Concrete

Mining in India: Moving Towards a Sustainable Future

Published

5 years ago

February 1, 2022

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The mining industry in India has to ramp up its efforts in order to be more energy efficient and sustainable. Since the process of mining plays an important role in cement manufacturing, we take a closer look at the impact of mining on the environment, human health and biodiversity, and the sustainable processes that are the need of the hour.

The mining industry in India contributes significantly to the economy, amounting to around 10 to 11 per cent to the industrial sector. This industry took a modern turn post the economic reforms of 1991, and the 1993 Mining Policy further helped its growth. India has a rich reserve of mineral and non-mineral ores distributed in five mineral belts across the length and breadth of the country. The geographical distribution of mineral belts are the North Eastern Peninsular Belt, Central Belt, Southern Belt, South Western Belt and North Western Belt. The index of mineral production of the mining and quarrying sector for November 2021 stood at 111.9, which was 5 per cent higher than the level in November 2020.

Mining in India falls under the legal and constitutional framework. Mining operations are regulated under the Mines and Minerals (Development and Regulation) [MMDR] Act of 1957. The State Governments, as owners of minerals, grant mineral concessions and collect royalty, dead rent and fees as per the provisions of MMDR Act. These revenues are held in the Consolidated Fund of State Government until the state legislature approves their use through budgetary processes. The MMDR Act was enacted to provide for the regulation of mines and development of minerals under the control of the Union. The Act has been amended in 1972, 1986, 1994 and 1999 in keeping with changes in the policy on mineral development.

In 2015, the act was amended with the intention of removing discretion and introducing more transparency in the grant of mineral concessions. The amendments now made to the MMDR Act, 1957 provide that mineral concessions will be granted only on the basis of bidding at an auction, for the prospecting stage or mining stage on a case to case basis.

The metals and mining sector in India is expected to witness a major reform in the next few years, owing to reforms such as Make in India Campaign, Smart Cities, Rural Electrification, and a focus on building renewable energy projects under the National Electricity Policy as well as the rise in infrastructure development.

The cement industry largely consumes two minerals – limestone and coal – in the cement making process, which are extracted by the mining from the reserves across the country. Limestone is the primary raw material used for making cement, while coal is extensively used to generate energy for the cement kilns.

The production level of limestone stood at 303 lakh tonnes as of November 2021. According to Invest India, National Investment Promotion and Facilitation Agency, India is home to 1,303 coal mines in 2019-2020, making it the second largest coal producer in the world, producing 716.084 MT coal.

Impact of mining on the environment

Mining of raw materials from quarries may result in enhanced production of the end product, but has an adverse impact on the environment. The effects can result in erosion, sinkholes, loss of biodiversity, or the contamination of soil, groundwater, and surface water by the chemicals emitted from the mining processes. These processes also affect the atmosphere from the emissions of carbon, which have an effect on the quality of human health and biodiversity.

The air around the mines is greatly impacted by the release of unrefined particles. Wind or vehicular movements make these fine particles airborne affecting people living close to the mines and causing health issues. Similarly, mining can also lead to the pollution of water bodies surrounding the mines, which could occur due to mineral or sediment deposits, acid mine drainage or waste disposal. This could hamper the quality of water surrounding the mines, leading to water pollution and health problems to those who may consume this water in some form. Land and biodiversity close to the mines are also impacted; it may lead to soil erosion and landslides while disrupting the life of living creatures in the area.

Mining and the cement industry

Mining is an integral part of the cement making process. It is the first step in obtaining the key raw material – limestone – from quarries to make the final product. Limestone is obtained from the deposits or rock by blasting or mechanical excavation depending on the hardness of the rock. It is then crushed into smaller chunks. After crushing the stone is sorted into different fractions by screening, after which it is processed further. In the grinding process, the limestone is ground to a fine powder.

Most of the limestone is obtained from open quarries. The extraction is carried out by open cast method on both small and large scales. The small-scale extraction of limestone is done manually by individuals using minimal machinery. The limestone beds are drilled for blast holes using drilling machines, after which the rocks undergo blasting. The limestone rocks undergo manual sizing, in order to obtain rock pieces of suitable sizes for easy transportation and processing.

