Concrete

Energy costs and supply are volatile

Published

5 months ago

September 20, 2024

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Vikas Garg, Energy Manager, Udaipur Cement Works Ltd (UCWL), discusses sustainability, cost reduction and meeting regulatory requirements while maintaining high production standards.

Provide an overview of your company’s current initiatives and strategies to enhance energy efficiency in cement production.

Enhancing energy efficiency in cement production is crucial for reducing costs, minimising environmental impact, and meeting regulatory requirements. Our company is adopting various initiatives and strategies to improve energy efficiency like:

Substitution of fossil fuels and raw material with alternative fuels like waste derived fuels and industrial by-products.
Implementation of ML/AI based process optimisation systems to optimise the kiln and grinding operations.
Implementing EMS for identifying areas for improvement, and ensuring energy efficiency goals are met with.
Improvement in kiln efficiency by upgrading or retrofitting kilns with more efficient preheaters and pre-calciners to reduce the amount of fuel required, leading to energy savings.
Energy efficient grinding technologies by replacing traditional ball mills with vertical roller mills and using high-efficiency separators in grinding circuits.
Focus on increasing blended cement.

What are the key challenges your company faces in implementing energy-efficient practices in the cement manufacturing process?

Implementing energy efficient practices in the cement manufacturing process presents several challenges. Here are some of the key challenges our companies often face:

The upfront costs for adopting energy-efficient technologies can be substantial. For companies with tight budgets or operating in low-margin markets, capital investment can be prohibitive.
Retrofitting existing equipment to accommodate new technologies may require extensive modifications, leading to downtime and additional costs
The regulatory landscape for energy use and emissions is constantly changing.
Energy costs and supply are volatile, making it difficult to predict the return on investment for energy-efficient initiatives.
Measuring the actual energy savings and verifying the effectiveness of new technologies are sometimes complex.
Maintaining energy efficiency measures without compromising production in high demand periods is challenging.

How do advancements in technology contribute to improving energy efficiency in your cement plants? Can you provide some examples?

Advancements in technology play a crucial role in improving energy efficiency in cement plants. Here are some ways in which these

technologies contributed:

Implementation of ML/AI based process optimisation system helped in optimising kiln and grinding operations
Waste Heat Recovery (WHR) systems help in reducing energy cost and dependency on grid, replacing old ball mills with a VRM reduced energy consumption in the grinding process by up to 30 per cent.
IoT-enabled sensors monitor energy use across different processes and automatically adjust operations to minimise energy waste, such as reducing power to idle equipment or optimising lighting and HVAC systems.
The use of multi-channel burners, which optimise the mix of primary and secondary air, improved combustion efficiency in the kiln, reducing energy use and emissions.
EMS provided an integrated platform for monitoring, analysing, and optimising energy use across the entire plant. It helped in identifying energy-saving opportunities and track the performance of implemented measures.
Floating solar technology improved overall renewable energy integration.

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 plays a significant role in enhancing energy efficiency and reducing the carbon footprint in cement manufacturing. Integrating renewable energy into cement operations aligns with broader sustainability goals and helps in mitigating the environmental impact of the industry. We have reduced our needs of electricity from the grid up to 50 per cent by utilising renewable energy.

Can you discuss any specific projects or upgrades your company has undertaken to reduce energy consumption and increase efficiency in your cement production facilities?

Cement companies have undertaken various projects and upgrades to reduce energy consumption and increase efficiency in their production facilities. Here are some specific examples of such initiatives:

Alternative Fuels and Raw Materials (AFR)
Installation of Vertical Roller Mills (VRM)
Modifications in Preheater and Kiln Burners.
Energy Management Systems (EMS)
Clinker Substitution Projects
ML / AI based Digitalisation and Automation Projects
Solar Power Integration
Modifications in Waste Heat Recovery (WHR) Systems to increase generation.

How do you measure and monitor energy efficiency in your cement manufacturing processes, and what metrics are most critical for your company?

Measuring and monitoring energy efficiency in cement manufacturing is essential for optimising operations, reducing energy consumption, and minimising environmental impact:

Energy Management Systems (EMS): EMS track energy consumption at different stages of cement production, identify inefficiencies, and suggest corrective actions.
Key Performance Indicators (KPIs)
Critical KPIs:- Specific Energy Consumption (SEC):
kWh/tonne of cement, kcal/kg of clinker
– CO2 emissions per tonne of cement
Fuel mix ratio
Clinker factor
Energy audits and benchmarking audit results are compared with industry benchmarks to evaluate performance and set improvement targets.
Data analytics and reporting: Data collected from various monitoring systems is analysed to generate detailed reports on energy performance.
Energy performance certificates and certifications such as ISO 50001.
Energy forecasting and planning.

