Concrete

Managing energy consumption and emissions is crucia

Published

5 months ago

September 23, 2024

admin

Raju Ramchandran, SVP Manufacturing (Cluster Head – Central), Nuvoco Vistas, discusses the company aims to reduce its carbon footprint and drive long-term environmental and operational improvements.

Can you provide an overview of your company’s current initiatives and strategies to enhance energy efficiency in cement production?
As a cement manufacturing company, managing energy consumption and emissions is crucial for achieving sustainable operations. At Nuvoco, significant measures have been taken to address this issue and leverage it as a competitive advantage. As part of its energy-efficient initiatives, Nuvoco is at the forefront of integrating green power and alternative fuels into its operations. This pivotal strategy significantly reduces Greenhouse Gas (GHG) emissions and underscores its dedication to sustainable practices. Additionally, by harnessing waste heat generated from manufacturing processes, Nuvoco converts it into clean energy, thereby reducing reliance on the grid and enhancing energy efficiency.
Furthermore, the company efficiently manages its power and fuel mix by incorporating alternative fuels into its operations. The manufacturing processes enable the use of waste materials from industries like steel and thermal power generation as alternative fuels. The company’s mix of alternative fuels includes solid waste, liquid solvents, biomass, refuse-derived fuels (RDF) from municipal solid waste, and other substances, with a focus on biomass. The company’s use of alternative fuels is a testament to its commitment to reducing its carbon footprint and supporting local areas by consuming waste, thereby making the city cleaner. The company has also implemented efficiency control measures by incorporating ‘Good Run Settings’ for kilns and mills and using an AI platform to strengthen Proportional Integral Derivative (PIDs).

How do advancements in technology contribute to improving energy efficiency in your cement plants? Can you provide some examples?
Nuvoco relies significantly on technological advances to improve energy efficiency. A key technology in this effort is the Waste Heat Recovery System (WHRS), which captures and utilises heat from clinker kilns to generate power, reducing dependence on fossil fuels.
This technology has been implemented across all the cement plants to reduce Specific Heat Consumption (SHC) and Specific Power Consumption (SPC) during clinker and cement manufacturing processes. The optimisation of power generation through WHRS contributes significantly in reducing environmental impact.
Additionally, Nuvoco has implemented an advanced system designed to utilise a wide range of waste materials, including agricultural waste, refuse-derived fuel (RDF), plastic waste, municipal waste, biomass, tyre chips, and other hazardous sources. This system integrates Alternative Fuel and Raw (AFR) feeding into the pyroprocess, ensuring uniform feeding and incorporating essential safety interlocks. By efficiently consuming alternative fuels, this initiative adheres to the environmental standards set by the Pollution Control Board of India.
Though the primary focus is on enhancing environmental sustainability, this project also significantly benefits clinker production and provides substantial cost savings through the alternative fuels programme.

What role does renewable energy play in your overall strategy for energy efficiency, and how is it integrated into your cement manufacturing operations?
Energy efficiency refers to using less energy while increasing the output of a manufacturing unit. As part of Nuvoco’s ESG agenda, the company focuses on reducing reliance on fossil fuels and minimising its environmental footprint through smart energy sourcing and in-house capabilities. Nuvoco’s cement manufacturing units are equipped with alternative fuel capabilities, supported by investments in alternative fuel material handling facilities. This enables the company to achieve optimal levels of Specific Heat Consumption (SHC) and Specific Power Consumption (SPC) in its clinkerisation and grinding units.
The company has made significant strides in renewable energy integration, with 1.5 MW solar power plants, 150 MW captive power plants, and 44.7 MW waste heat recovery systems (WHRS) in place.
Nuvoco has also made remarkable progress in its Alternative Fuel Rate (AFR) mix, which improved to 13 per cent in FY24, positioning the company among the industry’s leaders in this area. These initiatives collectively contribute to Nuvoco’s overarching strategy of energy efficiency and sustainability in cement manufacturing.

