Connect with us

Economy & Market

Demand Drivers

Published

on

Shares

The cement industry is expected to benefit from the country’s huge potential for development in the infrastructure and construction sectors, says NITIN MADKAIKAR.

India is the second largest producer of cement globally and the industry has been a vital part of its economic development, providing employment opportunities to more than a million people, directly or indirectly. Since its deregulation in 1982, the Indian cement industry has grown at a tremendous pace, attracting huge investments, both from domestic as well as foreign investors. The sector is expected to largely benefit from the country’s huge potential for development in the infrastructure and construction sectors. Some of the recent major initiatives like development of 98 Smart Cities will provide a major boost to cement demand.

Industry Structure
The Indian cement industry is dominated by a few companies. The top 20 cement companies account for almost 75 per cent of the total cement production of the country. A total of 188 large cement plants together account for 97 per cent of the total installed capacity in the country, with 365 small plants accounting for the rest. Of these large cement plants, 77 are located in Andhra Pradesh, Rajasthan and Tamil Nadu.

On the back of growing demand, due to increased construction and infrastructural activi-ties, the cement industry has attracted huge inve-stments and developments in recent years.

Construction Market
India’s construction business stands over at Rs 30,000 billion, and has been slowly expanding over the years. With value addition of over Rs 10,500 billion, its share in total GDP rose from 5.6 per cent in 1990-91 to over 7.7 per cent in 2016-17. This has given a major advantage to the cement industry, which is poised to expand with increased attention of the government promoting large infrastructure projects.

However, the growth of construction activity has slowed down significantly in recent years. The last highest yearly growth of 10.8 per cent was recorded in 2011-12, but thereafter it has not even touched 5 per cent until now. In 2016-17, it is estimated to have increased 3.1 per cent, slightly faster than the 2.8 per cent clocked in 2015-16. Going ahead, it appears that the growth will remain under 5 per cent, thus truncating demand for construction materials, including cement.

However, the growth will largely depend on the government’s initiative in developing infrastructure and the process of boosting the housing sector.

In construction, cement is the second-largest component, although its value accounts for only 12 per cent of total input cost of construction, whereas steel takes away nearly half the cost of inputs. Over Rs 2,000 billion worth of cement is consumed to construct a variety of structures. Within this premise, dwelling construction account for 30 per cent of all construction activity, while another 40 per cent is accounted for by non-residential buildings construction.

Roads and bridges, major infrastructure components, account for just 6 per cent of constru-ction. What remains is other structures and land improvement activity. Thus, housing and commer-cial construction is the major economic activity and it is largely dependent on cement and steel.

Cement production volume in 2016-17 has seen a year-on-year decline for the first time in 15 years, as the demonetisation exercise reduced demand. The industry, with an estimated capacity of around 420 million tonnes, saw production fall 0.7 per cent during the year. However, with no authentic data available on cement consumption or demand in the public domain, estimating actual production figures is a difficult exercise.

Cement demand has a close linkage with eco-nomic growth and government spends. Demand for housing is driven by income growth while infrastructure development largely depends on government expenditure, both state and Central.

In the recent past, demand for cement has remained poor as economic growth slowed down to less than 6 per cent between 2012-13 and 2016-17 from an average of 9 per cent between 2005-06 and 2010-11. During that period, cement demand had expanded by 8.5 per cent per annum, which has come down to around 4 per vcent per annum over the past five years.

Considering that the economy may grow at 8.50-9 per cent over the next five years, the statistical relation between cement demand and economic growth predicts that demand for the commodity may grow at the rate of 4 per cent per annum over the next five years.

The housing sector will be biggest demand driver for cement, which now accounts for about 45 per cent of total cement consumption. The other major consumers will include infrastructure (17 per cent), commercial construction (11 per cent) and the rest will be made up by industrial construction. Rural housing (40 per cent) and urban housing (25 per cent) will be the major demand drivers for the cement industry.

The industry is bullish over demand on account of the government’s focus on infrastructure and housing. The Union Budget for 2017-18 has raised the allocation for roads from Rs 5,798 billion in 2016-17 to Rs 6,490 billion in 2017-18, with a stress on laying 2,000 km of coastal roads.

According to estimates, cement comprises 30 per cent of the cost of laying a road and the budgetary allocation may translate into a Rs 1,947-billion business opportunity for the industry. For the transportation sector alone, Rs24,139 billion has been allotted for 2017-18.

Although demand for cement will not be significant, increase in volumes and prices will be pertinent for a cement industry as volume will satisfy increasing demand and prices will rise to help manage rising costs.

To boost cement demand, the government has been approving various investment schemes (see Box-1) as fast as possible.

