Nitin Jain, Unit Head – Integrated Plant, Nimbahera, Wonder Cement talks about how they are setting new standards for environmental stewardship in the industry.

Can you provide an overview of your company’s current circular economy initiatives and how they are integrated into the cement manufacturing process?
In recent years, the manufacturing sector has made significant progress in various areas. However, there’s an ever-increasing demand for solutions that are both environmentally responsible and economically viable. This is where Wonder Cement has carved out a distinctive niche. Wonder Cement has positioned itself as an industry pioneer, offering products that redefine quality standards in cement manufacturing. Their cement is engineered to deliver exceptional strength and durability, while also incorporating sustainable practices in its production. This combination of high performance and environmental consciousness sets Wonder Cement apart in a competitive market.
By focusing on innovation, we are not just meeting current industry needs, but actively shaping the future of sustainable construction. Their approach demonstrates how forward-thinking companies can drive positive change in the building materials sector, paving the way for more resilient and eco-friendly infrastructure. Wonder Cement is actively adopting circular economy strategies to reduce its ecological footprint and lead the way in sustainable cement production. By implementing innovative recycling and resource efficiency measures, the company is working to transform its manufacturing processes and promote environmental stewardship in the industry.

Utilisation of Alternative Fuels (AF) plays a pivotal role in advancing the circular economy within the cement industry. Wonder Cement is utilising waste materials such as plastics, RDF, MSW, Pharma waste, FMCG products, Hazardous industrial by-products, and biomass into the production process, thereby significantly reducing its reliance on traditional fossil fuels.
Utilisation of alternative raw materials in the cement industry is a key strategy for enhancing sustainability and resource efficiency. Wonder Cement has substituted traditional raw materials like limestone with industrial by-products such as fly ash, marble slurry, chemical gypsum, red mud, mine telling reject, alumina slat, iron sludge, etc. Wonder Cement not only reduces its reliance on natural resources but also mitigates environmental impacts.
Wonder Cement has embarked on a pioneering endeavour by integrating a Waste Heat Recovery System (WHRS), epitomising the circular economy paradigm. By harnessing the excess thermal energy generated during the clinkerisation process, the WHRS ingeniously repurposes this residual heat to produce electricity. This innovative closed-loop system significantly amplifies energy efficiency, substantially diminishes reliance on external power sources, and exemplifies a beacon of sustainability in the cement industry.
Low-carbon cement production is an innovative approach by Wonder Cement aimed to reduce the carbon footprint associated with traditional cement manufacturing. This process involves several strategies to minimise CO2 emissions, which are typically high due to the energy intensive nature of clinker production. The production of blended cement, Portland Pozzolana Cement (PPC) involves mixing clinker with supplementary materials like fly ash. This not only reduces CO2 emissions but also enhances the durability and performance of the cement.
Recycling and reuse: Wonder Cement is managing wastewater, ensuring environmental protection, and promoting sustainable practices by Effluent Treatment Plant (ETP) and Sewage Treatment Plant (STP). Also, bed ash and fly ash generated from Captive Power Plant are used as a raw material for cement production.
Sustainable mining practices: Wonder Cement has adopted fully mechanised opencast limestone mining, utilising advanced technology which provides a highly efficient and environmentally responsible method for resource extraction. State-of-the-art machinery enables controlled blasting, effective vibration management, and noise reduction, significantly minimising the environmental impact of mining operations.
Research and development: Wonder Cement is making significant investments in research and development to find alternatives to traditional fossil fuels such as coal and pet coke etc. as well as to explore substitutes for raw materials like limestone, mineral gypsum etc. used in clinker and cement production. These initiatives aim to enhance sustainability by reducing dependency on non-renewable resources and minimising the environmental impact of cement manufacturing. By developing innovative solutions and alternative materials, Wonder Cement is paving the way for a more eco-friendly and efficient approach to cement production.
Digital technologies: Advance technologies are transforming the cement industry by enhancing efficiency, reducing costs, and improving sustainability. In Wonder Cement, we have developed advanced predictive maintenance for equipment monitoring. With the help of predictive maintenance system AI/ ML algorithms analyse data from sensors on machinery to predict potential failures before they occur.

