Concrete

Managing energy consumption and emissions is crucia

Published

2 years ago

September 23, 2024

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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

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

2 days ago

June 5, 2026

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

Concrete

Building a Greener Future Together

Published

2 days ago

June 4, 2026

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

5 days ago

June 1, 2026

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.