Concrete

AFR has become integral to our fuel mix

Published

6 months ago

March 19, 2024

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Sanjay Joshi, Chief Projects and Manufacturing Officer, Nuvoco Vistas Corp, discusses the integration of alternative fuels and raw materials (AFR) into cement manufacturing.

Tell us about the alternative fuels and raw materials (AFR) used by your organisation in cement manufacturing.
The AFR usage can decrease environmental impacts, lower consumption of fossil fuels to reduce the economic impact to the cement industry. Fast depleting natural resources like limestone, increased cost of conventional fuels like pet coke and coal, have become a matter of great concern for cement industry all over the world. The high temperature and adequate retention time makes cement kilns most suitable for disposing of alternative fuels. Utilisation of AFR in the cement industry, helps in reduction of the carbon footprint, substituting consumption of fossil fuels and reducing its associated higher cost.
Nuvoco has been a pioneer in this regard, utilising substantial quantities of non-recyclable hazardous wastes, plastics, tire wastes, surplus biomass and RDF as alternative fuels since 2014. To support this initiative, Nuvoco has established comprehensive AFR storage, handling, and feeding facilities in all its plants. Additionally, Nuvoco incorporates alternative raw materials into its cement and clinker raw mix, sourced from industrial and mineral wastes in metallurgy, petrochemicals, chemicals, paper and pulp sectors. These materials include fly ash, slag, metallurgical slags, phosphogypsum and red mud, contributing to a reduced carbon footprint and decreased reliance on fossil fuels and natural conventional raw material.

What factors do you consider when selecting alternative fuels and raw materials?
The selection of AFR for usage in a cement kiln involves a thorough assessment of their potential impacts on clinker and cement manufacturing operations, product quality and the environment. Several important factors must be considered before finalising the choice of AFR.
Among these, key parameters include alkali, sulphur, chloride, trace element content, heat (calorific) value and moisture content. Regular reviews of the acceptance criteria are conducted in accordance with local regulations to ensure ongoing alignment with environmental standards and manufacturing requirements. This comprehensive evaluation
process ensures that the selected AFR optimally contributes to the cement kiln process while
minimising adverse effects on both the product and the surrounding environment.

What is the impact created on the environment by use of AFR in your organisation?
Concerning the co-processing of AFR, the cement industry is actively working towards reducing greenhouse gas emissions and preserving natural resources by incorporating a variety of AFRs in the cement kiln.
To ensure responsible handling, plants have implemented essential infrastructure, including AF storage sheds with impermeable flooring, leachate collection pits, firefighting arrangements and deodorisers, effectively mitigating the environmental impacts of AFR usage. The handling and feeding systems for alternative fuels are centrally operated from the Control Room (CCR), minimising manual interventions throughout the process. Rigorous monitoring and systematic storage procedures are in place for all wastes intended for co-processing in the cement kiln, ensuring a continuous and well-managed approach to environmental sustainability.

Have you faced any challenges or barriers when using AFR in cement production, and if so, how have you overcome them?
Certainly, when incorporating alternative fuels and raw materials, numerous challenges emerge throughout the process. These challenges span from the storage areas, where issues related to non-uniform quality of alternative fuel are encountered, to the pyro system, which has to adapt to process changes and blending during alternative fuel feeding.
In essence, the primary challenges faced in the utilisation of AFR can be succinctly summarised
as follows:

Non-homogeneity of the waste: Wastes received by cement plants have varying chemical compositions, which initially result in operational disturbances.
Coating, build-ups and refractory issues: The high content of chlorine and alkalis in hazardous solid waste combined with pet coke sulphur results in coating formation. Circulation of volatile salts increases and clogging arises in lower preheater cyclones and riser pipes.
Availability of odour control system at storage sites.
Wear and tear of equipment used for waste processing: AFR has different foreign materials like silt, glass, metal pieces so it makes heavy wear and tear of pre-processing equipment like shredder, trommel, belt conveyor, etc.
Inhouse testing laboratory facilities not being available to check the quality of received material.
CCR operators not being trained on operational parameters for alternative fuel usage.
All these issues have been analysed systematically, discussed with suppliers and plant original equipment manufacturers (OEM). Some modifications have been made in the feeding system to avoid operational issues. Process related improvements are executed after discussion with OEM, which results in smooth burning of alternative fuels in the system.