This helps in scheduling maintenance activities proactively, reducing downtime and extending equipment life.
Wonder Cement has introduced AI technology to optimise operations in cement kiln, raw mill and cement mill. By integrating AI technologies into cement kilns, raw mills, and cement mills, Wonder Cement has achieved greater operational efficiency, improved product quality and enhanced sustainability. AI-driven insights and automation help in optimising processes, reducing energy consumption, and maintaining equipment reliability, leading to a more efficient and environmentally friendly production process.
Wonder Cement recognises the critical role of Operational Technology (OT) in enhancing efficiency and productivity within the manufacturing sector. Understanding that the importance of robust OT cybersecurity measures cannot be overstated, we are actively working to safeguard our complex industrial processes from potential threats. By implementing a comprehensive security strategy and adhering to best practices, Wonder Cement positions itself as a future leader in protecting its operations, employees, and data, thereby ensuring uninterrupted production and resilience against the growing threat of cyberattacks.
The company leverages cutting-edge automation in its state-of-the-art robotic laboratory, enabling the complete automation of processes from sample collection through to the analysis of the final product, effectively eliminating the need for manual intervention. Additionally, Wonder Cement’s integration of an advanced cross-belt analyser system represents a strategic initiative aimed at achieving circular economy objectives by enhancing the efficiency and sustainability of natural resource utilisation.
Apart from the core technical prowess, our organisation has set a new benchmark in the cement industry by leading the way in digital transformation. By pioneering the use of advanced technology, the company has successfully implemented paperless systems across logistics, inventory management and financial accounting, establishing a new standard for operational excellence and efficiency.

What are the main challenges you face in implementing circular economy practices in the cement industry, and how are you addressing them?
Implementing circular economy practices in Wonder Cement involves navigating several challenges.

• Consistent quality of waste materials: Securing high-quality waste materials that meet rigorous standards is challenging due to variability. We address this by implementing stringent quality control measures and developing strong partnerships with suppliers to ensure reliability.
• Financial constraints: Adopting circular economy practices often requires significant investment in new technologies and processes. We focus on projects that provide substantial economic and environmental benefits to manage financial constraints.
• Regulatory challenges: Strict regulations around the use of certain waste materials can pose obstacles. We proactively collaborate with regulatory authorities to ensure compliance and advocate for supportive policies that facilitate the transition to circular economy practices.

How does your company incorporate waste materials and by-products into the cement production process to promote resource efficiency?
Wonder Cement integrates a diverse array of waste materials and by-products into its cement production process to boost resource efficiency. We incorporate various waste materials, including plastics, Refuse-Derived Fuel (RDF), Municipal Solid Waste (MSW), pharmaceutical waste, FMCG by-products, hazardous industrial residues, and biomass. This approach significantly reduces our dependence on conventional fossil fuels. Additionally, Wonder Cement has partially substituted traditional raw materials like limestone, mineral gypsum etc. with industrial by-products such as marble slurry, chemical gypsum, red mud, mining reject, alumina slat, iron sludge etc. This strategy not only lessens our reliance on natural resources but also mitigates environmental impacts. The use of fly ash in Portland Pozzolana Cement (PPC) is a key example, supplementing clinker to lower CO2 emissions while enhancing the durability and performance of the cement.

Can you discuss specific projects or partnerships your company has undertaken to advance circular economy principles in cement manufacturing?
Wonder Cement is leading the way in advancing circular economy principles through several innovative projects and partnerships. We have collaborated with local municipalities to use municipal solid waste (MSW) as an alternative fuel in our kilns. Additionally, we have teamed up with pharmaceutical and FMCG companies to process waste material as alternative fuels into our kilns. These partnerships help divert waste material, convert it into energy, and reduce our dependence on traditional fossil fuels. These collaborations are crucial in developing new materials and technologies that further enhance the sustainability of our operations.

