Economy & Market

Is Germany Making Too Much Renewable Energy?

Published

5 years ago

March 5, 2021

admin

Wind turbines are seen on a plain near Bremerhaven, Germany on Dec. 26, 2017. PATRIK STOLLARZ/AFP VIA GETTY IMAGES

For Germany, 2020 was a banner year in the production of renewable energy. Clean energy sources??ind farms and solar arrays as well as hydroelectric and biogas plants??atcheted their share of power consumption up to 46 percent, nearly equaling that of coal, gas, oil, and nuclear power combined. And after a period of stagnation in the 2010s, the greenhouse emissions of the world?? fourth-largest economy have been dropping again, last year by around 80 million tons of carbon dioxide. That puts Germany 42 percent down from its 1990 emissions level, thus surpassing its decade target by 2 percentage points. This trajectory is good news for Germany??nd for the EU, which wants to turn the continent carbon-neutral by 2050.

Yet Germany?? move to a power system largely reliant on weather-dependent renewables is quickly running up against limits??ssues that all countries exchanging conventional fuels for wind and solar will eventually face. What happens when the sun doesn?? shine and the wind doesn?? blow for hours or even days at a time? And what about the short, dark, cold days of midwinter when renewables of Germany?? power demand?

And it?? not only shortages that are problematic but also surpluses: Stormy days can be so windy that the power flows from wind parks on- and offshore overwhelm the power grid, even triggering its collapse.

These electricity tsunamis can threaten the stability of neighboring countries??energy systems, a brickbat the Poles and Czechs wield. Moreover, when there?? excess power in the grid, prices can go negative, forcing grid operators to pay customers to take the electricity,

The transition from a conventional energy system with 24/7 production to one based on intermittent renewables entails more than just swapping one set of energy sources for another; it demands rethinking and restructuring the entire energy system.

Georg Stamatelopoulos, an energy expert at the utilities company EnBW, sums up the conundrum: ??enewables now cover around half of the demand, and there is still sufficient available power in the system and there is still the possibility of obtaining electricity from our neighbors. What is certain, however, is that further expansion of renewables will increase the volatility in the system. That is why we will always need available service, i.e., service that is available to us when we have the corresponding need.??/p>

Energy blackouts are the bugbear that industrialists and the conventional energy sector have long warned about in ominous tones. Too much or too little power in the grid can indeed prompt energy shortfalls, causing whole regions to go dark and assembly lines to halt. But thus far, in highly industrialized Germany, blackouts have not??et??ome to pass. There?? been no countrywide blackout for years, and last year, the average German experienced just 12 minutes of outage: the lowest in Europe and infinitesimal compared the U.S. citizen?? 2019 average of 4.7 hours.

The Germans??feat was possible, however, only because the country has mostly just added clean energy capacity to the supply over the last two decades, investment encouraged through price supports that make its energy among the most costly in Europe. At the same time, the country maintained much of its fossil fuel generation and a handful of nuclear plants. The surplus power is exported??t a handsome profit for coal-plant-owning utilities.

This whole calculation is changing dramatically, however, as Germany moves to shutter its coal-fired plants (the country?? last will close, at the latest, in 2038) and nuclear power stations (which will be disconnected from the grid in 2022). On Jan. 1, 11 coal-fired plants??ine in North Rhine-Westphalia and two near Hamburg??ent dark, and others will soon follow. Of the six remaining nuclear plants, three will terminate at the year?? end and the final three a year later.

Moreover, while utility power storage options, such as batteries, are quickly improving, batteries still don?? have the capacity to bottle up enough clean power for Germany to hold out even for a couple of fossil-free hours, much less days. Another factor: Even if energy efficiency improves dramatically??hrough the mass insulation of buildings and modernization of their energy systems, for example??ermany will in the future still need more power than it uses today for its fleets of electric cars and trucks, for public transportation, for electrified heating, and for producing the hydrogen and e-fuels that will fly planes and produce cement.

This drop-off is steep and fast, and it throws the Germany energy system into unknown territory??here the interests of energy providers, environmentalists, politicians, and grid operators clash fiercely. There?? more than one way to balance the grid, and it will have wide-ranging implications for Germany?? march to carbon neutrality.

