Economy & Market

Revival of small scale cement manufacturing

Published

7 years ago

January 7, 2019

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The availability of most of the AFR is limited or scattered which may not be economically viable for use in most of the large cement plants because of logistics, quantity, preparation and technical issues, says Dr KN Bhattacharjee.

The availability of most of the AFR is limited or scattered, which may not be economically viable for use in most of the large cement plants because of logistics, quantity, preparation and technical issues. This is a great roadblock for the effective use of AFR. However if an industry can find means to utilise its own by-product or waste in its own premises or nearby then it will be a win- win situation for all. Cement manufacturing process is a very appropriate process to recycle many industrial and agricultural wastes. The black meal process of vertical shaft kiln technology is a proven technology in China and India and can serve as a very good outlet for consuming AFR in the vicinity of industries generating the waste in small quantities.

This will also help in reducing environmental pollution. The author has carried out numerous plant scale trials with various industrial and agricultural wastes in VSK plants in India with reasonable success and feels that it may be worthwhile to go backward technology-wise to improve India’s usage of AFR. With the recognition of performance-based cements in most of the standards of world, composite cements are to gain ground and many alternate materials mainly industrial wastes can find profitable use again in small-sized cement plants.

The vertical shaft kiln (VSK) technology is an old technology of Portland Cement manufacture and even the modern versions have almost phased out from India mainly because of economics of scale and taxation issues. In China, still 30 per cent of its cement production comes from shaft kiln plants. The VSK process technology is still a workable proposition for use of wastes available in limited quantities. Also by virtue of the simple process a plethora of process issues associated with modern pre-heater, pre-calciner rotary kiln system are eradicated while using AFR. Plant scale trials with many wastes have shown improvement in VSK clinker quality and better productivity from the kilns. Also it is possible to add many wastes in small quantities directly to VSK clinker to produce high performing composite cements. Although the plan sounds to be reverse engineering but sometimes an old concept can regain its past glory due to changing national needs and environmental issues.

The modern vertical shaft kiln technology is technically sound and institutes like National Council of Cement and Building Materials (NCCBM) and the then Regional Research Laboratory (RRL), Jorhat had done a commendable work in modernising the technology in India. Also the village-based Saboo technology created a stir in India in the 80s when they brought cement manufacturing under the umbrella of small scale industry. During that period, the objective was to increase production as India was cement deficit and VSK technology was a partial answer to quickly bridge the gap between demand and supply. In the hilly terrain of North East, it is still a viable proposition to use scattered small limestone deposits in the midst of logistical challenges.

The advantages and disadvantages of black meal process of vertical shaft kiln technology:

Advantages:

Small scale cement production and still suitable in hilly terrains having limestone deposits for local distribution of cement.
Energy efficient process: Specific heat consumption is in the range 600 to 650 Kcal/kg of clinker. Specific power consumption is in the range 0f 60 to 70 Kwh/tonne OPC although authentic figures are not available. Since drying, pre-heating, calcining, burning and cooling are integrated in the same vessel, heat losses due to convection and radiation is much reduced.
Porous VSK clinker is much easier to grind thus cement grinding power requirement is less.
Very low refractory consumption as kiln is stationery and low abrasion as material flow is vertically downward with slow speed.
Vast scope of using AFR available in smaller quantities is the major advantage. Some alternate waste materials can act as flux or mineraliser. Mineralising ions can increase the rate of reaction in burning zone leading to complete burning in burning zone.
Thus the technology offers avenue not only in the use of wastes but also utilise the waste in improving burnability by stabilising phases at lower temperatures.
recirculation of obnoxious gases and materials which ensures smooth operation and higher productivity.
Due a constant bed of wet green nodules above the calcining zone the green nodules bed acts as an effective filter to arrest all dust particles. No additional gas cleaning device is required.
Since fuel is inter-ground with raw materials elaborate arrangement of fuel preparation and firing is eliminated
Very effective and controlled flow of material through flat grate using variable frequency drive (VFD). This helps to position the burning zone constantly at the same level.
Relatively simple machines to operate and maintain.
Gestation period of starting a new plant is very low.
No highly skilled manpower is required and local folk/plant staff can be easily trained for operations.
Possible to manufacture a variety of clinkers and thereafter produce various kinds of low cost Portland cements.
Very little chance of cold air in-leakages. Diversion of combustion air during clinker discharge has been ably dealt by either triple air locking arrangement or material block tube in the modern VSKs.
Since each nodule has its independent fuel system significantly higher temperatures are not achieved leading to no issues of NOx.