What role do recycling and reuse of materials play in your circular economy strategy, and can you provide examples of successful implementations?
Recycling and reuse are key components of Wonder Cement’s circular economy strategy. We prioritise the integration of recycled industrial by-products and waste materials, including fly ash, marble slurry, chemical gypsum, red mud, mining rejects, alumina salt, and iron sludge. Additionally, we manage wastewater through our Effluent Treatment Plant (ETP) and Sewage Treatment Plant (STP), ensuring environmental protection and promoting sustainable practices. Bed ash and fly ash from our Captive Power Plant are also utilised as raw materials in our cement production process.

How do you measure the impact and success of your circular economy initiatives, and what key metrics are used?
Wonder Cement measures the impact and success of our circular economy initiatives using a variety of environmental, operational, and financial metrics. Key performance indicators include the percentage of alternative raw materials and fuels used in production, reductions in CO2 emissions per tonne of cement and the amount of waste diverted from landfills through recycling and reuse. We track our energy consumption and water usage to evaluate the efficiency of our resource management practices. Our integrated management systems provide real-time data and insights on these metrics. Regular audits and assessments help us gauge the effectiveness of our initiatives, identify areas for improvement, and refine our strategies. The insights gained from these evaluations guide the setting of new sustainability targets and the continuous enhancement of our practices.

What innovations or technologies are being developed or utilised by your company to support circular economy practices in cement production?
Advanced technologies are revolutionising the cement industry by improving efficiency, lowering costs, and boosting sustainability. At Wonder Cement, we have implemented advanced predictive maintenance software for equipment monitoring. Our predictive maintenance system uses AI/ ML algorithms to analyse data from machinery sensors, enabling us to predict potential failures before they occur. This proactive approach helps schedule maintenance activities, reduce downtime and extend equipment life. Additionally, we have integrated AI technology to optimise operations across kiln, raw mill and cement mill. This integration has led to improved operational efficiency, enhanced product quality, and greater sustainability. AI-driven insights and automation optimise processes, reduce energy consumption, and ensure equipment reliability, contributing to a more efficient and environment friendly production process.

Looking ahead, what are your company’s strategic priorities for enhancing circular economy practices, and what future projects or goals do you have in this area?
Wonder Cement is committed to enhancing circular economy practices through several strategic priorities. We plan to increase the use of alternative raw materials and fuels in our production processes and expand our collaborations with industries that produce compatible by-products. Our goal is to develop new products with higher recycled content, such as eco-friendly cement blends, to deliver additional environmental benefits. We are conducting research and development to explore the possibility of synthetic gypsum as a substitute of mineral gypsum and many more such alternative raw materials. By focusing on these priorities, we aim to lead the cement industry in circular economy practices and contribute to a more sustainable future.

– Kanika Mathur

MM Rathi, Joint President – Power Plants, Shree Cement, speaks about their comprehensive approach to sustainability, which includes renewable energy and cutting-edge technologies.

Can you provide an overview of your company’s current initiatives and strategies to enhance energy efficiency in cement production?
At Shree Cement, we are committed to advancing energy efficiency in cement production through a comprehensive and forward-thinking strategy. We recognise that energy efficiency is crucial not only for reducing operational costs but also for minimising our environmental impact. To this end, we have undertaken several initiatives and adopted innovative strategies to enhance energy efficiency across our cement production processes. We have progressively integrated the use of alternative fuels, such as biomass and waste-derived fuels, into our production process. This not only reduces our dependence on traditional fossil fuels but also lowers greenhouse gas emissions.
Moreover, at the project stage itself, we select and implement energy-efficient drives and key equipment, including fans, compressors and
other critical components, to optimise performance and reduce overall energy consumption. Through advanced data analytics and real-time monitoring, we have optimised key processes such as clinker production, raw material grinding and cement milling, which has led to significant reductions in specific energy consumption.
We conduct Computational Fluid Dynamics (CFD) analysis for our plants right before project execution as a best practice to optimise energy efficiency and ensure informed decision-making in our energy-saving initiatives. We also implement regular energy audits to continuously assess and optimise our energy consumption. These audits help identify areas for improvement, track progress and ensure that our energy efficiency measures are effective.
We are proud to have achieved a renewable energy share of 55.9 per cent in FY 23-24, the highest among Indian cement industries. This achievement underscores our commitment to reducing our carbon footprint and reliance on non-renewable energy sources. Our total power generation capacity is 1 GW, with 50 per cent derived from solar, wind and Waste Heat Recovery (WHR), 30 per cent from Independent Power Producers (IPP), and the remaining 20 per cent from coal-based captive power plants. We have invested in Waste Heat Recovery (WHR) systems with a total capacity of 245 MW across several of our plants. These systems capture waste heat from the production process and convert it into electrical energy, reducing our overall energy consumption and enhancing efficiency. Further, we are exploring emerging technologies i.e. battery energy storage, pumped hydro energy storage, electric trucks etc.
As part of our long-term sustainability goals, we have joined the RE100 initiative, pledging to achieve 100 per cent renewable electricity by 2050. This commitment reflects our dedication to leading the industry in transitioning to a low-carbon future. In alignment with global climate goals, we have set ambitious targets to reduce our Scope 2 emissions by ~27-28 per cent and Scope 1 emissions by ~12-13 per cent by 2030, compared to 2019 levels. These targets highlight our proactive approach to mitigating climate change.