The German gas sector and most German industry underscore that flexible, gas-fired electricity generation is the perfect partner for fluctuating renewables. Indeed, the most modern gas-fired power plants emit significantly less carbon than coal and oil. (Damning reports about gas methane emissions, another greenhouse gas, have tarnished its brand but not enough to disqualify it.) The gas lobby and many experts want more state-of-the-art gas-fired plants constructed, which they say will operate to 2050 and beyond. The gas companies, which now advertise their product as ??reen energy,??are naturally all in favor of replacing nuclear, coal, and oil with their product as fast as possible. Gas-fired electricity, they argue, will also be essential to producing hydrogen, which will power fuel-celled vehicles and produce synthetic fuels as well as store electricity.

Economists, however, point out that as higher carbon pricing boosts the surcharge on carbon dioxide to new highs, natural gas will price itself out of the market. ??as looks like the easiest answer,??said Toby Couture, director of E3 Analytics, an independent renewable energy consultancy in Berlin. ??ut in the near future, gas is increasingly likely to be outpriced. The question is: Can other technologies and approaches balance more cheaply? And the answer is yes.??/p>

Experts like Couture say demand management has enormous, thus far mostly untapped, potential. Through price incentives, massive quantities of power demand can be shifted from, for example, daytime peaks to night hours when demand is almost none. The state-financed German Energy Agency argues that management of electricity demand can be accomplished through ??he targeted switching off and on of loads according to market signals. This can be done ??in mills, furnaces, or pumps.??/p>

??n short,??Couture said, ??hat we need to do is flip the previous paradigm on its head used to build power plants to meet demand. Now we need to intentionally shape our electricity demand so that it is better adapted to our supply: variable, renewable, and abundant.??/p>

Storage is the obvious go-to option. Utility-size batteries can give back in the dark the surplus they collect during the day??nd tank up on super blustery days so upsurges don?? crash the system or cost grid operators. Other, non-battery means of storage, such as hydrogen, seawater, and aluminum storage, are currently advanced enough to pitch in. ??ven when the excess electrons aren?? enough to crash the system, they have to go somewhere. Now, absurdly, power stations are shut down or other countries actually paid to take this electricity off Germany?? hands,??said Gretchen Bakke, author of The Grid: The Fraying Wires Between Americans and Our Energy Future.

Battery technology has advanced vastly in recent years and already contributes to the short-term reliability of Germany?? grid. California has gone further, though: Utility battery developers have actually undercut the prices of gas companies to provide back-up capacity to the state?? energy system. California energy authorities expect that storage coupled with deft energy management and renewables will replace natural gas and coal-fired generations across the American West.

Most importantly, according to climate experts, is the broad, rapid rollout of renewables??ive to 10 times what Germany now has??ncluding geothermal, bioenergy, hydroelectric, and wave/tide energy, all of which are less weather dependent than solar and wind. Until then, even environmental groups like Friends of the Earth and Greenpeace acknowledge that natural gas is going to be part of the solution??hough exclusively as reserve capacity that may run just 5 or 10 percent of the time. ??as will be like a fire brigade,??said grids expert Werner Neumann of Friends of the Earth. ??here for when we need it and compensated accordingly.??/p>

Cross-border trade in energy is another way to compensate for shortfalls. Policymakers in the European Union have sketched visions of a long-distance smart transmission network that would extend from the Arctic Circle to the Mediterranean Sea, capable of seamlessly balancing shortfalls and surpluses??ventually with 100 percent green energy. Trans-European energy grids will be linked to decentralized small-scale grids and plants, making the dream come true of an EU-wide energy market. Although the project is in motion and already helps shift power between Germany and Denmark, as well as France and the United Kingdom, it won?? cover all of Europe anytime soon.

ABOUT THE AUTHOR:

Paul Hockenos is a Berlin-based journalist. His recent book is Berlin Calling: A Story of Anarchy, Music, the Wall and the Birth of the New Berlin (The New Press).

Concrete

The primary high-power applications are fans and mills

Published

3 weeks ago

October 10, 2025

admin

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

3 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

3 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.