A Macro View
ACC believes that the prospects for economic growth have become buoyant with the rural economy benefiting from a good monsoon after two successive rain-deficient years. However, the Goods and Services Tax and the demonetisation scheme which aimed to usher in greater tran-sparency in financial transactions and a transition towards a cashless economy, over the short term, has squeezed liquidity and consumption across the economy, notably in the construction sector.

The outlook for 2017 is bright, as liquidity in the economy has moved towards normalisation, with expectations for early revival and growth in overall consumption across several sectors including construction and building materials. The Union Budget with thrust on the rural sector, infrastructure development and housing will boost the overall investment climate. If 2017-18 experiences a normal monsoon, GDP growth is likely to rebound during the year. Better liquidity and improved tax collections will enhance the government’s ability to spend on infrastructure and other development projects, leading to faster growth.

ACC foresees that the industry will continue to be dogged by the challenge of excess capacity leading to intense competition. If the government is successful in increasing its investment expen-diture on large infrastructure and other develo-pment projects as announced in the Budget, it will further energise construction activity. Any cut in interest rates on housing loans will boost investment in the housing sector. Together, these developments will provide the much-needed fillip to demand for cement and concrete in the coming year.

According to Gujarat Ambuja Cement, despite several challenges, the economy has immense potential, which will power economic growth. The securitisation of real estate – Real Estate Inve-stment Trusts and Infrastructure Investment Trusts – is likely to foster greater economic activity, along with a more efficient and transparent market.

For demand growth, the government has provided incentives for rural development and also allowed 100 per cent FDI in the construction of development and industrial parks. Overall, cement demand growth is expected to rise in 2017-18 on account of higher government spending on various initiatives as announced in the Budget along with incentives for affordable housing by providing it with ‘Infrastructure Status’. This will boost demand for cement by a positive multiplier.

Sensitive Outlook
Housing demand is not expected to see a significant turnaround in the short term. However, much would depend on higher-than-expected demand or significant progress by the government on schemes such as ‘Housing for All’ or Smart Cities. If they are well implemented, it could result in good demand for cement in the near future. A below-than expected pick up in construction and infrastructure projects could affect demand for cement and the credit profile of cement companies. This may play a negative role for cement demand.

The cement industry has now become intensely competitive, with the foray of new entrants and existing players expanding inorganically. This could potentially impact market share and margins.

With the new Mines and Minerals (Development & Regulation) Amendment Act 2015, the earlier policy of deemed renewal has been discontinued and all the mining leases will be allotted through an auction. This has made it difficult for cement companies to retain or acquire existing leases. Forest and wildlife clearances are now a prerequisite and land acquisition is becoming more challenging and expensive.

Concrete Push
Here are a few initiatives taken by the government in the recent past to boost cement demand:

  • Assigning ‘infrastructure status’ to affor-dable housing projects and facilitating higher investments and better credit facilities, with an aim to provide ‘Housing for All’ by 2022. The cement industry stands to gain from the grant of infra-structure status to affordable housing;
  • Interest rate rebate of 3 per cent for Rs 12 lakh housing loans will boost demand for real estate in Tier-II and Tier-III cities;
  • The Finance Minister has announced that the National Housing Bank will refinance individual housing loans of around Rs 2,000 billion ($3 billion) in 2017-18. The minister has also set a target of completing 10 million houses by 2019;
  • Increased allocation to rural low-cost housing under the Pradhan Mantri Awaas Yojana- Gramin scheme to Rs 2,300 billion ($3.45 billion) from Rs 1,600 billion ($2.4 billion) in FY17. This will directly drive a 2 per cent increase in cement demand;
  • With the Parliament clearing the amendments to the Mines and Minerals Development and Regulation (MMDR) Act, it has enabled companies to transfer captive mine leases, similar to mines won through auctions. This will lead to more mergers and acquisitions among cement companies;
  • The government’s plans to revive state-run cement factories across India will give a boost to road and realty projects by bringing down construction costs;
  • A 15 per cent increase in capital outlay on infrastructure projects will create cement demand in roads, railway projects, irrigation and port projects;
  • Higher allocation to MNEGRA will boost rural income and have a catalytic effect on rural consumption. This is expected to help the cement industry, as it will lead to increased and sustained levels of cement consumption.

Continue Reading
Click to comment

Leave a Reply

Your email address will not be published. Required fields are marked *

Concrete

The primary high-power applications are fans and mills

Published

on

By

Shares

Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

Continue Reading

Concrete

We conduct regular internal energy audits

Published

on

By

Shares

Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

Continue Reading

Concrete

Digitalisation is pivotal in driving energy efficiency

Published

on

By

Shares

As energy costs continue to dominate the cement industry, efficiency and sustainability are proving to be vital components. MM Rathi, Joint President, Power Management, Shree Cement, explains the company’s long-term strategy is focused on cutting emissions while powering growth with renewable energy solutions.