How do you see the use of AFR in cement production evolving in the future, and what role do you think your company will play in this process?
In the current landscape of fuel availability and cost considerations, AFR has become integral to our fuel mix. Government initiatives have played a leading role in raising awareness about AFR usage, resulting in a notable uptick. The proliferation of pre-processing facilities, coupled with in-depth research and consultations with cement industries facilitated by catalyst bodies like Confederation of Indian Industry (CII) and Cement Manufacturers Association (CMA), has positioned co-processing as the preferred choice. This approach not only reduces production costs but also contributes significantly to resource conservation on a broader scale.
At Nuvoco Cement, we have embraced co-processing of AFR in all our integrated cement
plants. Our commitment to sustainability is evident through the adoption of new technologies aimed
at increasing the utilisation of AFR. We remain dedicated to continuously exploring and implementing innovative technologies across all our plants, demonstrating our proactive stance towards environmental responsibility.

–Kanika Mathur

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Concrete

Indian cement makers to invest $ 14.3 bn

The bulk of this growth will come from the top-three cement producers–Ultratech, Ambuja and Shree Cement

Published

2 days ago

September 6, 2024

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Indian cement manufacturers are set to invest approximately USD 14.3 billion over the next four years to increase capacity by 25 %. This move, driven by rising domestic demand, is expected to add an additional 160-170 million tons of cement production annually. The industry’s expansion will be predominantly funded through internal accruals, with minimal reliance on debt. The expansion is spurred by government’s massive infrastructure push, with plans to invest USD 1.7 trillion in infrastructure projects by 2030. According to S&P Global Ratings, the demand for cement in India is projected to grow at a compounded annual growth rate (CAGR) of 7 % over the next four years, aligning with the planned capacity additions.
The bulk of this growth will come from the top-three cement producers–Ultratech, Ambuja and Shree Cement, which will account for over 70 % of the country’s total capacity increase. This expansion equates to an annual capital expenditure of close to Rs 300 billion, which will be more than double the average annual capex of the past decade. The leading cement companies, which produce 70 % of India’s total cement output, are in a strong financial position to support this expansion. Rising cement prices have bolstered their balance sheets, allowing them to reduce debt significantly while maintaining robust cash flows.

Concrete

SEBI Places JSW Cement’s Rs.4,000 Cr IPO on Hold

SEBI halts JSW Cement’s ?4,000 crore IPO.

Published

4 days ago

September 4, 2024

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The Securities and Exchange Board of India (SEBI) has placed the proposed ?4,000 crore Initial Public Offering (IPO) of JSW Cement on hold, citing regulatory concerns. This development comes as a significant pause in the cement manufacturer’s plans to raise capital through the public markets, a move that was expected to bolster its expansion and growth strategies in the competitive construction sector.

IPO Overview: JSW Cement, a key player in the Indian cement industry, had announced its intentions to launch a ?4,000 crore IPO. The offering was aimed at raising funds to support the company’s ongoing expansion projects, reduce debt, and improve operational efficiency.

SEBI’s Decision: SEBI, the regulatory body overseeing the capital markets in India, has decided to withhold its approval for the IPO. The decision was made after careful scrutiny of the draft red herring prospectus (DRHP) submitted by JSW Cement. While specific reasons for the hold have not been disclosed, it is understood that SEBI has sought further clarifications on certain aspects of the filing.

Impact on JSW Cement: The postponement of the IPO is likely to impact JSW Cement’s financial planning and expansion initiatives. The company had intended to use the proceeds from the IPO to fund new projects, including the construction of additional cement plants, modernization of existing facilities, and investments in sustainable practices.

Market Reactions: The decision by SEBI has led to a cautious response in the market. Investors and market analysts are closely monitoring the situation, as the delay could affect investor sentiment towards the company and its future fundraising efforts. The construction sector, which heavily relies on capital-intensive projects, may also be impacted by this development.

SEBI’s Concerns: SEBI’s decision to put the IPO on hold highlights the regulatory body’s commitment to ensuring transparency and investor protection in the capital markets. The regulator may be seeking additional information regarding JSW Cement’s financials, corporate governance practices, or other disclosures to ensure that the IPO meets all necessary requirements.

JSW Cement’s Response: JSW Cement is reportedly working closely with SEBI to address the concerns raised and to provide the required clarifications. The company remains optimistic about receiving the necessary approvals in due course and proceeding with the IPO as planned.

Industry Context: The Indian cement industry has seen significant activity in recent years, with companies looking to expand their capacities to meet growing demand. IPOs have become a popular route for raising capital, allowing companies to fund expansion and reduce debt. However, the regulatory environment remains stringent, with SEBI playing a crucial role in maintaining market integrity.

Future Prospects: While the IPO is currently on hold, JSW Cement’s long-term growth prospects remain robust, driven by its strong market position and ongoing investments in capacity expansion. The delay in the IPO may prompt the company to explore alternative fundraising options, such as debt financing or private equity, to meet its immediate capital needs.

Regulatory Environment: SEBI’s decision underscores the importance of regulatory compliance in the IPO process. Companies looking to tap the capital markets must ensure that their disclosures are thorough and transparent, meeting all regulatory standards to gain investor confidence.

