energy efficiency showing a possibility of 7.2 per cent, alternative fuel a possibility of 10.5 per cent and clinker substitution 7 per cent. However, the investments needed for these and the abatement cost per tonne of CO2 would look very different for each. For example, alternative fuel would still need disposal cost, carbon capture and storage as well and the investments for these would make this category the highest in terms of abatement cost. The following table gives this as follows among all the levers:

So far, the cement industry has focused on the low hanging fruits, mostly clinker substitution after working on efficiency improvement levers, where the abatement costs were negative, giving economic benefits to the cement makers. Driven by the country’s landfill laws and pollution control norms, some of the advanced countries have outright rejected use of coal and PetCoke in cement kilns, replacing that with alternative fuel and biomass. However, these have to go through the abatement cost of Carbon Capture and Storage, which has been so far very high. Let us go through each category and see what is the current stage of development of these areas of focus.
Efficiency Improvement: The last step change for cement kiln technology was in the case of dry process replacing the wet process, thereafter the recent advancement has happened in the use of electrical energy instead of thermal energy for the kiln conversion process. This has been put to commercial use but till we use renewable energy in kilns, this does not give any advantage in terms of overall gain in emission. The replacement cost of thermal to electrical could be very high as well, so the future electrification of kilns, depends on use of renewables that must be part of a stable grid power, which raises many actions to be taken.
Clinker Substitution: Maximum gains have happened so far in reduction of emission by adopting various means to replace clinker with fly ash, slag etc., but the future could actually have very little of this available as generation of electricity moves to the renewable mode and the steel companies adopt more of the green technology that would generate far less waste eventually from the process.
Alternative Fuel: The availability of alternative fuels depends largely on the development of local supply chains that must wade through a number of constituencies like the local municipalities for the municipal wastes and the development of logistics systems have a lot to be desired. The only hope remains the use of biomass, which is the highest growing segment. The investments here include not only the platforms but also avenues of de-chlorination, etc.
Carbon Capture Use and Storage (CCUS): This method isolates and collects CO2 from industrial emissions and either recycles it for further industrial use or safely stores it underground. Once captured, a wide variety of potential uses for CO2 could be possible, such as in the production of glass, plastics, or synthetic fuels. Though carbon-capture technologies do exist commercially, they are utilised in very few plants—one example being natural-gas plants. Therefore, the progress of extensive decarbonisation will not only depend on the economic viability of storing and sequestering the carbon but also on the availability of CO2 marketplaces, through which the captured CO2 can be sold.
Carbon-cured Cement: This technology injects CO2 captured during cement production to accelerate the curing process and ‘lock in’ CO2 in the end product. Current low-carbon cement technologies can sequester up to 5 per cent of CO2, with the potential of 30 per cent. In fact, 60 million tonnes of CO2 per year are projected to be stored via carbon-cured concrete in 2050.
Alternative Building Materials: In the years to come, alternative building materials could shift demand away from cement. To date, cross-laminated timber (CLT) has attracted the most attention. Made by gluing wooden panels and boards together, CLT is an adequately fire-resistant building material that can reach large dimensions. Its application has recently increased and includes projects in Canada, Japan, and Sweden. Assuming a 10 per cent replacement of concrete—and considering the CO2 captured in the wood has been abated—would reduce the overall cement footprint by 25 per cent, as even more
CO2 is captured than avoided by reducing the cement production.
Recycled Concrete: Use of recycled concrete and demolition waste is the new development especially in Europe with the sources of limestone becoming limited in the future.
The potential reduction of 50 per cent of the CO2 emissions by 2050 depends on the progress of carbon capture and storage systems and technologies, where we have a few start-ups who have come up with very different processes. For example, one start-up uses a lower proportion of limestone in its cement, which results in fewer process and fuel emissions; this company’s process also locks in additional CO2, which is added before the concrete cures. Adding CO2 makes the concrete stronger and reduces the amount of cement needed. Carbon-cured concrete could also use CO2 captured during cement production. Today’s methods could sequester up to 5 per cent of the CO2 produced during production, but newer technologies could sequester 25 to 30 per cent. Products such as carbon-cured concrete, positioned differently, could earn a ‘green premium,’ potentially giving companies an edge among environmentally conscious buyers and greater pricing power.
The Indian cement industry must move steadily to these new innovations, after making the maximum gains from the low hanging fruits. Innovation remains the key word and investments in innovation, including the mindset, for cement is the first step in this journey.

