Concrete

Mukutban plant is among the most advanced cement plants: Birla Corp

Published

3 years ago

June 24, 2022

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Arvind Pathak, MD & CEO, on why the plant was planned in Maharashtra

Birla Corporation had signed a deal with Reliance Infrastructure whereby it took over its cement production unit (RCCPL) for Rs 4,800 crore at a valuation of $140 a tonne* in 2016. RCCPL had three cement units — an integrated cement plant at Maihar (Madhya Pradesh) and grinding units at Kundanganj (Uttar Pradesh) and Butibori (Maharashtra) — with an aggregated capacity of 5.58 mtpa (million tonne per annum) of cement and 3.30 mtpa of clinker. With the Mukutban plant and debottlenecking, the total capacity under the RCCPL units comes to 9.81 mt against its operational capacity of 10.19 mt in its holding company, which includes plants in Satna, Chanderia, Durgapur and Raebareli.

Arvind Pathak, Managing Director & CEO, Birla Corp, shares more on the Mukutban plant, its technological advancements and why the plant was planned in Maharashtra in conversation with Shriyal Sethumadhavan.

At Rs 2,744 crore, the Mukutban plant is the Company’s largest greenfield investment in its history. In terms of operational capacity of 3.9 mt, it is second to your Chanderia plant in Rajasthan, which has 4 mt. How would you distinguish its technical prowess?
I would compare the Mukutban plant to the Maihar plant in Madhya Pradesh. Maybe, the cement grinding capacity in Chanderia could be higher because it does not have any attached grinding unit. Whereas in Maihar, if you look at it clinker-wise, it is a 10,000-ton per day unit. Also, Maihar so far has the distinction of being our most efficient plant. But the Mukutban plant would be a step ahead as it is supported by all the latest technological changes.

In terms of parameters of technology and efficiency, what makes this plant one of the most advanced cement factories in the country?
The plant incorporates state-of-the-art technology. It is 100 per cent operated on captive power, which will give us a cost advantage over time. We have also opted for an air-cooled condenser wherein we are trying to conserve the water required for cooling fuel gases within the plant. The entire conveying system is done through belts. We do not have any mobile equipment in place and the gamma metrics control helps us make the stockpile. We have opted for a roller press, which is the most efficient mode for this type of raw material. Every equipment we have used is the most efficient in the country or maybe in the industry across the world.

Also, tell us about the plant’s efforts towards minimising water consumption and the technology used to achieve the same.
The highest water consumption takes place in a power plant. The hot flue gases need to be condensed and the water recirculated. Instead of water cooled, we have gone in for an air cool condenser. Although it is slightly more power consuming, it saves a lot of water. Also, normally in cement plants, they use vertical mills, which also do not require much water. For the cooler for the clinker, after it comes out, companies generally economise on the length, saving on the capex, and only to control the exit temperature of the clinker, water is sprayed on it. However, we have opted for the full length of the cooler and are trying to cool it with the air from cooler fans. We have the permission to utilise ground water but we do not intend to use it. When it comes to full capacity, this plant will be water-positive.

Further, you have used fly ash – a waste product of thermal power plants – to build the plant….
Most infrastructure companies and companies developing multi-storied sites would prefer OPC cement. This is not because of any difference in quality, performance or durability but for speed of construction. The industry is aware of the positive attributes of blended cement. With inhouse R&D, we tried to see if the setting time required with the fly-ash-based cement could more of less match that of OPC. Once we cracked this, we wanted to use it as a demonstration both for the construction industry as well as from the point of view of sustainability. We wanted to walk the talk and show the world that a big plant of this nature could also be constructed in time using fly ash-based cement. We wanted to demonstrate that this product can be as efficiently used for speedy construction as OPC.

With regard to cement production in this plant, will the consumption of slag and fly ash be scaled up?
Going forward, our endeavour would be to have 100 per cent blended cement, be it with the use of slag or fly ash. Delivery is key. We need to educate the market and our customers and, if we can offer the benefit of speed of construction, we could expect to see demand.