What partnerships or collaborations has your company engaged in to promote and enhance energy efficiency within the cement industry?

UCWL is engaged in partnerships and collaborations to promote and enhance energy efficiency within the industry.

Collaborations with technology providers of ML/AI based process optimisation systems.
Global cement and concrete association (GCCA).
National cement associations: collaborating with national cement associations allows companies to contribute to and benefit from industry-wide efforts to improve energy efficiency through shared knowledge, resources and advocacy.
Supply chain collaborations like green procurement practices and efficient transportation networks.
Collaborating with academic institutions for educational programs, workshops, and research can help develop the next generation of energy-efficient technologies and practices in the cement industry.
Carbon trading and offset programmes.

How does your company balance the need for energy efficiency with maintaining high production levels and meeting market demands?

Balancing energy efficiency with maintaining high production levels and meeting market demands is a critical challenge for cement companies. Achieving this balance involves strategic planning, process optimisation, and continuous improvement.

Optimising production processes by using sensors and automation systems to monitor and adjust real time operation.
Flexible energy management by participating in demand response programs which can help manage energy use during peak periods and using energy storage systems to manage fluctuations in energy supply.
Balancing production and efficiency targets by setting key performance indicators (KPIs) for both production output and energy efficiency ensuring that both goals are tracked and managed effectively.
Employee training and engagement.
Implementing best practices and industry standards.
Strategic production planning using forecasting tools to predict market demand and adjust production schedules accordingly.

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?

UCWL is likely to focus on several strategic priorities to further improve energy efficiency and address future energy challenges. These priorities typically align with broader sustainability goals and emerging trends in technology and regulation such as:

Expanding renewable energy integration because increasing the use of renewable energy sources helps reduce reliance on fossil fuels and lower carbon emissions.
Accelerating technology adoption by integrating digital tools, automation and energy-efficient equipment
Enhancing waste heat recovery and improving waste heat recovery systems can significantly reduce energy consumption.
Researching and producing low-carbon cements that require less energy to produce and reduce overall emissions.
Improving energy efficiency in existing operations by energy audits and energy management systems.
Adopting circular economy principles by implementing practices to recycle and reuse materials within the production process, such as
using industrial by-products as supplementary cementitious materials.
Strengthening regulatory and industry collaborations working with industry peers and organisations to share best practices, collaborate on research, and develop common standards for energy efficiency.
Addressing future energy market dynamics by developing flexible energy procurement strategies to manage cost fluctuations and ensure stable energy supply.

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Concrete

Organisations valuing gender diversity achieve higher profitability

Aparna Reddy, Executive Director, Aparna Enterprises talks about company plans.

Published

6 hours ago

February 22, 2025

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The building materials industry is projected to grow by 8-12 per cent over the next five years. How is Aparna Enterprises positioning itself to leverage this momentum and solidify its market presence?

The Indian construction and building materials industry is projected to witness significant expansion, with estimates suggesting an 8-12 per cent compound annual growth rate (CAGR) over the next five years. This growth is fuelled by rapid urbanisation, increased infrastructure investments and sustainability-focused policies. With India’s real-estate market expected to reach $ 1 trillion by 2030, the demand for high-quality building materials is at an all-time high.

The Government of India’s flagship programmes, such as PM Gati Shakti, the Smart Cities Mission and the Housing for All (PMAY-Urban) initiative, are key drivers of this surge. The infrastructure sector alone is expected to receive a budgetary push of over Rs 11 trillion in FY25, with enhanced capital expenditure allocation.

At Aparna Enterprises, we are proactively aligning with this momentum through capacity expansion, product diversification, and cutting-edge technological integration.

Our key strategic priorities include:

Expanding operations in high-growth regions across Tier-2 and Tier-3 cities, ensuring access to quality building materials nationwide
Investing in automation, AI-driven quality control systems and digital integration, enhancing efficiency and precision in manufacturing
Scaling up production capabilities in our RMC, tiles, uPVC and other divisions to meet the anticipated surge in demand.

