Concrete

Themes of Sustainable Development

Published

2 years ago

October 19, 2023

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Asok Kr. Dikshit, Richa Mazumder, Sanjeev Kr. Chaturvedi and Lok Pratap Singh, National Council for Cement and Building Materials (NCCBM), discuss the various tenets that are critical for sustainable development of India’s cement sector, in the first piece of a
three-part series.

India is the second largest producer of cement in the world and accounts for approximately 8 per cent of global cement production (WBCSD 2019). The cement production in India will reach 1.360 billion tonnes annually by 2050 as estimated by the Cement Manufacturers Association (CMA) (WBCSD 2019). The Indian cement sector is the fifth-largest contributor to India’s economy and plays a fundamental role in the socio-economic growth of the nation as it directly provides essential support to the economy, employment and infrastructural development (Dasgupta and Das 2021).
As per the WBCSD report (2019), four themes that are most critical towards India’s sustainable development in the cement sector are: i) energy and climate; ii) people and communities; iii) circular economy; and iv) natural resource management (Fig 1). The Indian cement sector is already facing sustainability issues due to a number of factors like energy and water consumption, material and resource management, reduction in GHG emissions, waste management etc. The viable solutions are energy efficiency, green power generation, reducing reliance on depleting fossil fuels and using alternative fuels and raw materials, enabling water conservation, environment biodiversity protection, reduction in CO2 emissions, setting targets of sustainability for future, etc.
India has made the pledge to cut the CO2 emissions in the COP26 summit at Glasgow, UK, on the new climate action targets ‘Panchamrit’ as below: (i) A net zero target for India by the year 2070; (ii) installing non fossil fuel electricity of 500 GW by 2030; (iii) sourcing 50 per cent of energy requirement from renewables by 2030; (iv) reducing one billion tonnes of projected emission from now till 2030 and achieving carbon intensity reduction of 45 per cent over 2005 levels by 2030.
The first theme i.e., energy and climate include the impact opportunities in the form of low-carbon transportation and logistics, resilient and sustainable built environment and energy efficiency and use of clean energy. The second theme, people and communities include skills enhancement, enhance diversity and inclusiveness and transport safety. The third theme which is circular economy mostly concentrates on using waste as resource and the fourth theme is natural resource management in terms of limestone, fuel, water, biodiversity etc. In this paper, the R&D work carried out in NCB under these themes has been discussed in detail.

ENERGY AND CLIMATE
For sustainable cement production one of the key aspects is energy efficiency. To optimise processes and minimise energy consumption the cement sector has been actively investing in energy-efficient technologies. Cement production requires electrical energy at several stages, from crushing of raw materials over clinker production and cement grinding. In a cement plant, power for different operations is typically distributed as follows: 5 per cent for raw material extraction and blending, 24 per cent for raw material grinding, 6 per cent for raw material homogenisation, 22 per cent for clinker production, 38 per cent for cement production, 5 per cent for conveying, packing and loading (refer Fig 2).

As per Xu et al (2013) the savings from reduced use of coal are in general less cost effective compared to electricity savings, mainly due to much lower coal price. Morrow et al (2014) substantiates that for the Indian cement sector, the largest potential in electricity saving is from low temperature WHR power generation, which saves purchased electricity by generating electricity from the waste heat onsite and replacing a ball mill with a vertical roller mill in finish grinding. As per the CMA’s estimates, the WHR potential of the Indian cement sector is more than double the currently installed capacity (WBCSD 2019).
To capture and utilise excess heat, upgradation of kilns and equipment, preheaters, cogeneration, optimising production processes and waste heat recovery systems are being deployed in plants so that less energy is needed to produce cement. These help in significantly reducing the energy consumption and associated greenhouse gas emissions. This will not only lead to reducing greenhouse gas emissions but also contribute to the overall energy efficiency of the plant. By improving energy efficiency and using renewable energy sources, the industry can reduce its dependence on fossil fuels and lower its operating costs.
To address the barriers to energy efficiency within the industrial sector, the Indian Bureau of Energy Efficiency (BEE) has implemented the Performance, Achieve and Trade (PAT) scheme. It focuses on incentivising energy efficiency in the industrial sector which also includes the cement sector. The selected facilities or the Designated Consumers – DC represent the highest energy consumers within each of the selected sectors. They have their own assigned target for energy consumption (Marinelli 2022). This target is defined as a percentage reduction from the corresponding baseline and depends on the best per- forming plant within the sector on a proportional basis. Indian Bureau of Energy Efficiency would issue Energy Saving Certificates (ESCerts) to Designated Consumers on achievement of the targets established, based on respective savings. Designated Consumers that do not meet the targets will be required to either buy Energy Saving Certificates from entities that over achieve the targets and are issued excess certificates or pay penalties. The Energy Saving Certificates will be tradable and bankable in a market between the Designated Consumers, with their price being determined by the market. In its first cycle (2012–2015), PAT has mandated an energy reduction of 6.86 million metric tonnes of oil equivalent (Bhandari and Shrimali 2018).
It is evident that the cement industry is an energy intensive industry and is predominantly reliant on conventional fuels and responsible for 6 to 9 per cent of global CO2 emissions due to which it has a huge impact on the environment. It has been estimated that out of the total CO2 emission caused due to anthropogenic activity, approximately 5 per cent is caused by the cement sector worldwide. These emissions are released in the course of activities like clinker production, fuel consumption in cement kilns, use of coal in captive power plants and supply chain operations. Apart from CO2 other GreenHouse Gases (GHGs) like sulphur dioxide and nitrogen dioxide are also amplifying the problem of emissions due to its ill effects like ozone depletion, global warming, acid rain, various health issues, etc. By adopting green technologies and practices, the cement sector not only can reduce its GHG emission but also help in protecting the environment while doing cost optimisation.
Best Available Technology (BAT) is the way on which the Indian Cement industry has always relied to stay most efficient and sustainable. To achieve techno-economic viability and remain ahead, the cement sector is continuously performing R&D on green technology/products at scale. It is well noticeable that to reduce energy as well as process related greenhouse gases emission Indian cement sector has adopted decarbonisation levers as shown in Fig 3.