What are the key challenges your company faces in implementing energy-efficient practices in the cement manufacturing process?
While we are committed to enhancing energy efficiency, a few challenges persist. For example, the use of alternative fuels is impacted by supply chain issues and resource availability. Fluctuations in alternative fuel supply (quantity and quality) can disrupt the consistent implementation of energy-efficient practices. Also, upgrading infrastructure to incorporate energy-efficient technologies, including the higher costs of battery and pump storage systems, requires substantial capital investment. There could also be technological constraints related to compatibility and operational disruptions when integrating new, energy-efficient technologies into existing plants. Addressing these challenges requires a thorough approach to enhance energy efficiency throughout the cement manufacturing process, which our engineers are constantly endeavoring to find solutions to.

How do advancements in technology contribute to improving energy efficiency in your cement plants? Can you provide some examples?
Technological advancements are crucial for improving energy efficiency at our cement plants. We leverage Industry 4.0 technologies, including centralised data servers and remote data monitoring, to optimise operations. These technologies provide real-time insights and control over plant performance, enabling precise energy management and reducing downtime. Also, ISO 50001-certified energy management systems provide a structured approach to continuous energy performance improvements.
Additionally, our manufacturing plants leverage the latest and state-of-the-art equipment such as waste heat recovery systems, MVDs/VFDs, IE4 motors, centrifugal compressors, etc. Our meticulous planning and adoption of energy-efficient technologies have helped us overachieve the targets that were notified under the various Perform, Achieve and Trade
(PAT) schemes.

What role does renewable energy play in your overall strategy for energy efficiency, and how is it integrated into your cement manufacturing operations?
Renewable energy is a cornerstone of our strategy for energy efficiency and sustainability at Shree Cement. Our commitment to integrating renewable energy is reflected in our energy mix, where renewable sources account for 55.9 per cent of our total energy consumption. This significant share has enabled us to avoid 0.94 million tons of CO2 emissions, demonstrating our impact on reducing greenhouse gasses. Our total power generation capacity is 1 GW, with 50 per cent derived from renewable sources, including solar, wind and WHR.
WHR systems, with a capacity of 245 MW, capture and reuse heat generated during production, converting it into electricity. This integration supports our goal of transitioning away from non-renewable fossil fuels and aligns with our commitment to achieve 100 per cent renewable electricity by 2050.
Our energy management strategy leverages renewable energy to stabilise and optimise our energy supply. We are exploring advanced energy storage solutions, such as battery and pump storage systems, to manage the variability of renewable sources and ensure a consistent energy supply. Renewable energy is pivotal in achieving our sustainability targets, including substantial reductions in Scope 1 and Scope 2 emissions. By increasing our renewable energy share, we have significantly lowered our carbon footprint and contributed to global climate goals.