For cement, limestone mining takes place on a large scale by the underground mining method. The basic operations in underground mining are drilling, blasting, loading and hauling, scaling and roof bolting. Drilling equipment includes horizontal drills and down hole track drills. This equipment results in much smaller blast holes and a lower volume of rock produced with each blast. Other equipment required in the underground mine includes powder loaders, which are used to blow ammonium nitrate–fuel oil mixtures into the blast holes. Scaling rigs, which are used to remove loose rocks from the ribs and roof of the mine, and roof-bolting equipment may also be required in an underground mine.

“Mining is undertaken as per the approved mine plan. All environmental parameters as per the norms of the Ministry of Environment, Forests and Climate Change (MoEFCC) are taken into consideration while preparing the mine plan. Since mining is localised to a few hectares of area only, hence its impact is negligible. The areas of concern are air, water and noise pollution, which are monitored regularly while dust suppression is a regular process as per the guideline of DGMS as well as IBM. Impact on the lease area is minimal,” says Hitesh Sukhwal, Senior Manager (Head Environment), JK Lakshmi Cement Ltd.

“The mining area is selectively identified, and parameters such as reducing diesel consumption, less lead distance, fuel efficient equipment, separate dumps for rejects, dust suppression with less quantity of water (like fogging system), optimum utilisation of resources, working and calibration of cross belt analyser are some considerations, which are taken into account while carrying out mining. Monitoring of all the mentioned parameters helps in identifying areas of concern and thereby leads to optimisation of the mining operations,” he adds.

Cement making is an energy intensive process and coal provides for 90 per cent of the energy consumed by cement plants around the world. India is one of the largest producers and consumers of coal, with the cement sector dominating its consumption. The Coal India Limited (CIL) is the state-owned miner for the country and accounts for over 80 per cent of domestic coal production. CIL coal production target for India is set to 1 billion tonnes by FY2020. However, the cement industry gets about 5 per cent of coal from within the country, and the rest of its coal demand is met through imports. The combustion process results in the emission of carbon dioxide, which is a prominent reason for air pollution.

There are four types of coal available in India, namely, peat, lignite, bituminous coal and anthracite coal. The most consumed amongst these are lignite and bituminous. The cement industry mainly uses non-coking bituminous coal and lignite in small quantities in plants in Tamil Nadu and Rajasthan. Specifically, the coal used by the cement companies is of grade G4, G5, G6, G7, G8 and G9.

The industry is constantly looking for alternative solutions to replace coal and reduce the carbon emission by substituting it with other energy giving materials. This is a conscious effort taken by all large players in the cement industry.

This leads to the cement industry being one of the largest consumers of coal and buyers of the mined mineral. Coal mining has its own set of impacts on the environment. “Coal mining activities change the land use pattern and thus, impact the flora, fauna, water table and vegetation in the mining area and surrounding to an extent. However, by deploying sustainable practices, which are part of mine planning and implementation, this impact can be reduced to a great extent,” says Pukhraj Sethiya, Associate Vice President – Mining & Integrated Coal Management, Adani Enterprises.

“We have been deploying sustainable mining practices in our mines, which has mitigated the impact of mining activities on the environment to a great extent while at the same time generating a large number of employment opportunities. The sustainable practices that we have adopted include transplantation of trees rather than simply cutting them, soil storage, water treatment and reutilisation and coal transportation through mechanised and covered means,” he adds.

Mining waste – a resource or hazard?

According to the Indian Bureau of Mines, it is estimated that well over 170 million tonnes of solid wastes related to mining are generated in India every year. This is expected to rise substantially to 300 million tonnes with the increase in production of various minerals. Due to shortages of some minerals in the natural reserves and depletion of high-grade ores, leaner grade ores are being mined which generate a large amount of waste. Adding to this, the preferred method of mining for industries is the open cast method for its high productivity, economic viability and safety aspects, which leads to large volumes of waste generation.

This rock waste generated cannot be immediately back filled due to geological constraints and has to be planned and phased out. This results in stacking of this waste externally creating a mining waste dump.