The pandemic’s impact on the world economy, the cement industry in India and major disruptions on account on COVID-19 must have led to several challenges, such as logistics, labour shortages and stoppage of work. How did you build this plant in these tough circumstances?
We did two things that helped. In hindsight, the infrastructure facilities created for the contractor’s workmen were far superior to what is normally found on construction sites. This resulted in hygiene, and good health and comfort of all employees working with us. Along with excellent facilities, we provided an online mechanism or toll-free lines where their family members could reach out for help. With this, they were individually satisfied with the infrastructure they had and, relatively, had some comfort that their families were being attended to. With these efforts, though we could not mitigate the challenges 100 per cent, the impact was reduced to a large extent, enabling us to complete this project without huge delay despite three waves of COVID.

Also, achieving 10 million manhours of construction with zero accidents and the completion of the entire project without a single major accident or fatality is a unique achievement in the cement industry. How was this achieved?
It was a concentrated effort. We did hire and take the help of an external agency. This ensured that all systems and processes were followed and no deviations permitted. We also ensured extensive training for everybody who entered the project site. This training was reinforced time and again to ensure everyone was always up to the mark. Some refresher courses were also extended. Last, our protocols for every typical job – having a hazard review and then taking appropriate measures under the expert guidance of our consultants – yielded significant results.

How do you see this plant further supporting your footprint in western India?
At Birla Corporation, we normally prefer expanding the market adjoining the unit where we operate. If we are operating in Madhya Pradesh, in some parts of Rajasthan, it does make logical sense to us to move in a continuous direction till we go pan India. Maharashtra being an important State, we felt we should move our footprint in this direction. From the Maharashtra plant, we will be selling cement to Telengana. So, tomorrow, if we have to make an entry into Telengana, there will be some base that will always exist there. Such is our approach.

The geopolitical scenario has had its share of impact on cement and steel prices. How has the company been addressing this situation?
While production has not been affected much, the cost of production has certainly been impacted. Amid this scenario, we have been innovating some ways of working. And if you can keep ahead of your competitors, it does not hit us that badly. In absolute terms, yes; but in relative terms, it may not. Ultimately, if this is going to be the scenario going forward, or some amount of this increases, we will mitigate it through some innovative measures.

A significant portion of the cost is especially because of fuel and power. Power is also nothing but coal. With the rise in coal prices, the Ukraine war, the quantum of coal we require and the power crises in our country, the only silver lining we see is that we already have one coal mine. We are expecting to start one more before year-end. This is a testing time for us for the next six to seven months. Once these two coal mines are in operation, we will be covering 40 to 50 per cent of our fuel requirement.

Please tell us about your products.
We have one of the largest product bouquets in the industry. As we have been selling in Maharashtra for quite some time, we know the requirements of the State. What we are offering today is superior to other products within the same bracket available in the market. What we bring to the customer is value for money.

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Concrete

The primary high-power applications are fans and mills

Published

1 day 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

1 day ago

October 10, 2025

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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

Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

The airport is set to become Asia’s largest air connectivity hub.

Published

1 day ago

October 10, 2025

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Enlight Metals has supplied 3,200 metric tonne of steel for the newly inaugurated Navi Mumbai International Airport, marking a major contribution to one of India’s largest infrastructure projects and reinforcing the company’s commitment to supporting national development.

The Navi Mumbai International Airport, developed under a Public-Private Partnership led by the Adani Group, was inaugurated today by Prime Minister Narendra Modi. The airport is set to become Asia’s largest air connectivity hub, enhancing regional connectivity, boosting economic growth, and expanding trade opportunities. Prime Minister Modi described the project as a “glimpse of Viksit Bharat,” highlighting its transformative impact on infrastructure and development in the region.

“The supply of 3,200 metric tonne of steel for this key project aligns with our focus on supporting critical infrastructure development through reliable and timely metal sourcing. Enlight Metals is committed to enhancing transparency and efficiency in the steel supply chain, contributing to projects integral to India’s growth objectives,” said Vedant Goel, Director, Enlight Metals.

Enlight Metals has implemented technology-driven solutions to strengthen supply chain efficiency, ensuring consistent availability of construction materials for large-scale projects nationwide. Its contribution to the Navi Mumbai International Airport underscores the company’s growing role in supporting India’s infrastructure development initiatives.

This milestone reflects Enlight Metals’ ongoing engagement in delivering quality materials and timely services for major national projects, further cementing its position as a reliable partner in India’s infrastructure sector