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Concrete

Global Start-Up Challenge Launched to Drive Net Zero Concrete Solutions

Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations

Published

2 days ago

February 21, 2025

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Start-ups worldwide are invited to contribute to the global cement and concrete industry’s efforts to reduce CO2 emissions and combat climate change. The Global Cement and Concrete Association (GCCA) and its members are calling for applicants for the Innovandi Open Challenge 2025.

Now in its fourth year, the Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations that help decarbonise the cement and concrete industry.

The challenge is seeking start-ups working on next-generation materials for net-zero concrete, such as low-carbon admixtures, supplementary cementitious materials (SCMs), activators, or binders. Innovations in these areas could help reduce the carbon-intensive element of cement, clinker, and integrate cutting-edge materials to lower CO2 emissions.

Thomas Guillot, GCCA’s Chief Executive, stated, “Advanced production methods are already decarbonising cement and concrete worldwide. Through the Innovandi Open Challenge, we aim to accelerate our industry’s progress towards net-zero concrete.”

Concrete is the second most widely used material on Earth, and its decarbonisation is critical to achieving net-zero emissions across the global construction sector.

Concrete

StarBigBloc Acquires Land for AAC Blocks Greenfield Facility in Indore

The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands.

Published

3 days ago

February 19, 2025

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StarBigBloc Building Material, a wholly-owned subsidiary of BigBloc Construction, one of the largest manufacturers of Aerated Autoclaved Concrete (AAC) Blocks, Bricks and ALC Panels in India has acquired land for setting up a green field facility for AAC Blocks in Indore, Madhya Pradesh. Company has purchased approx. 57,500 sq. mts. land at Khasra No. 382, 387, 389/2, Gram Nimrani, Tehsil Kasrawad, District – Khargone, Madhya Pradesh for the purpose of AAC Blocks business expansion in central India. The total consideration for the land deal is Rs 60 million and Stamp duty.

StarBigBloc Building Material Ltd currently operates one plant at Kheda near Ahmedabad with an installed capacity of 250,000 cubic meters per annum, serving most part of Gujarat, upto Udaipur in Rajasthan, and till Indore in Madhya Pradesh. The capacity utilisation at Starbigbloc Building Material Ltd for the third quarter was 75 per cent. The planned expansion will enable the company to establish a stronger presence in Madhya Pradesh and surrounding regions. Reaffirming its commitment to the Green Initiative, it has also installed a 800 KW solar rooftop power project — a significant step toward sustainability and lowering its carbon footprint.

Narayan Saboo, Chairman, Bigbloc Construction said “The AAC block industry is set to play a pivotal role in India’s construction sector, and our company is ready for a significant leap forward. The proposed expansion in Indore, Madhya Pradesh aligns with our growth strategy, focusing on geographic expansion, R&D investments, product diversification, and strategic branding and marketing initiatives to enhance visibility, increase market share, and strengthen stakeholder trust.”

Bigbloc Construction has recently expanded into construction chemicals with Block Jointing Mortar, Ready Mix Plaster, and Tile Adhesives, tapping into high-demand segments. The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands, ensuring superior bonding, strength, and performance.

In May 2024, the board of directors approved fund-raising through SME IPO or Preferential issue to support expansion plans of Starbigboc Building Material subject to requisite approvals and market conditions, Starbigboc Building Material aims to expand its production capacity from current 250,000 cubic meters per annum to over 1.2 million cubic meters per annum in the next 4-5 years. Company is targeting revenues of Rs 4.28 billion by FY27-28, with an expected EBITDA of Rs 1.25 billion and net profit of Rs 800 million. In FY23-24, the company reported revenues of Rs 940.18 million, achieving a revenue CAGR of over 21 per cent in the last four years.

Incorporated in 2015, BigBloc Construction is one of the largest and only listed AAC block manufacturer in India, with a 1.3 million cbm annual capacity across plants in Gujarat (Kheda, Umargaon, Kapadvanj) and Maharashtra (Wada). The company, which markets its products under the ‘NXTBLOC’ brand, is one of the few in the AAC industry to generate carbon credits. With over 2,000 completed projects and 1,500+ in the pipeline, The company’s clients include Lodha, Adani Realty, IndiaBulls Real Estate, DB Realty, Prestige, Piramal, Oberoi Realty, Tata Projects, Shirke Group, Shapoorji Pallonji Group, Raheja, PSP Projects, L&T, Sunteck, Dosti Group, Purvankara Ltd, DY Patil, Taj Hotels, Godrej Properties, Torrent Pharma, GAIL among others.