“We practice zero waste mining as part of our sustainable process. The waste generated during the mining (while removing the soil or hard rocks) we use the waste for the back filling. When we move the limestone that is exposed through drilling and mining, a pit is formed and we use the waste material from the mining process to fill back the pit,” says SK Tiwar, Director Technical, Heidelberg Cement (India).

Besides occupying a large area of land, these dumps impact the landscape forestry and vegetation of the location. Wash-offs from these dumps pose siltation of nearby water bodies and agricultural fields. They are also prone to wind erosion.

While this waste is an unavoidable damage to the land, there are many ways of rehabilitating the area where the waste is dumped. The design of the waste should accommodate progressive rehabilitation to ensure a minimum area is disturbed at any given time. This waste can also be used in alternative jobs, like construction or landfills, to put it to good use and reduce the stacking and dumping of the same.

It must be ensured that a proper drainage channel is created from the waste dump in case heavy rainfall is expected in the area. This shall prevent the nearby land from getting contaminated with the waste residues. Proper rehabilitation of tailings must be planned in order to avoid contamination of water sources around the dump area.

Rehabilitation of the mining waste dump areas should aim to establish a vegetative cover and increase rainfall infiltration. Dumps with higher salt content must be screened with overburden of the lowest salt content.

In all the above methods, the mining waste dump must be attended to and should be put to use or rehabilitated to avoid damage to the environment, water and people around the area.

Neeraj Akhoury, CEO India, Holcim Group and Managing Director & CEO, Ambuja Cements Ltd for World Cement, said, “Building a sustainable green construction sector will be the outcome of an active participation of not only cement and other building materials manufacturers but also end consumers and governments. The level of awareness among all stakeholders is much better than what it used to be even a decade or so ago. We can draw a lot of confidence and optimism about the future of a sustainable construction sector from similar achievements like the growth in clean mobility (electric vehicles) and also the impressive strides made in India’s renewable energy sector. A very green construction sector is not very far behind.”

The cement industry consumes mined materials for their varied processes, and its volume has the potential to change the game for the environment. Shifting practices towards sustainable means can lead to a greener country with cleaner air. With advanced technology and better planning, this is an achievable feat. Influential players in the cement industry are making efforts to help heal the environment and create mining processes that do more good than harm.

Kanika Mathur

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Concrete

ABB Extends Drive Lifespan at ACC Cement Plant Without Production Shutdown

Published

1 day ago

November 12, 2026

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ABB reconditions 25 drives at ACC’s Jamul cement plant, avoiding 16 tonnes of CO₂ emissions while improving reliability through predictive maintenance.
Chhattisgarh

ABB has signed a multi-year Motion OneCare service agreement with ACC Limited, part of the Adani Group, to modernise ageing industrial drives at its Jamul cement plant in Chhattisgarh, improving operational reliability while avoiding approximately 16 tonnes of carbon dioxide (CO₂) emissions without disrupting production.

Announced on 27 October 2026, the agreement combines scheduled drive reconditioning, digital condition monitoring and energy appraisals to extend equipment lifespan, improve plant uptime and optimise maintenance costs. The initiative marks a shift from conventional equipment replacement towards a more resource-efficient approach to industrial asset management.

The first phase, completed in April 2026, involved the on-site reconditioning of 25 ABB ACS800 variable speed drives without a major plant shutdown. By retaining the existing cabinets and restoring the drive modules rather than replacing entire panels, ABB helped ACC preserve capital investment, minimise material consumption and avoid approximately 16 tonnes of CO₂ emissions.

A second phase, covering an additional 25 ACS800 drive modules, is scheduled for the fourth quarter of 2026. The programme is designed to improve long-term equipment reliability while allowing maintenance activities to be aligned with the plant’s operational schedules.

The ACS800 drives, installed at Jamul in 2010, had delivered more than a decade of near-continuous service in demanding cement manufacturing conditions. However, ageing electrical components and changing fault patterns had begun to affect their ability to meet the plant’s reliability requirements.

Rather than opting for complete equipment replacement, ACC engaged ABB’s certified engineers to conduct a comprehensive asset health assessment. The evaluation found that the existing cabinets and enclosures remained structurally sound, making targeted reconditioning a technically viable and cost-effective alternative to full replacement.