Conclusion: The hold placed by SEBI on JSW Cement’s ?4,000 crore IPO is a reminder of the challenges that companies face in navigating the regulatory landscape. While this may delay the company’s fundraising plans, it also provides an opportunity to strengthen its disclosures and align with regulatory expectations, ultimately benefiting both the company and its investors.

JSW Cement now faces the task of addressing SEBI’s concerns to move forward with its IPO, a crucial step in its growth trajectory within the Indian cement industry.

Concrete

Smart Building Choices: Enhancing Life with Green Practices

Published

5 days ago

September 3, 2024

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As urban areas expand and cities continue to grow, the need for sustainable building practices becomes more pressing than ever. Today, more people recognize the importance of creating urban environments that coexist harmoniously with nature. The question we must ask is: Can we build cities that not only meet our needs but also embrace the natural world?

The Rise of Sustainable Building

The concept of sustainable building is not new, but its importance has dramatically increased in recent years. With over 5.3 billion square feet of green building space in India alone, the shift towards eco-friendly construction is clear. This transition isn’t just a trend—it’s a necessary evolution as we confront the environmental challenges posed by rapid urbanization.

Reducing Our Carbon Footprint

Buildings are significant contributors to carbon emissions, accounting for nearly 40% of global emissions due to construction activities and the use of energy-intensive materials like steel and concrete. In India, the construction sector is responsible for 30% of the nation’s carbon emissions and generates an astounding 530 million tons of waste annually. This waste could fill 200,000 Olympic-sized swimming pools, highlighting the urgent need for more sustainable practices.

However, sustainable building practices are helping to reduce these impacts. For instance, green buildings in India are already reducing energy consumption by up to 40%, with a significant portion of their energy coming from renewable sources. By 2030, these buildings are projected to decrease carbon emissions by 33-35%. This is a testament to the power of sustainable construction methods and the positive impact they can have on our environment.

Building Smarter with Sustainable Materials

The choice of materials plays a crucial role in sustainable construction. Traditional materials like steel and concrete are energy-intensive and have a high environmental impact. For example, producing new steel emits over 2.5 tons of CO2 per ton of steel. However, using recycled steel can reduce these emissions by up to 60%. Similarly, conventional concrete production emits about 1 ton of CO2 for every ton of cement produced. By incorporating eco-friendly alternatives like geopolymer concrete, we can cut down these emissions by up to 35%.

The Power of Local Materials

Another key aspect of sustainable construction is the use of locally sourced materials. Materials like rammed earth not only reduce transportation emissions but also offer excellent thermal insulation, reducing the need for additional heating and cooling. Rammed earth construction can lower embodied energy by up to 30% compared to conventional materials. This practice not only supports local economies but also minimizes the environmental impact of transporting materials over long distances.

Innovative Approaches to Green Building

Around the world, innovative sustainable building projects showcase the potential of eco-friendly construction. In India, several projects have set remarkable benchmarks in sustainability by integrating cutting-edge technologies, adopting eco-friendly practices, and prioritizing environmental conservation.

The construction industry is one of the largest contributors to environmental degradation. Yet, it also holds immense potential to drive positive change. By adopting sustainable building practices, we can reduce the environmental impact of construction and create healthier, more livable urban environments.

Integrating renewable energy sources into building designs is a key component of sustainable construction. Solar panels, wind turbines, and other renewable energy technologies can significantly reduce a building’s reliance on fossil fuels, cutting down on carbon emissions and promoting a more sustainable energy future.

Water Conservation

Water is another critical resource that must be conserved in sustainable building practices. Rainwater harvesting, greywater recycling, and efficient water fixtures can help reduce water consumption and preserve this precious resource. By implementing these practices, buildings can significantly reduce their water footprint and contribute to more sustainable water management.

As the construction industry continues to shape the landscapes of our cities and communities, it must embrace a more sustainable path forward—one that prioritizes the health of our planet and the well-being of future generations. The choices we make today in building materials, design, and construction practices will have lasting impacts on our environment and quality of life.

By choosing sustainable building practices, we are not just constructing buildings but also building a better future. We are creating cities that work with nature, not against it, and ensuring that our urban environments remain healthy and vibrant for generations to come.

Eco-Blueprints: Mastering Sustainable Construction

By integrating sustainable practices into every aspect of construction, we can reduce our environmental footprint, conserve valuable resources, and create healthier, more livable spaces. The future of urban development lies in embracing these eco-blueprints and mastering sustainable construction practices. The time to act is now, and the path forward is clear. Let’s build a future that enhances life with green practices and ensures a sustainable world for all. To dive deeper into how sustainable building practices are shaping our future, don’t miss our latest YouTube video https://www.youtube.com/watch?v=QYmRyVu-cLwF