Disadvantages:

Viability can be at stake due to taxation policies and lower scale of operation. However if Government gives tax rebates on use of AFR the plants can be viable. Also it is possible to reduce cost of production by using low cost or free of cost non- conventional materials and waste fuels available locally. Maybe the savings can be shared with customers.
Quality issues: Many believe that VSK clinker cannot be at par with modern rotary plant clinker. In this respect a few conflicting issues are prevalent. It is true that using the same raw materials and fuel the modern rotary clinker will be better performing especially the later age compressive strengths and soundness of cements produced. However the soft burnt nature of the VSK clinker opens up possibilities of addressing customer requirements of good early age compressive strength and early setting in the case of PPC and PSC. The author has found that early age compressive strengths and setting can be matched with modern plants while making PPC with a maximum of 30 per cent fly ash absorption. The Black meal process is capable of producing sound clinkers with less than 1.5 per cent free lime and 45 per cent C3S component. The author’s experience in few VSK plants in Jodhpur-Rajasthan region supports this viewpoint. Experiences with various limestone in Northern India and Bhutan reveals that the technology cannot tolerate high magnesia limestone primarily due to the absence of rapid cooling arrangement but adding certain industrial wastes with mineralising minor constituents gives amazing results in reducing or mitigating this deleterious effect.
Consistency of clinker: Consistency does get affected if the raw mix is not well homogenised and nodulisation is not controlled. However these can be easily solved by using good homogenisation and blending techniques. Nodulisation can be automated to yield nodules of good strength. In some cases nodule strength can be improved by double nodulisation. Various industrial wastes like bagasse from sugar industry have been found to improve nodule strength together with bonus addition of heat value. Waste oils can be added at this stage to give very good results.
Heat difference between the central and peripheral charge especially in the large dia kilns of 100 TPD per day can be a matter of concern in some cases depending of raw materials and fuels used. The 50 tonne/day Saboo shaft kiln design was found to very efficient in this respect. Crust formations were found to be minimal. Dustry clinker due to beta to gamma conversion of C2S is prevalent in few cases but can be eliminated by stabilisation of phases even with the inherent disadvantage of rapid or quench cooling.

Plant scale trials using various alternate materials and fuels:

Use of pond ash, bottom ash and boiler fired rice husk ash in a 50 TPD VSK plant in Kanpur Dehat, Uttar Pradesh: Both bottom and pond ash were procured from Panki Thermal power plant and were used as components of raw mix separately as a source of Silica and Alumina by partial replacement of plastic clay by 15 to 20 per cent. There was drop in free lime from 2.2 per cent to 1.8 per cent and the dust content in clinker reduced drastically. There was increase of 1.5 to 2.0 MPa in 3 days and 3 MPa in 28days compressive strength of 43 grade OPC. The pond and bottom ash had substantial carbon particles (LOI- 15 to 20 per cent) which added some heat value and perhaps the reactivity of the raw mix increased by the presence of some amount of reactive alumino-silicates. Indirect effects noticed was smooth kiln operations with a slight increase of production from the 50 TPD VSK. Pond ash which is generally wet can be added directly during nodulisation if a dosing arrangement is designed to avoid the drying operation. Boiler fired Rice Husk was tried in the same plant which gave very good results in improving clinker quality. The material was black in colour with LOI around 10 per cent indicating unburnt carbon which must have supplemented the heat input. It was possible to add rice husk as it is but plant scale trial was not attempted with the apprehension that the husk fibres may not give a homozenised mix in the existing raw grinding arrangement.
Use of Phosphorus furnace slag, alkali bypass dust and bag house dust from a Calcium Carbide plant: All these materials were tried with a contention to capitalise mineralising effect from the wastes due to some minor constituents or the presence of reactive silica or Alumina. Even granulated blast furnace slag (GBFS) was also tried. Improvements in kiln productivity and quality was noticed of clinker in most of the cases. In VSK operation any measure which goes to ensure completion of the reactions in the short burning zone will definitely go in improving clinker quality and smooth kiln operations. Appropriate raw mix fineness with correct proportioning of waste materials and fuels, homogenisation hold the key to success.
Additions of alternate waste materials with VSK clinker to make composite cements The future of cement making is composite cements. This not will helps to use some industrial or agricultural wastes in the final product but also help to improve performance of cements and reduce the carbon footprint. In many cases it can lead to low cost cements together with better performance.