Drawing on nearly two decades of experience with ACC’s equipment and operating requirements, ABB developed a maintenance framework tailored to the plant’s shutdown windows, budget cycles and production priorities.

The Motion OneCare agreement incorporates planned equipment restoration, condition-based monitoring and energy assessments, enabling ACC to adopt a more systematic approach to maintaining critical electrical infrastructure.

As part of the programme, ACC has implemented ABB Ability™ Digital Powertrain Insights to monitor drive performance and identify emerging operational issues before they result in equipment failures.

The digital platform provides continuous visibility into parameters such as temperature, current, vibration and fault patterns. These insights allow maintenance teams to detect early signs of equipment deterioration, schedule interventions more effectively and reduce the likelihood of unexpected downtime.

Amit Gupta, Local Division Manager, Motion Services, ABB India, said: “We know what unchecked wear costs over time: a small inefficiency that eats away at ROI for years. At Jamul, the evidence pointed clearly to assets with productive life still in them.”

“Our job was to restore them properly and give the team the tools to stay ahead of the next problem. At ABB, we don’t just fix what fails. We want to protect what works.”

The initiative also demonstrates the growing relevance of circular economy principles in cement manufacturing, where extending the service life of existing industrial equipment can reduce capital expenditure, material consumption and the environmental impact associated with manufacturing replacement components.

According to ABB, drive reconditioning can reduce lifecycle emissions by 50 to 80 per cent compared with complete equipment replacement. By preserving functional components and restoring critical modules, the process helps retain the economic and material value of existing industrial assets.

The addition of energy appraisals in subsequent phases will further expand the programme beyond equipment restoration, enabling ACC to assess drive performance, identify energy-saving opportunities and improve operating efficiency.

For cement manufacturers, variable speed drives play an important role in controlling motors and optimising energy consumption across production processes. Maintaining their reliability and efficiency is essential for minimising operational disruptions and managing electricity costs.

Vinod Bahety, CEO – Cement Business, Adani Group, said: “Moving from reactive firefighting to a structured maintenance plan was exactly what this operation needed. That kind of peace of mind doesn’t come easily. It comes from a partner that understands how your business runs.”

“We didn’t need a full system overhaul; we needed expert support, actionable insights, and a plan we could execute around our schedule. That’s what we got.”

The project supports ACC’s broader strategy to improve manufacturing efficiency through digital transformation, preventive maintenance and sustainable asset management.

ACC, a subsidiary of Ambuja Cements and part of the Adani Group, operates 20 cement manufacturing facilities and 119 ready-mix concrete plants across India. The company has been advancing initiatives focused on renewable energy, circular economy practices and technology-driven operational improvements.

Alongside Ambuja Cements, ACC is part of a large-scale building materials business committed to achieving net-zero emissions by 2050, with near-term and net-zero targets validated by the Science Based Targets initiative (SBTi).

The Jamul initiative aligns with these sustainability objectives by demonstrating how equipment life extension and digital monitoring can contribute to resource efficiency without requiring large-scale replacement of existing infrastructure.

ABB, a global technology company specialising in electrification and automation, brings more than 140 years of industrial expertise and employs approximately 110,000 people worldwide. Its Motion Services business supports industrial customers through equipment maintenance, modernisation, digital monitoring and lifecycle management solutions.

The agreement also reflects a wider shift in industrial maintenance practices, with manufacturers increasingly adopting predictive technologies to improve equipment availability, manage costs and reduce unplanned shutdowns.

With 25 drives already reconditioned and another 25 scheduled for restoration, ABB’s collaboration with ACC illustrates how targeted modernisation, digital monitoring and circular maintenance practices can extend the operational life of critical equipment while supporting more efficient and sustainable cement production.

Concrete

ABB Drives Digital Transformation at TCI MAX Cement Plant in J&K

Published

1 day ago

November 12, 2026

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ABB deploys advanced process control at TCI MAX’s Srinagar cement plant to improve clinker quality, energy efficiency and sustainable manufacturing.