How do you measure and monitor energy efficiency in your cement manufacturing processes, and what metrics are most critical for your company?
Nuvoco has established a rigorous system for measuring and monitoring energy efficiency across its cement manufacturing processes. Key metrics are tracked using advanced monitoring systems to ensure both optimal performance and strict regulatory compliance.
One critical aspect of this monitoring involves the consistent tracking of air emissions from fuel combustion in cement production and power generation operations. This includes pollutants like oxides of sulphur (SOx), oxides of nitrogen (NOx) and particulate matter (PM). Nuvoco employs Continuous Emission Monitoring Systems (CEMS) to observe these emissions in real-time, ensuring adherence to environmental standards.
Additionally, the use of Smart Motor Control Centers (MCCs) and the latest technology energy managers helps to monitor energy consumption at the lowest possible levels. This enables better energy consumption analysis and optimisation of energy usage, leading to significant cost savings and improved 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?
Nuvoco is steadfast in its commitment to enhancing energy efficiency as a key driver of sustainable growth. Looking ahead, the company has outlined several strategic priorities to further advance its energy efficiency efforts and address future challenges in the cement industry. One of the core priorities is the continued integration of renewable energy sources into operations. Nuvoco plans to expand its solar energy capacity and optimise its existing Waste Heat Recovery Systems (WHRS) to reduce reliance on non-renewable power sources. The company is also focused on increasing the use of alternative fuels, such as refuse-derived fuel (RDF), biomass, and other waste materials, to further reduce its carbon footprint and promote a circular economy.
Innovation and technology will play a crucial role in achieving these goals. Nuvoco is investing in advanced energy management systems and digital technologies to monitor and optimise energy consumption across its plants. This includes the implementation of smart grids, predictive maintenance systems, and real-time energy monitoring tools
that enable more efficient operations and reduce energy waste.
In alignment with its commitment to sustainability, Nuvoco’s ‘Protect Our Planet’ (POP) agenda, launched in FY 2022-23, has progressed significantly, representing a major step forward. By integrating sustainability into every facet of operations and utilising a governance system with monthly performance tracking, the POP agenda focuses on key areas identified through materiality assessments. This strategic approach has led to the creation of sustainability roadmaps that target decarbonisation, water management, circular economy, biodiversity and waste reduction.
Through these initiatives, Nuvoco not only meets regulatory requirements but also contributes positively to environmental conservation, reinforcing its role as a leader in sustainable cement manufacturing.

Can you discuss any specific projects or upgrades your company has undertaken to reduce energy consumption and increase efficiency in your cement production facilities?
The cement industry is inherently energy and resource-intensive, and at Nuvoco, we are committed to leveraging cutting-edge technologies to reduce energy consumption and increase efficiency across our production facilities.
The adoption of Industry 4.0 principles has been pivotal in driving this transformation. We’ve integrated advanced technologies such as IoT, Artificial Intelligence (AI) and Advanced Process Control (APC) into our operations. These digital innovations, coupled with specialised robots and online equipment, have significantly enhanced the production processes, reduced environmental impact while increased energy efficiency.

– Kanika Mathur

Up Next

Sustainable Procurement Practices

Don't Miss

Our large motors are engineered to boost productivity

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

22 hours ago

February 21, 2025

admin

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

admin

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.

Concrete

World Cement Association Calls for Industry Action

The cement industry is responsible for 8 per cent of global CO2 emissions

Published

4 days ago

February 18, 2025

admin

The cement industry is responsible for 8 per cent of global CO2 emissions—a staggering figure that demands urgent action, particularly as 2024 marked the first year the planet surpassed the 1.5°C global warming limit. Recognising this critical juncture, the World Cement Association (WCA) has released a landmark White Paper, “Long-Term Forecast for Cement and Clinker Demand”, which projects a sharp decline in long-term cement and clinker demand. By 2050, annual clinker production is expected to fall below 1 Gt from its current level of 2.4 Gt, with far-reaching implications for global carbon emissions and the viability of carbon capture projects.

WCA CEO Ian Riley underscores the complexity of this challenge:
“Carbon capture remains a vital tool for tackling emissions in hard-to-abate sectors like cement. However, flawed demand assumptions and the fragmented nature of cement production globally could undermine the feasibility of such projects. Industry stakeholders must rethink their strategies and embrace innovative, sustainable practices to achieve meaningful emissions reductions.”

Key Findings from the WCA White Paper
The WCA White Paper provides a comprehensive roadmap for the industry’s decarbonisation journey, highlighting the following critical insights:
1. Declining Cement and Clinker Demand: Global cement demand is expected to drop to approximately 3 billion tonnes annually by 2050, while clinker demand could decline even more steeply, reaching just 1.5 billion tonnes annually.
2. Implications for Carbon Capture and Storage (CCS): With reduced clinker production, the need for CCS is expected to decline, necessitating a shift in investment and policy priorities.
3. Alternative Materials and Clinker-Free Technologies: These innovations hold transformative potential for reshaping demand patterns and cutting emissions.
4. Supply Chain Optimisation: Enhancing logistics and reducing waste are key strategies for adapting to evolving market dynamics.

A Path to Lower Emissions
Clinker production, the largest source of CO2 emissions in cement manufacturing, generates one-third of emissions from fuel combustion and two-thirds from limestone decomposition. According to our white paper, transitioning to lower-carbon fuels could reduce specific fuel emissions per tonne of clinker by nearly 70% by 2050. Overall CO2 emissions from cement production are forecast to decline from 2.4 Gt in 2024 to less than 1 Gt by 2050, even before factoring in carbon capture technologies.

Ian Riley emphasised: “This white paper provides actionable insights to help the cement industry accelerate its decarbonisation journey. By prioritising innovation and collaboration, the industry can achieve substantial emissions reductions and align with global climate goals.”