The study by IEA (2013) predominantly highlights the major levers for both direct and indirect reduction of emissions in the context of the Indian cement sector: (i) the use of fuels such as biomass and alternative materials like industrial or sorted municipal waste (e.g. waste tyres, sewage sludge, animal residue, waste oil, paper residue, plastic, textile), (ii) the substitution of limestone by other blending materials (e.g. slag or fly ash), (iii) the use of state-of-the-art technologies to increase thermal and electrical energy efficiency in cement plants, (iv) and the converting to waste heat recovery (WHR) technologies to convert thermal energy, otherwise lost in cement manufacture, to electricity.

People and Community
NCB has been imparting the required skills for technical manpower for the cement and construction sectors since 1972. NCB’s Continuing Education Services Centre (CCE) with its experienced faculty and modern infrastructural facilities like lecture halls, auditorium, computer centre, hostel, canteen etc., is imparting training on cement, concrete and construction technologies through its various Training Programmes (Short Term courses in Cement and Concrete Technology, Long Term, Simulator Based, Contact and Special Group Training Programmes) to technical professionals of all levels in various organisations in India and abroad. NCB organises customised Special Group Training Programmes giving emphasis on specific topics related to cement and concrete. The training programmes include class room lecture, presentations, laboratory demonstrations and site visits wherever necessary.
NCB organises international seminars on Cement, Concrete and Building Materials biennially since 1987. The 17th NCB International Seminar including the technical exhibition was successfully organised in December 2022 in the series of biennial seminars.

Circular Economy
Circular economy aims towards maximisation of efficiency of resources and minimisation of waste/by-products generated by different industries. Cement industries are actively exploring ways to incorporate industrial waste and by-products as raw materials or fuel substitutes in cement production. This will not only help in reducing the consumption of natural resources (limestone, gypsum etc.) but also diverts waste from landfills and reduces environmental impact. Circularity in cement and concrete industries can be clustered in three technological categories: CO2 emissions, materials and minerals and energy. The cement sector is well positioned to create closed loops or circularity for carbon dioxide, materials, and energy. This necessitates circular economies, which are based on the principles of eliminating waste, by-products, pollution and maximisation of resources. (Fig.4)
Circular Economy in cement sector helps in reducing GHG emissions in cement production because circular technologies follow the paradigm of three crucial decarbonisation strategies: redesign, reduce, and repurpose. (GCCA 2021) To start, addressing the total volume of materials needed or redesigning materials, buildings, and infrastructure can play a critical role. Second step is shifting from fossil to alternative fuels can help reduce emissions from materials. The last step i.e., repurposing, repairing, and refurbishing existing assets and infrastructure will help limit the need for new products by utilising captured carbon dioxide emissions and reinserting them into the value chain.1
Cement industry contribution to circular economy is primarily under two heads i.e. (i) Circular Supply Chain, (ii) Recovery and Recycling. Indian cement industry is playing a key role by enhancing the application of Renewable Energy for electrical power generation. The renewable energy installed capacity (wind and solar) in cement plants increased by more than 40 per cent to 276 MW from 2010 to 2017. Out of the total, 42 MW is solar power, while off-site wind installations account for 234 MW. A company has undertaken the target of switching over to renewable energy for 100 per cent of all electrical energy needs by 2030.2 Big players like UltraTech Cement are targeting 25 per cent share of their total power consumption by green energy technologies by 2021.3

References:

www.mckinsey.com
www.wbcsd.org
www.thehindubusinessline

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The primary high-power applications are fans and mills

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Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

Concrete

We conduct regular internal energy audits

Published

2 days ago

October 10, 2025

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Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

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