-Procyon Mukherjee

Concrete

Lower sales realization impacts margins for cement makers in Q2 FY25

The industry encountered several challenges, including an extended monsoon season.

Published

on

By

Shares



Major cement manufacturers reported a decline in margins for the September quarter, primarily due to lower prices, which led to decreased sales realization.

With the exception of three leading cement producers—UltraTech Cement, Ambuja Cement, and Dalmia Bharat—smaller companies, including Nuvoco Vistas Corp, JK Cement, Birla Corporation, and Heidelberg Cement, experienced a drop in both topline and sales volume during the second quarter of the current fiscal year.

The industry encountered several challenges, including an extended monsoon season, flooding, and a slow recovery in government demand, all contributing to weak overall demand.

Despite these challenges, power, fuel, and other costs largely remained stable across the industry. The all-India average cement price was approximately Rs 348 per 50 kg bag in June 2024, which represented an 11 per cent year-on-year decrease to Rs 330 per bag in September, although it saw a month-on-month increase of 2 per cent.

In the first half of FY25, cement prices declined by 10 per cent year-on-year, settling at Rs 330 per bag. This decline was notable compared to the previous year’s average prices of Rs 365 per bag and Rs 375 per bag in FY23, as reported by Icra.

Leading cement manufacturer UltraTech reported a capacity utilization rate of 68 per cent, with a 3 per cent growth in volume. However, its sales realization for grey cement declined by 8.4 per cent year-on-year and 2.9 per cent quarter-on-quarter during the July-September period.

In response to a query regarding cement prices during the earnings call, UltraTech’s CFO Atul Daga indicated that there had been an improvement in prices from August to September and noted that prices remained steady from September to October. He mentioned that the prices had risen from Rs 347 in August to approximately Rs 354 currently.

Continue Reading

Concrete

Steel companies face Rs 89,000 crore inventory crisis

Steel firms grapple with Rs 89,000 crore stockpile amid import surge.

Published

on

By

Shares



Steel companies in India are facing a significant challenge as they contend with an inventory crisis valued at approximately Rs 89,000 crore. This situation has arisen due to a notable increase in steel imports, which has put pressure on domestic producers struggling to maintain sales in a competitive market.

The surge in imports has been fueled by various factors, including fluctuations in global steel prices and increased production capacities in exporting countries. As a result, domestic steel manufacturers have found it difficult to compete, leading to rising stock levels of unsold products. This inventory buildup has forced several companies to reassess their production strategies and pricing models.

The financial impact of this inventory crisis is profound, affecting cash flows and profitability for many steel firms. With domestic demand remaining volatile, the pressure to reduce prices has increased, further complicating the situation for manufacturers who are already grappling with elevated production costs.

Industry experts are urging policymakers to consider measures that can support local steel producers, such as imposing tariffs on imports or enhancing trade regulations. This would help to protect the domestic market and ensure that Indian steel companies can compete more effectively.

As the steel sector navigates these challenges, stakeholders are closely monitoring the situation, hoping for a turnaround that can stabilize the market and restore confidence among investors. The current dynamics emphasize the need for a robust strategy to bolster domestic production and mitigate the risks associated with excessive imports.

Continue Reading

Concrete

JSW and POSCO collaborate for steel plant

JSW Group and POSCO ink MoU for steel project.

Published

on

By

Shares



JSW Group has signed a Memorandum of Understanding (MoU) with South Korea’s POSCO Group to develop an integrated steel plant in India. This collaboration aims to enhance India’s steel production capacity and contribute to the country’s growing manufacturing sector.

The agreement was formalized during a recent meeting between executives from both companies, highlighting their commitment to sustainable development and technological innovation in the steel industry. The planned facility will incorporate advanced manufacturing processes and adhere to environmentally friendly practices, aligning with global standards for sustainability.

JSW Group, a leader in the Indian steel industry, has expressed confidence that the joint venture with POSCO will bolster its position in the market and accelerate growth. The project is expected to attract significant investments, generating thousands of jobs in the region and contributing to local economies.

As India aims to boost its steel output to meet domestic demand and support infrastructure projects, this partnership signifies a crucial step toward achieving those goals. Both companies are committed to leveraging their expertise to develop a state-of-the-art facility that will produce high-quality steel products while minimizing environmental impact.

This initiative also reflects the increasing collaboration between Indian and international firms to enhance industrial capabilities and foster economic growth. The MoU sets the stage for a promising future in the Indian steel sector, emphasizing innovation and sustainability as key drivers of success.

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds