Concrete

We are geared up for adoption of carbon reducing technologies

Published

3 years ago

February 14, 2023

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Manish Toshniwal, Vice President and Mines Head, JK Cement, talks about the various aspects of sustainable mining.

Tell us about the volume of mined raw materials and fuels consumed by your organisation annually.
Limestone is a major raw material for cement manufacturing mined from our captive limestone mine, with consumption of over 10.0 million tonnes per annum, and the fuel (high speed diesel) being consumed at the rate of 0.42 litres per tonne of limestone.

What are the conveyor channels used to carry the mined materials to the plants?
Limestone is majorly conveyed through OverLand Belt Conveyor (OLBC) from the mine crusher to the plant. OLBC stretched up to a distance of 7.5 km crossing highway and railway tracks, and covered completely with rain hood along with acoustic hood provided near habitant areas to minimise dust and noise pollution, and reducing carbon footprints.

Mining leads to depletion of natural resources. Is there any action taken to combat the same?
The availability of natural resources is limited and mining leads to depletion of natural resources. It is quite important that on the one hand we meet the needs of the present, and on the other, we conserve natural resources to meet future needs. We have taken various actions for mineral conservation as below:

Detailed exploration was carried out in G1 Category under UNFC Classification for reassessment of the deposit. It is well supported in optimum utilisation and blending of different grades of minerals from depth. It resulted in enhancement of proven reserves and in turn the mine life.
The data obtained from exploration was converted into a geological database in SURPAC software to determine the extent of the ore deposit and its geo-statistical characteristics.
The total volume of reserves is estimated by developing a solid block model comprising all bore hole data. Mine planning is carried out by dividing the ore body into suitable blocks and sub blocks. Suitable ultimate pit depth selected from which mine pit is designed. With this, the different grades of mineral blended effectively for optimum utilisation and consumption of low-grade minerals. The sub grade minerals, which are lower than cutoff grade minerals, are consumed by adding high-grade limestone (sweetener) procured from nearby areas for their effective utilisation, leading to increase in mine life.
In a few block areas, clay was found interbedded with limestone, which needed to be separated to improve the quality of limestone. A screen reject separator installed with a crusher, which separates out the clay through a reject belt conveying system, and only the clean limestone is transported to the plant. It results in more quantity of low-grade utilisation and consumption from mine.
Real time production data is monitored continuously including quality, quantity and productivity. Cross-belt analyser installed at conveying belt, which is linked with Automated XRF analyser.

How does your organisation address the issue of dust pollution and noise pollution while mining and grinding limestone?
The key effective measures taken for combating the dust and noise pollution while mining and crushing of limestone are as below:

A high-pressure jet is installed in water tankers to wet the blasted muck before loading of limestone, to minimise the fugitive emissions during loading.

Automated stationary water sprinklers installed along haul roads and cold dry fogging in crushing units were installed, which proved to be effective in fugitive dust control. Moreover, it resulted in reduction of water consumption to half per square metre of haul road as compared to mobile water sprinkling.

The limestone from the crusher is transported to the plant by closed conveyor belts to control dust generation. The conveyor system stretched from the crusher to the plant covering a distance of 7.5 km crossing highway and railway lines.

The drill machines are automated and equipped with wet drilling systems. The green belt developed all along the periphery of the lease boundary or ultimate pit limit boundary and on both sides of the roads.

There are continuous on-line ambient air quality monitoring stations (CAAQMS) installed at various locations. All the on-line monitoring stations are connected with SPCB site for capturing real time data. The drone survey of mining lease is carried out as per provisions of MCDR.

What is the technology behind mining of limestone for the cement process?
What is its impact on the productivity of the organisation?
Mine planning and scheduling carried out using SURPAC block modelling for developing scientific and systematic formation of benches in the ore body.
To enhance equipment and workforce productivity, higher capacity equipment deployed in mine. Fleet Management System (FMS) implemented in mine. Fleet management system upgraded subsequently to maintain real time health monitoring system to attain high reliability, real time quality monitoring system, real time productivity monitoring systems to capture, monitor and analyse various KPI’s.
Controlled blasting techniques are in practice at the mine. Nonel initiation system is used to limit the fly rocks and ground Vibrations. The haul roads and ramps are designed to always maintain the shortest lead. The haul roads were maintained with road graders and compactors for attaining shorter cycle time of equipment used for transportation of limestone from mine to crusher.

Tell us about the efforts taken by your organisation to make limestone mining a sustainable process?
Mining can become more sustainable by developing and integrating practices that ensure cost effective mining, reduce the environmental impacts of mining operations, improve socio economic development of people, and comply with statutory obligations. The various measures adopted by us to make limestone mining a sustainable process are:

Higher capacity equipment is deployed in the mines that are highly productive and cost effective. A highly skilled workforce is deployed to attain higher output per man shift. It has resulted in reduction of mining costs.
Conveying of limestone through OLBC from the mine crusher to the plant, stretching up to 7.5 km crossing highway and railway lines, has resulted in improved productivity, cost effective mining while mitigating environmental hazards like carbon emissions and dust generation associated with road transportation.
Massive plantations have been taken up for conservation of flora and fauna in the mines.
So far, the plantation drive in mines involves planting 4,07,294 saplings covering an area of 158.07 hectares.
The development of bio diversity park, to create safe and secure habitat for local flora and fauna to improve the ecological footprint of the mine, spreads over an area of 50.0 hectares. The park will be developed in three phases with a total of 50,000 saplings and is targeted to be complete by FY 2024-25. In the first phase, planting of saplings of a variety of species in consultation with DFO to the tune of 25,000 is under process.
The mining equipment is loaded with safety features as required by DGMS. A Safety Management plan is prepared and implemented in the mine through which the workers’ participation in safety management is promoted. Both internal and third-party authorities conduct safety audits.
By installing solar panels and fulfilling power consumption of the mines through solar energy, the mine is able to reduce its carbon footprint to a considerable extent.
Vocational training is imparted on various H&S aspects. The mine has a well equipped Group VTC with internal and external trainers. On the job training is imparted through OEM trainers for skill upgradation and capacity building.
Water harvesting measures are implemented such as construction of storm water drains and ponds within the mine area for storage of rainwater, artificial ground water aquifer recharge structures to improve the groundwater level and collection of rainwater in mine-pits. Our rainwater harvesting activities are beneficial to the mine as well as to the community surrounding mines. Water ponds constructed in the surrounding villages and water infrastructures have been created to supply water from the mine to these ponds for agriculture, livestock etc.
The mine has also undertaken well appreciated CSR activities, which are aligned with the pressing needs of the nation – public health and sanitation, education, water infrastructure to provide water for irrigation and drinking, infrastructure development etc. We have built schools, colleges, training institutes, hospitals, temples and other social infrastructure as a part of our community intervention.

Tell us about the government compliances that your organisation strictly adheres to.
The mining activities are carried out as per the Mining Plan approved by Indian Bureau of Mines under the Mineral Conservation and Development Rules (MCDR) amended as on date, and all the provisions of MCDR are complied with. The technical aspects are complied as per provisions of the Metalliferous Mining Regulations (MMR), to ensure safe operations in the mine. The welfare of mine employees as per provisions of Mines Rules and Mines Act amended as on date under DGMS directives and guidelines are complied with. The records, registers and returns are regularly submitted to concerned authorities as prescribed within the timelines. The conditions of Environment Clearances, CTE and CTO are complied with, as per provisions of the Air and Water Act amended as on date and as per MOEF/SPCB directives and guidelines.

What are your plans to make mining a sustainable process for the cement business?
To achieve climate change targets, we are geared up for adoption of carbon reducing technologies like use of alternative fuels such as LNG, hydrogen powered base mining equipment, integrating electrification with automation and digital systems as well as the use of renewable energy, recycling and reuse for minimising the amount of waste produced.

–Kanika Mathur

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Concrete

Cement Margins to Erode as Energy Costs Rise: CRISIL

CRISIL warns of 150–200 bps margin decline this fiscal

Published

1 day ago

April 17, 2026

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Crisil Intelligence (CRISIL) released a report on April 13, 2026, indicating Indian cement manufacturers face margin erosion of 150–200 basis points this fiscal, reducing operating margins to between 16 per cent and 18 per cent. The firm noted that this represents a reversal from the prior year when margins expanded by 260–280 basis points. The analysis attributed the shift to rising input costs despite steady demand.