Can you discuss any specific projects or upgrades your company has undertaken to reduce energy consumption and increase efficiency in your cement production facilities?
Shree Cement has undertaken several strategic projects to reduce energy consumption and enhance efficiency in its cement production facilities. A key focus has been the integration of alternative fuels and raw materials into the production processes. The company has made notable progress by utilising hazardous waste, Municipal Solid Waste (MSW) in the form of Refuse Derived Fuel (RDF), and biomass waste such as crop residue. We have been steadily increasing our replacement of fossil fuels with agro-waste and have replaced over +300 billion kCal in FY24. This shift significantly reduces reliance on traditional fossil fuels and promotes the use of renewable resources in cement manufacturing.
We are the pioneers within the cement industry in implementing WHR system to capture waste heat and convert it into usable electricity. Having proven its success, as a policy, Shree Cement is implementing WHR systems across all the existing and upcoming kilns.
Further, Shree Cement manufactures blended cement by incorporating fly ash and ground granulated blast-furnace slag (GBF slag), replacing clinker. This approach not only reduces the demand for clinker but also conserves essential natural resources, such as limestone, and lowers fossil fuel consumption, aligning with our sustainability goals. Additionally, we have focused on improving energy efficiency in our operations. We have successfully reduced clinker energy use by approximately 12 to 18 Kcal/kg clinker produced.

How do you measure and monitor energy efficiency in your cement manufacturing processes, and what metrics are most critical for your company?
To effectively measure and monitor energy efficiency in our cement manufacturing processes, Shree Cement employs several critical metrics. The primary metric is Specific Energy Consumption (SEC), which quantifies the energy required per unit of cement produced, typically expressed in kWh per ton. Reducing SEC is a fundamental objective for enhancing energy efficiency.
Thermal energy consumption is also closely monitored, focusing on the energy required for pyro processes, especially in the kiln. This helps identify opportunities to improve fuel efficiency and optimise Pyro process. Similarly, electrical energy consumption is tracked across various plant components, such as grinding mills, process fans pumps and conveyors. Monitoring this metric helps identify potential areas for improvement in electrical energy use. Another metric is cooler efficiency, which measures how effectively cooling air is utilised back in the
pyro processing, which is crucial for lowering operational costs.
Additionally, WHR systems are evaluated for their effectiveness in capturing and reusing waste heat, as higher recovery rates from these systems can significantly reduce overall energy consumption.
Lastly, monitoring CO2 emissions per tonne of cement provides insight into the environmental impact of our production activities and helps us align with our sustainability goals.

What partnerships or collaborations has your company engaged in to promote and enhance energy efficiency within the cement industry?
Shree Cement has adopted a proactive approach in promoting and enhancing energy efficiency within the cement industry through various strategic partnerships and collaborations.
One of the key avenues has been our partnership with leading technology providers and equipment suppliers to integrate advanced energy-efficient technologies into our production processes. These partnerships enable us to access the latest innovations in energy management, process optimisation, and waste heat recovery systems. Besides teaming up with tech companies, we engage with government agencies and regulatory bodies to stay informed about and contribute to energy efficiency regulations and policies. Our participation in public consultations and policy development helps shape industry standards and supports our compliance with energy efficiency mandates.
Shree Cement is part of various sustainability networks and forums that focus on energy efficiency and environmental impact reduction. These networks provide opportunities to learn from peers, share experiences and collaborate on industry-wide sustainability projects.
We are also actively involved in industry associations such as the Cement Manufacturers’ Association (CMA) and the Confederation of Indian Industry (CII). Through these platforms, we participate in knowledge-sharing, best practice exchange and collaborative efforts on energy efficiency and sustainability initiatives across the cement sector. Shree Cement has also joined the RE100 initiative, a global platform of businesses committed to achieving 100 per cent renewable electricity. This collaboration aligns with our goal to transition to renewable energy sources and drives collective action toward sustainability in the cement industry.
These strategic alliances are instrumental in advancing our sustainability goals and driving industry-wide improvements.

How does your company balance the need for energy efficiency with maintaining high production levels and meeting market demands?
At Shree Cement, balancing energy efficiency with high production levels and market demands involves a multifaceted approach. One of the methods is process optimisation. We continuously refine our manufacturing processes using advanced control systems and data analytics. This approach enhances our operational efficiency while maintaining our production capacity, allowing us to meet market needs effectively. Additionally, Shree Cement has established strong energy management systems that monitor energy consumption in real time. This helps us identify areas for savings and reduce waste while sustaining production levels, ensuring optimal energy use.
Furthermore, Shree Cement also invests in innovation by adopting new technologies such as more efficient clinker coolers which enhance energy efficiency and production levels. To manage energy costs and support high production levels, we run our cement mills during the day when our solar plants are operational. For the remaining energy demand, we plan to meet it during off-peak times of the day (TOD). This strategic energy use helps us optimise energy costs while maintaining efficient production.

Looking ahead, what are your company’s strategic priorities for further improving energy efficiency, and how do you plan to address future energy challenges in the cement industry?
Shree Cement is focused on several key strategic priorities to enhance energy efficiency and address future energy challenges in the cement industry. We plan to expand our investments in solar and wind energy projects to further increase our renewable energy capacity, enhance our reliance on clean energy sources and reduce our overall carbon footprint. To ensure a stable and reliable supply of renewable energy, we are exploring solar plants integrated with battery storage systems. This will enable us to store excess solar power and use it during periods of low sunlight, improving energy efficiency and continuity.
We are also exploring the development of pump hydro storage plants as a means to balance energy supply and demand. This technology will help us manage fluctuations in renewable energy generation and enhance our overall energy resilience.
To reduce emissions from our logistics operations, we are looking at electric trucks, which will decrease our reliance on fossil fuels for transportation and contribute to our sustainability goals.
Further, we are making investments to establish a comprehensive, end-to-end solid waste feeding system for the consumption of municipal solid waste to substantially enhance the thermal substitution rate through a pilot at one of the locations. Upon success, this shall be replicated in other units as well.

– Kanika Mathur

Piyush Joshi, Associate Vice President – Systems and Technical Cell, Wonder Cement, shares their strategies and initiatives aimed at enhancing energy efficiency in cement production, showcasing their commitment to sustainability through innovation and advanced technology.

Can you provide an overview of your company’s current initiatives and strategies to enhance energy efficiency in cement production?
At Wonder Cement, our commitment to energy efficiency is integral to our operational philosophy, encompassing every facet of our production process. One of our cornerstone initiatives is the deployment of Vertical Roller Mills (VRMs), which are recognised for their superior energy efficiency compared to traditional ball mills. These VRMs are equipped with high-efficiency separators, significantly reducing the energy required for cement grinding while maximising output.
We have also invested substantially in Waste Heat Recovery Systems (WHRS) across our facilities. These systems effectively capture waste heat from our kilns, converting it into usable electricity. This approach not only diminishes our dependency on external energy sources but also supports our sustainability objectives by curbing greenhouse gas emissions. Additionally, we have optimised our operational processes through the implementation of energy-efficient lighting, the utilisation of variable frequency drives (VFDs) on motors, and the execution of regular energy audits to identify and mitigate inefficiencies. Our unwavering dedication to innovation and the adoption of cutting-edge technology ensures that Wonder Cement remains a leader in energy efficiency within the cement industry.

What are the key challenges your company faces in implementing energy-efficient practices in the cement manufacturing process?
While our energy efficiency efforts have yielded significant results, the implementation of such practices within the cement manufacturing process presents several challenges. Chief among these is the substantial capital investment required to upgrade existing infrastructure to more energy-efficient alternatives. Integrating new energy efficient systems with existing infrastructure can be technically challenging and may cause temporary disruptions in production processes. Although the long-term benefits of these upgrades are evident, the initial financial outlay can be substantial, particularly when applied across multiple production sites.
Another persistent challenge is the variability in raw material quality, which can directly impact the efficiency of our kilns and mills. Fluctuations in the chemical composition of raw materials necessitate frequent adjustments in our processes, potentially leading to suboptimal energy consumption. Furthermore, the inherently energy-intensive nature of cement production, especially during the clinkerisation process, means that achieving significant reductions in energy use often requires comprehensive overhauls of traditional methods rather than incremental improvements.
Regulatory and compliance challenges play a significant role. Ensuring that our energy efficiency measures align with both local and international environmental standards is a complex process, particularly in regions with stringent regulations. Despite these challenges, Wonder Cement is steadfast in its commitment to overcoming obstacles through continuous innovation, strategic collaboration, and a focus on sustainable practices.