Kashmir

ABB has deployed its advanced process control technology at TCI MAX Cement’s Srinagar facility in Jammu and Kashmir, marking the region’s first reported implementation of advanced process control (APC) in cement manufacturing and strengthening efforts towards more efficient, digitally enabled production.

Announced on 5 November 2026, the deployment of ABB Ability™ Expert Optimizer at the facility, operated by Trumboo Industries Pvt. Ltd., aims to improve process stability, clinker quality, energy efficiency and overall plant productivity. The implementation forms part of TCI MAX’s strategy to modernise its manufacturing operations through automation and digital technologies.

Following the integration of ABB’s advanced process control solution and supporting IT infrastructure, TCI MAX has reported improvements in operational productivity, product quality and sustainability-related performance indicators. The technology focuses on optimising the cement pyro process, a critical stage of production involving high-temperature processing and clinker formation.

Waseem Ahmed Trumboo, Director, Trumboo Industries Pvt. Ltd., said: “Introducing advanced process control at TCI MAX is an important step in how we are evolving our operations. Our focus is on improving the stability and efficiency of our processes while maintaining consistent clinker quality. We have been encouraged by the performance of the solution during commissioning and by the support from the ABB team, and we look forward to realizing its full potential.”

ABB Ability™ Expert Optimizer combines advanced process control, model predictive control (MPC) and artificial intelligence (AI) to continuously monitor and optimise manufacturing operations. By analysing process conditions, predicting operational behaviour and automatically adjusting key parameters, the system enables more consistent production while reducing process variability.

In cement manufacturing, maintaining stable pyro-processing conditions is essential for achieving uniform clinker quality and optimising thermal energy consumption. Fluctuations in operating parameters can affect fuel efficiency, production output and product consistency.

The deployment is designed to address these challenges through real-time process optimisation, helping operators maintain more stable kiln operations while improving the utilisation of fuel, electricity and raw materials.

Kapil Agarwal, Senior Vice President and Local Division Manager, Process Industries Division, ABB India, said: “Cement producers are increasingly looking to adopt digital technologies to achieve greater consistency and efficiency while addressing their sustainability priorities. ABB Ability™ Expert Optimizer brings advanced process control and deep cement process expertise together to help operators make their processes more stable and efficient. We are pleased to support TCI MAX as it takes this important step in its digital transformation.”

The technology also supports sustainability objectives by optimising fuel consumption, improving electrical energy efficiency and minimising process waste. More stable operations can contribute to lower energy intensity and reduced emissions associated with cement production.

For TCI MAX, the investment represents a move towards data-driven manufacturing, where automated control systems complement operator expertise to improve production performance and operational reliability.

The implementation is particularly significant for Jammu and Kashmir’s cement industry, as it introduces advanced process optimisation technology to a regional manufacturing facility. Its deployment could demonstrate the potential for wider adoption of digital automation across cement plants seeking to modernise their operations.

The project builds on ABB’s experience in delivering advanced process control solutions to cement manufacturers worldwide. Through the integration of industrial automation, predictive technologies and process engineering expertise, the company supports manufacturers in improving resource efficiency and maintaining consistent production quality.

As cement producers face increasing pressure to manage energy costs, improve productivity and reduce their environmental footprint, technologies such as AI-enabled process control and predictive optimisation are becoming important components of plant modernisation strategies.

ABB’s Expert Optimizer provides a platform for addressing these priorities by enabling automated adjustments based on changing process conditions, reducing reliance on manual intervention and supporting more efficient plant operation.

ABB, a global technology company specialising in electrification and automation, has more than 140 years of industrial experience and approximately 110,000 employees worldwide. Its Automation business employs around 26,000 people and provides technologies and services across process, hybrid and maritime industries.

The TCI MAX deployment reinforces ABB’s growing role in the digital transformation of cement manufacturing in India, where improving process efficiency and reducing energy consumption remain critical to the industry’s long-term sustainability.

With the advanced process control system now implemented at its Srinagar facility, TCI MAX aims to build on the initial operational improvements and further optimise production efficiency, clinker consistency and environmental performance.