Energy efficiency has always been a cost-saving lever for the cement industry. Today, it is the backbone of sustainability and competitiveness. Cement manufacturers are under growing pressure to optimise consumption, diversify power sources and align with decarbonisation targets. Shree Cement has been at the forefront of this transformation, significantly scaling up its green power capacity and embedding advanced technologies across operations. In this exclusive conversation, MM Rathi, Joint President – Power Management, Shree Cement, shares insights on the company’s approach to energy efficiency, challenges in brownfield modernisation and long-term strategies for achieving net zero alignment.

What percentage of your total operational cost is attributed to energy consumption?
At Shree Cement, energy is one of the most significant components of production cost, accounting for nearly 30 per cent to 40 per cent of total operational expenses. Within this, thermal energy typically contributes around 20 per cent to 25 per cent, while electrical energy forms about 10 per cent to 15 per cent. The exact share varies depending on factors such as the fuel mix (coal, pet coke or alternative fuels and raw materials), the power source (grid-based or captive like solar, wind or thermal), raw mix quality, and regional fuel and electricity price variations. This makes energy efficiency and the adoption of sustainable power sources a key focus area, both from a cost and sustainability perspective.

How has your company improved energy efficiency over the past five years?
Over the past five years, Shree Cement has consistently invested in enhancing energy efficiency across operations. Our green power capacity, covering wind, solar and Waste Heat Recovery (WHR), has more than doubled from 245 MW in 2020 to 592 MW in 2025. All grinding units are now equipped with biomass firing facilities, reducing dependence on conventional fuels. From the project stage itself, we prioritise efficiency by selecting advanced technologies such as six-stage kilns with integrated WHR, CFD-designed plants, and equipment fitted with VFDs, centrifugal compressors and high-efficiency fans. We also review and upgrade equipment systematically, replacing fans, compressors, blowers, pumps, boilers and turbines with more efficient options. This continuous approach has reduced costs while significantly advancing our sustainability journey.
What technologies or practices have shown the highest energy-saving potential in cement production?
WHR stands out as one of the most effective solutions, offsetting a significant portion of electricity required for clinker production. Hot air recirculation has also proven highly beneficial in reducing heat losses. Additionally, regular energy audits help us identify opportunities for improvement and implement corrective measures in daily operations. Together, these practices play a critical role in optimising energy efficiency and driving sustainable operations.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
The biggest challenge is the significant upfront investment required for upgradation. Retrofitting existing facilities often involves complex civil and structural modifications, which add costs and extend downtime. Integration is another hurdle, as new high-efficiency equipment may not align seamlessly with older kiln systems, fans, mills or automation setups. These factors make the transition in brownfield plants more resource-intensive and time-consuming compared to greenfield projects.

How do you measure and benchmark energy performance across different plants?
We track key performance indicators such as specific heat consumption and specific power consumption for each unit, benchmarking them against internal and external standards. Thermal Substitution Rate (TSR percentage) is another critical metric, measuring the share of alternative fuels in the thermal energy mix. Internally, we benchmark performance across plants to encourage best practice sharing. Externally, we compare against national averages and align with the Bureau of Energy Efficiency’s PAT (Perform, Achieve, Trade) scheme, which sets Specific Energy Consumption (SEC) baselines and targets for cement plants. This multi-layered approach ensures continuous monitoring, improvement, and industry leadership in energy efficiency.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation is pivotal in driving energy efficiency at Shree Cement. IoT sensors integrated with SCADA and DCS systems allow real-time monitoring of parameters like heat consumption and energy use, moving beyond periodic reports. Our digital platforms consolidate plant data, enabling management to compare metrics such as SPC, SHC, kWh per tonne and kcal per kg across units in real time. This visibility supports data-driven decisions, faster corrective actions, and higher operational efficiency.

How do government policies and incentives influence your energy-saving decisions?
Government policies and incentives strongly shape our energy-saving decisions. The Perform, Achieve, Trade (PAT) scheme sets plant-specific SEC targets. Non-compliance incurs penalties, while compliance earns tradable energy-saving certificates. This ensures energy efficiency is both cost-driven and regulatory. Additionally, subsidies and viability gap funding for renewable energy projects in wind, solar and AFR co-processing help reduce payback periods and make energy-saving investments more viable.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
Our long-term strategy aligns energy efficiency with India’s net zero 2070 goals. Key levers include improving efficiency, expanding green electricity, producing more blended cement, and increasing alternative fuel use. Today, more than 60 per cent of our electricity comes from green sources such as solar, wind, and WHR, the highest in India’s cement industry. Our blended cement products, which reduce limestone and fuel consumption, further lower emissions. These products are certified under the GreenPro ecolabel by CII, validating our sustainability practices and environmental standards.

Continue Reading

Trending News