How do advancements in technology contribute to improving energy efficiency in your cement plants? Can you provide some examples?
Technological advancements are pivotal in enhancing energy efficiency within Wonder Cement plants. One of the key innovations we have embraced is the integration of automation and digitalisation throughout our production processes. By implementing advanced process control (APC) systems, we can monitor and optimise our operations in real-time, ensuring the most efficient use of energy at all times. These systems leverage data analytics and machine learning algorithms to predict and address energy inefficiencies proactively, resulting in substantial energy savings.
Another significant technological advancement is the incorporation of alternative fuels within our kilns. By utilising waste-derived fuels, such as refuse-derived fuel (RDF) and biomass, we reduce our reliance on traditional fossil fuels. This not only lowers our carbon footprint but also enhances the energy efficiency of our kilns by maintaining a consistent energy input with minimal fluctuations. The adoption of smart sensors and Internet of Things (IoT) devices has further augmented our energy management capabilities. These technologies provide real-time insights into energy consumption across various stages of production, enabling rapid identification and resolution of inefficiencies. For example, our predictive maintenance programs, powered by IoT, allow us to foresee equipment failures and schedule maintenance proactively, thereby reducing downtime and ensuring continuous, efficient operations.

What role does renewable energy play in your overall strategy for energy efficiency, and how is it integrated into your cement manufacturing operations?
Renewable energy is a fundamental component of Wonder Cement’s broader energy efficiency strategy. We have integrated renewable energy sources, such as solar and wind power, into our manufacturing operations to reduce our reliance on non-renewable energy. Our solar power plants, strategically positioned across our manufacturing sites, contribute significantly to our overall energy needs. By generating clean energy on-site, we not only reduce our electricity costs but also achieve substantial reductions in carbon emissions, underscoring our commitment to sustainability.
In addition to on-site renewable energy generation, we have entered into power purchase agreements (PPAs) with renewable energy providers. These agreements guarantee a consistent supply of green energy to our plants, further diminishing our reliance on grid power derived from fossil fuels. Moreover, our participation in carbon credit markets, facilitated by the integration of renewable energy, has opened up additional revenue streams while reinforcing our role as a responsible corporate citizen.
Our approach to renewable energy extends beyond electricity generation. We are actively exploring the potential of renewable fuels for our kiln operations. Through partnerships with research institutions and technology providers, we are investigating the viability of hydrogen and other renewable energy sources to further reduce our carbon footprint and enhance energy efficiency.

Can you discuss any specific projects or upgrades your company has undertaken to reduce energy consumption and increase efficiency in your cement production facilities?
Wonder Cement has embarked on several key projects aimed at reducing energy consumption and enhancing efficiency across our production facilities. A prominent example is the installation of high-efficiency clinker coolers, designed to maximise heat recovery from the clinker. This recovered heat is then utilised to preheat raw materials, significantly reducing the energy required for subsequent grinding processes. Another critical upgrade involves the widespread implementation of variable frequency drives (VFDs) across our production lines. VFDs allow us to adjust motor speeds based on real-time load requirements, ensuring that we use only the necessary amount of energy for each operation. This has led to considerable energy savings, particularly in our grinding and milling processes.
We have also modernised our lighting systems by transitioning to LED technology, which is notably more energy-efficient and durable compared to traditional lighting solutions. This transition not only reduces our energy consumption but also lowers maintenance costs. Our commitment to continuous improvement is further demonstrated through regular energy audits and the implementation of advanced energy management systems (EMS) that meticulously track and optimise energy usage across all our facilities.