The report said that power and fuel, which typically account for about 26–28 per cent of production cost, are expected to increase by 10–12 per cent year on year, driven by higher prices for crude oil, petroleum coke and thermal coal. Brent crude was assessed as likely to trade between $82 and $87 per barrel, and industrial diesel prices rose by 25 per cent in March, raising logistics and procurement expenses. Such increases have therefore heightened cost pressures across the value chain.

Producers plan to raise selling prices by one–three per cent, which would put the average retail price of a cement bag at around Rs355–Rs360, according to the report. CRISIL’s director Sehul Bhatt was cited as saying that these hikes will at best offset a four–six per cent rise in production costs, leaving little room for higher profitability. The report added that intense competition and continual capacity additions constrain the extent to which firms can pass on costs.

Demand conditions remain supportive, with CRISIL projecting volume growth of six point five–seven point five per cent this fiscal on the back of accelerated infrastructure projects and steady industrial and commercial consumption. Nonetheless, the pace of recovery is sensitive to developments in West Asia, the speed of government infrastructure execution and monsoon performance. The agency noted that any further escalation in energy prices or delays in project execution would widen margin pressures.

Overall, the sector will continue to grow but with compressed margins as energy cost inflation outpaces the limited ability to raise prices. Investors and policymakers will therefore monitor both input cost trajectories and policy measures aimed at alleviating supply chain constraints.

Concrete

Haver & Boecker Niagara to showcase solutions at Hillhead

Focus on screening tech, diagnostics and quarrying efficiency

Published

1 day ago

April 17, 2026

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Haver & Boecker Niagara will showcase its mineral processing technologies at Hillhead 2026, scheduled from June 23–25 in Buxton, UK.

At Stand PA3, the company will present its end-to-end solutions including screeners, screen media and advanced diagnostics, with a focus on improving efficiency, uptime and throughput for aggregates producers.

Highlighting its screen media portfolio, the company will feature Ty-Wire media with hybrid design offering up to 80 per cent more open area, alongside FLEX-MAT® solutions designed to enhance wear life and throughput while reducing blinding and clogging.

The showcase will also include its PULSE Diagnostics suite, comprising vibration analysis, condition monitoring and impact testing, aimed at assessing equipment health and preventing unplanned downtime.

Commenting on the event, Martin Loughran, Sales Manager, UK & Ireland, said, “Hillhead presents an excellent opportunity for us to demonstrate how we deliver innovative technologies along with long-term service and technical support.”

The company will also highlight its Niagara F-Class vibrating screen, designed to reduce structural vibration and improve operational reliability under demanding conditions.

The participation reflects Haver & Boecker Niagara’s focus on supporting quarrying operations with advanced screening solutions and predictive maintenance technologies.

Concrete

Siyaram Recycling Secures Rs 21.03 mn Order From Anurag Impex

Domestic Fixed Cost Contract To Be Executed Within Seven Days

Published

3 days ago

April 15, 2026

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Siyaram Recycling Industries Limited (Siyaram Recycling) has informed the stock exchange that it has secured a purchase order for brass scrap honey from Anurag Impex. The company submitted the intimation on 10 April 2026 from Jamnagar and requested the filing be taken on record. The filing was made under the provisions of regulation 30 of the SEBI listing regulations and accompanying circular. The intimation referenced the SEBI circular dated 13 July 2023 and included an annexure detailing the terms.

The order carries a fixed cost value of Rs 21.03 million (mn) and is to be executed domestically within seven days. The contract was described as a fixed cost engagement and the customer was identified as Anurag Impex. The announcement specified that the order size contributes a short term consideration to the company. Owing to the brief execution window, logistics and dispatch were expected to be prioritised.

The filing clarified that neither the promoter group nor group companies have any interest in the purchaser and that the transaction does not constitute a related party transaction. Details were provided in an annexure and the document was signed by the managing director, Bhavesh Ramgopal Maheshwari. The company referenced compliance with SEBI disclosure requirements in its notification. The notice indicated that no related party approvals were required owing to the nature of the transaction.

The order is expected to provide a modest near term revenue inflow and to be processed within the stated execution window given the nature of the product and the fixed cost terms. Management indicated the contract will be executed in accordance with standard operational procedures and accounting recognition at completion. The development signals continuing demand in the secondary metals market for brass scrap.