Concrete

Ramco Cements’ Hard Worker Wins Eight Awards at ‘Love of Advertising Awards 2026’

Published

2 days ago

November 12, 2026

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Ramco Cements’ Hard Worker brand wins eight awards for excellence in advertising, packaging and brand identity at the Love of Advertising Awards 2026.

Hyderabad

The Ramco Cements Limited’s construction chemicals brand, Hard Worker, has secured eight awards at the Love of Advertising Awards 2026, recognising its creative excellence across television, digital advertising, packaging design and brand identity.

Organised by the Advertising Club of Trivandrum, the awards were presented at a ceremony held at The Leela Raviz, Kovalam, on 24 October 2026. The recognition highlights Hard Worker’s integrated marketing strategy and its efforts to establish a distinctive presence in India’s competitive construction chemicals market.

The eight awards span multiple creative categories, reflecting the brand’s approach to combining product-focused communication with engaging storytelling, humour and innovative design. Through its campaigns, Hard Worker has sought to simplify technical product benefits and make construction chemicals more accessible and relatable to consumers and construction professionals.

Built around the philosophy of “Hard-working products for hardworking people”, the brand focuses on communicating practical product advantages through memorable advertising narratives while maintaining a consistent identity across different marketing platforms.

Its campaigns for Ramco Hard Worker Eco Plaster and Tile Fix have been central to this approach. The Eco Plaster campaign highlights water conservation through the product’s self-curing properties, positioning it as a solution that supports more efficient construction practices. Meanwhile, Tile Fix promotes specialised tile-fixing solutions by presenting their practical benefits through relatable situations and creative storytelling.

Beyond advertising, Hard Worker has invested in distinctive packaging and brand identity development to improve product recognition and maintain consistency across customer touchpoints. This integrated approach has helped the brand differentiate itself in a category where marketing communication has traditionally focused on technical specifications and functional performance.

A V Dharmakrishnan, CEO, Ramco Cements, said, “Winning eight awards at the Love of Advertising Awards is a proud moment for Ramco Cements and the Hard Worker team. We believe that building a strong brand requires not only quality products but also the ability to communicate their value in a compelling and differentiated manner. Hard Worker’s journey reflects our commitment to combining product performance with innovative marketing to create meaningful connections with our customers and strengthen our presence in the construction chemicals market.”

The recognition comes as building materials manufacturers increasingly focus on brand differentiation, product awareness and customer engagement to strengthen their position in the construction chemicals segment.

By using humour and storytelling to explain product applications and benefits, Hard Worker aims to bridge the communication gap between technical construction solutions and the practical requirements of contractors, applicators and end-users.

Balaji K. Moorthy, Executive Director – Marketing, Ramco Cements, said, “Hard Worker was conceived to bring a fresh perspective to the construction chemicals category, where product communication has traditionally been functional and technical. Our endeavour has been to break through the clutter with distinctive ideas, humour and storytelling, while keeping the product proposition at the heart of every campaign. The recognition across TV and digital advertising, packaging design and brand identity design demonstrates our integrated approach to building the brand. These eight awards are an encouraging recognition of the creative thinking and collaborative effort behind Hard Worker’s marketing initiatives.”

The awards add to Hard Worker’s growing portfolio of creative recognitions and reinforce Ramco Cements’ emphasis on integrating product innovation with strategic marketing.

The brand’s communication initiatives also reflect a wider shift in the construction materials industry, where manufacturers are increasingly adopting consumer-focused marketing strategies to improve product understanding and strengthen relationships with construction professionals.

With its portfolio of construction chemicals, Hard Worker aims to address evolving requirements for durability, application efficiency and construction quality. Its marketing efforts seek to complement these product attributes by building stronger awareness and encouraging the adoption of specialised construction solutions.

Ramco Cements, one of India’s established cement manufacturers, operates across cement and allied building solutions. Through Hard Worker, the company is expanding its presence in the construction chemicals segment with products designed to enhance performance, quality and durability in modern construction applications.

The latest recognition strengthens Hard Worker’s brand visibility and underscores the growing importance of creative communication in promoting technical building materials. Ramco Cements intends to continue combining product development with distinctive marketing initiatives to support the brand’s growth in India’s construction chemicals market.