How do you measure and monitor energy efficiency in your cement manufacturing processes, and what metrics are most critical for your company?
Precise measurement and monitoring of energy efficiency are paramount to achieving our sustainability objectives. We have established a robust energy management system (EMS) that delivers real-time data on energy consumption across every stage of our production process. This system is equipped with advanced metering and monitoring tools that track energy usage at granular levels, enabling us to swiftly identify inefficiencies and implement corrective measures.
Among the critical metrics we monitor are specific energy consumption (SEC), which quantifies the energy required to produce a unit of cement, and thermal energy consumption (TEC), which tracks the energy utilised during the clinkerisation process. By closely monitoring these metrics, we can assess the effectiveness of our energy efficiency initiatives and make informed decisions to further optimise our operations. In addition to continuous monitoring, we conduct regular energy audits to evaluate our performance against industry benchmarks and identify opportunities for improvement. These audits, conducted by both internal teams and external experts, ensure that our energy management practices remain objective, accurate, and aligned with industry best practices. The insights gained from these audits are instrumental in refining our energy management strategies and setting ambitious targets for energy reduction.
To promote energy efficiency through innovations, we are having groups of employees at every
production centre for identification, evaluation and execution of new ideas related to energy efficiency for continual improvement.

What partnerships or collaborations has your company engaged in to promote and enhance energy efficiency within the cement industry?
Collaboration is a cornerstone of Wonder Cement’s approach to enhancing energy efficiency within the cement industry. We actively engage with various stakeholders, including technology providers, industry associations, and research institutions, to promote and advance our energy efficiency initiatives.
Our partnerships with technology providers are instrumental in integrating state-of-the-art solutions into our operations, ensuring that we remain at the forefront of energy efficiency advancements. Additionally, our participation in industry associations and knowledge-sharing platforms enables us to exchange best practices with our peers and stay informed about emerging trends and technologies.
We also collaborate with research institutions to explore innovative materials and processes that can further reduce our energy consumption. These collaborations have led to pilot projects where novel solutions are tested and validated before being implemented on a larger scale across our production facilities. Through these partnerships, we are not only advancing our energy efficiency goals but also contributing to the broader sustainability of the cement industry.

How does your company balance the need for energy efficiency with maintaining high production levels and meeting market demands?
We recognise the importance of balancing energy efficiency with maintaining high production levels and meeting market demands. Achieving this balance requires a strategic approach that integrates energy efficiency into every aspect of our production process without compromising on output quality or quantity.
One of the key strategies we employ is the use of advanced process control (APC) systems that optimise our operations in real-time. These systems enable us to maintain consistent production levels while minimising energy consumption by adjusting process parameters based on real-time data. This ensures that we achieve maximum efficiency without disrupting our production schedules. We also emphasise continuous improvement through the application of lean manufacturing principles, which focus on the elimination of waste and the efficient use of resources. By streamlining our processes and reducing inefficiencies, we can maintain high production levels while minimising energy usage. Additionally, our investment in employee training ensures that our workforce is equipped with the necessary knowledge and skills to operate our facilities efficiently, contributing to both productivity and energy efficiency.

Looking ahead, what are your company’s strategic priorities for further improving energy efficiency, and how do you plan to address future energy challenges in the cement industry?
Looking ahead, Wonder Cement is committed to further advancing our energy efficiency through a combination of technological innovation, process optimisation, and strategic investments. Our primary focus will be on expanding our use of renewable energy sources, particularly solar and wind power, to meet a larger portion of our energy needs. We are also exploring the potential of emerging technologies, such as carbon capture and utilisation (CCU) and hydrogen-based fuels, to further reduce our carbon footprint and enhance energy efficiency.
In addition to technological advancements, we plan to continue our efforts in process optimisation through the implementation of advanced data analytics and artificial intelligence (AI) in our energy management systems. These tools will enable us to identify and address inefficiencies in real-time, ensuring that we maintain optimal energy usage at all times.
We are also committed to expanding our collaborations with industry stakeholders, research institutions, and technology providers to drive innovation and share best practices in energy efficiency. By staying at the forefront of industry trends and continuously challenging ourselves to improve, we are confident that we can meet the future energy challenges of the cement industry while maintaining our position as a leader in sustainability.

– Kanika Mathur