Udai Singh, Vice President – Power Systems, Greater India, Schneider Electric, discusses the collaborative efforts undertaken by the industry for sustainable manufacturing operations.

A s the second-largest cement producer worldwide, India is experiencing a surge in demand, driven by rapid infrastructure development and residential expansion. In response to the pressing climate change concerns, the country is taking proactive measures and aligning its progress with sustainable practices. With a clear objective of achieving a net-zero economy by 2070, the cement industry plays a pivotal role in this transformative journey, necessitating a shift towards sustainable cement manufacturing through robust decarbonisation strategies and collaborative endeavours.
The global cement industry accounts for 7-8 per cent of the world’s carbon emissions. This is largely because cement production is a complex and highly energy-intensive process. The industry’s heavy reliance on coal for energy needs significantly contributes to elevated carbon emissions. This makes it critical for this industry to adopt a decarbonisation roadmap supported by technology, innovation and collaboration.

Collaboration for sustainability
Formulating a well-defined decarbonisation strategy in collaboration with expert consultants is crucial for cement companies to address operational challenges and identify key areas for emission reduction and energy efficiency. With a tailor-made decarbonisation roadmap, they can expedite the realisation of their emission reduction and energy efficiency targets. This approach involves benchmarking their facilities against industry peers on critical parameters, such as energy efficiency, carbon footprint reduction, adoption of renewable energy sources, minimising fossil fuel reliance and embracing sustainable practices. By diligently tracking their decarbonisation efforts through benchmarking, cement makers can gain valuable insights and knowledge, leading to better resource allocation, optimisation of energy-intensive processes and adoption of efficient practices for overall carbon reduction.
Also, considering the urgency to switch to renewable energy sources and reducing dependency on coal, the cement makers can use technology solutions with the help of technical sustainability experts to simulate the best mix of alternative fuels including biofuels, municipal waste, etc. Process Simulation can empower them to identify optimal combinations, reduce costs and gain flexibility in fuel choices, thereby minimising environmental impact and fortifying their resilience against market fluctuations and supply chain volatilities.
In addition, a decarbonisation strategy leveraging technological solutions not only enhances manufacturing efficiency but also extends to related operations. For instance, they can reduce idle hours of heavy earth-moving machinery to reduce energy demand and gain cost advantages. Moreover, deploying advanced digital solutions offers them better management and monitoring of the machinery with effective scheduling of equipment. Additionally, process optimisation and real-time dynamic simulations across various parameters within the facility lead to higher operational efficiency, reduced clinker to Cement ratio, reduced fuel and thermal energy consumption, predictive maintenance, and proactive issue detection of alternative fuels and raw material feed availability.

Beyond decarbonisation
While reducing carbon footprint is one of the primary objectives of sustainable cement manufacturing, cement manufacturers can gain a multitude of benefits from it. For instance, achieving sustainability in operations results in higher energy efficiency and reduced energy consumption. This massively lowers operational costs for cement companies and ultimately might result in reduction in prices of their end products, making them more competitive and resilient in the market.
Moreover, the surge in consumer awareness surrounding sustainable practices has elevated the significance of sustainable manufacturing. In today’s landscape, consumers are increasingly drawn to products with minimal environmental impact. Thus, by adopting sustainable practices, cement companies can align their offerings with consumer preferences, gaining a significant business advantage.
In addition to consumer preferences, fostering collaboration with technology partners paves the way for accelerated innovation and the deployment of cutting-edge technologies. This collaborative approach propels the cement industry towards greener production methods and reinforces its position at the forefront of the sustainability mission. By executing a robust decarbonisation strategy guided by collaborative efforts, the cement industry plays a pivotal role in supporting the transition towards a low-carbon future. The benefits of sustainable cement manufacturing extend well beyond reducing carbon emissions. Energy efficiency, cost savings, consumer appeal, and technological innovation all converge to enhance the industry’s overall environmental stewardship and competitiveness in the pursuit of a greener and more sustainable future.

ABOUT THE AUTHOR
Udai Singh, Vice President – Power Systems, Greater India, Schneider Electric is a a seasoned business leader with extensive experience in sales, marketing, and operational management.