Significant improvement was observed when 5 per cent bag house dust from a calcium carbide plant was added in a quaternary mix of 60 per cent Granulated Blast Furnace slag (GBFS) and 3 per cent gypsum using VSK clinker. Initial setting time was reduced from 180 minutes to 40 minutes when compared with plain control sample of PSC. There was an improvement of 2 MPa at 3 days and 28 days compressive strength was more or less the same. Quaternary blends using Alkali bypass dust and 60 to 70 per cent GBFS , gypsum and VSK clinker also performed well in terms of faster setting and improvement of early age compressive strength. Similar results were obtained while using brick kiln ash and calcined clay Pozzolana in dosages of 15 to 20 per cent while making PPC mixes using VSK clinker.

Thus VSK clinker can act as a performance enhancer for early setting and early age compressive strength in presence of high dosage GBFS containing PSC cements and fly ash/CCP based Pozzolanic cements. Hydration studies have revealed that the soft burnt VSK clinker releases soft burnt lime at a faster rate in the early ages leading to higher quantity hydration products both with GBFS and Pozzolana.

Conclusion
The author was associated with VSK plants for six years while doing his Ph.D. His doctoral work is mainly associated with hydration studies of composite cements and VSK clinker doped with ions coming from various industrial and agricultural wastes. He feels that the black meal process using modern vertical shaft kiln technology can be a viable proposition to use localised waste materials available in limited quantities. The process simplicity of the Black Meal process opens up immense potential for use of wastes (both agricultural and Industrial) with improved cement performance in many cases. Waste generating plants can have captive VSK plants or sub let this activity to local entrepreneurs. All performance enhancements have been validated by actual hydration studies which is available with the author for anyone who is interested. This has been a part of the author’s doctoral work. The author feels that for India till we incorporate large scale AFR facilities catering to large cement plants the VSK plants can be revived mainly for use of localised AFR as the project cost and gestation period from concept to commissioning is very low.

Acknowledgement
The author is grateful to AKS University administration for allowing to publish this paper.

About the author
Prof (Dr) KN Bhattacharjee has 37 years experience in the global cement industry. He has worked with all process technologies of cement manufacture and has done considerable work on use of AFR in mini-cement plants. His Ph.D thesis is in applied cement chemistry and his findings helped many mini-cement plants in India to improve their profitability during the late 80s. He has publications in reputed international and national journals like Cement and Concrete Research, ZKG International, Silicate Industrials, Transactions of Indian Ceramic Society, etc. After his retirement in 2016 from Dangote-Africa, he is teaching cement technology to B.Tech students in AKS University, Satna. Dr KNB has worked with ACC in India, two plants in Oman, Lafarge Canada and Dangote, Africa.

Concrete

The primary high-power applications are fans and mills

Published

2 weeks ago

October 10, 2025

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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.

Concrete

We conduct regular internal energy audits

Published

2 weeks ago

October 10, 2025

admin

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.

Concrete

Digitalisation is pivotal in driving energy efficiency

Published

2 weeks ago

October 10, 2025

admin

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.