Concrete

Waste Heat Recovery System is a key area for cement producers

Published

2 years ago

June 12, 2023

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Guilherme Mendonca, Head Energy Business, Siemens, elaborates about co-creating innovative technology solutions for the cement industry.

What are the key features of your Waste Heat Recovery System that make it an eco-friendly solution for cement manufacturing?
Steam turbines are the heart of every power plant. In waste heat recovery (WHR), steam turbines act as an essential piece of the whole system. Our modular design concept ensures high flexibility, availability, and efficiency, playing a significant role in many industrial plants for waste heat recovery and cogeneration application. In India different technologies exist to convert thermal heat into power like Steam Rankine Cycle (SRC), Organic Rankine Cycle (ORC) and Supercritical Carbon Dioxide Cycle (sCO2). However, only SRC and ORC are fully commercialised with SRC being a more popular technology with decades of proven results. Through efficient use of our steam turbines our customers can extract high power output with the available waste heat, enabling them to reduce their carbon footprint. Siemens Energy WHR solutions are capable of meeting all these requirements which are specific to the Indian
cement industry.

How does your system help reduce carbon emissions during the cement production process?
Waste Heat Recovery System (WHRS) is a key area for cement producers to improve plant efficiency and reduce their carbon footprint by utilising the waste heat from the cement manufacturing process. Siemens Energy’ waste heat recovery system is highly efficient with Heat ReCycle Power Plants offsetting the emissions when compared to other technology that is typically used to generate equivalent power, like diesel generators and reciprocating engines or small coal fired power plants. This results in overall reduced emissions and reduction in dependability on fossil fuels.

What are the estimated energy savings that can be achieved by installing your system in a cement plant?
These plants are highly customised solutions and savings can vary depending upon various factors such as source of upstream power generation, plant configuration and degree of waste heat available. Given ideal conditions, waste heat recovery power plants can offset approximately 30 per cent of total electricity requirement of a typical cement plant in India. In 2012, the Rohrdorf cement works in Germany commissioned the first waste heat and gas power plant in Europe. The plant produced over 30 per cent of the site’s power while saving 12,000 tpa of fossil fuels and reducing CO2 emissions by 30,000tpa. We have come a long way since then in terms of technology adoption and benefits. In practical applications, plants that have implemented waste heat recovery systems have been proven to reduce carbon intensity by as much as 25kg/t of clinker produced.

How long does it take for the system to pay for itself through energy savings?
The pay-off is faster than conventional grid-connected power plants by up to 40 per cent in an ideal situation. This return-on-investment calculation considers 30 per cent electricity offset and variations in energy prices as well as carbon credits and cost of decarbonisation.

What is the expected lifespan of the system, and what maintenance is required to keep it functioning optimally?
Generally, the operating lifespan of steam-based WHRS is 20 years. Typically, it works for 8,000 operating hours per year. The availability and adoption of digital solutions such as remote diagnostic services that allow proactive, predictive maintenance and minimises forced outages.

Can your system be customised to meet the specific needs of different cement plants?
Yes. This is a fully customised solution taking into account all the cement plant constraints and available waste heat sources and quality of waste heat.

What are the major challenges of a WHRS when installed in a cement plant?
Some key challenges of installing WHRS are design limitations due to available technologies and constraints such as source of heat, space available and integration. With these being mostly brownfield projects, the integration with minimum downtime and minimum process disruption also add to the challenges. However, this can be planned and mitigated with efficient project management from Siemens Energy.

How do you envision your collaboration with the cement industry in the decade to come?
We envision a strong collaboration with the cement industry in the decade to come, which is primarily driven by a shared commitment to sustainability and reducing carbon emissions with WHRS at the centre. We see WHRS as a key technology that can help cement manufacturers achieve their sustainability goals while also providing energy savings and cost reductions. Looking to the future, our collaboration with the cement industry will continue to be focused on co-creating innovative technology solutions that are tailored to the specific needs of individual cement plants in India.

–Kanika Mathur

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UltraTech Cement Ventures into Wires and Cables with Rs 18 Bn Plan

The New Gujarat Plant Marks Expansion in Construction Value Chain.

Published

1 week ago

February 28, 2025

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UltraTech Cement has announced its foray into the wires and cables segment, further expanding its footprint in the construction value chain. The Aditya Birla Group company will invest Rs 18 billion in setting up a state-of-the-art manufacturing facility near Bharuch, Gujarat, which is expected to commence operations by December 2026. An initial investment of Rs 1 billion has already been made towards the project.

The UltraTech board of directors approved the strategic expansion, reaffirming the company’s commitment to strengthening its position as a comprehensive building solutions provider. This move follows last year’s entry into the decorative paints sector with the launch of Birla Opus, signalling the company’s diversification beyond its core cement business.

Strategic Market Entry and Growth Potential
UltraTech Cement aims to tap into the growing demand for wires and cables across residential, commercial, infrastructure, and industrial sectors. The wires and cables industry in India has witnessed a robust revenue growth of approximately 13% between FY2019 and FY2024, driven by rising urbanisation, infrastructure development, and increasing adoption of branded products over unorganised players.

UltraTech believes its entry into this high-growth sector will be value accretive for its shareholders, presenting a compelling opportunity to establish a credible, large-scale presence in the organised market.

Core Cement Business Remains a Priority
Despite this diversification, UltraTech Cement remains firmly committed to its core cement business. The company recently achieved a milestone cement production capacity of over 175 million tonnes per annum (mtpa) in India. It continues to strengthen its leadership position through strategic acquisitions and capacity expansions, especially amid intense competition from Ambuja Cements, owned by the Adani Group.

Industry Outlook: A Diversified Future for Construction Materials
The construction materials industry in India is witnessing rapid evolution, with companies increasingly diversifying their portfolios to cater to a growing and dynamic market. With infrastructure development and urbanisation on the rise, demand for complementary building materials such as wires, cables, and paints is expected to surge. UltraTech’s strategic expansion aligns with this trend, positioning it to capitalise on emerging opportunities while reinforcing its leadership in cement manufacturing.

Concrete

Star Cement to Invest Rs 32 Bn in Assam for New Clinker Plant

The MoU was signed at Advantage Assam 2.0 to boost state’s industrial growth.

Published

1 week ago

February 28, 2025

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In a significant boost to Assam’s industrial expansion, Star Cement Ltd has announced a Rs 32 billoninvestment to establish a state-of-the-art cement clinker and grinding plant in the region. The commitment was formalised with the signing of a Memorandum of Understanding (MoU) between the Assam government and the company on the concluding day of the Advantage Assam 2.0 Investment and Infrastructure Summit 2025.

Chief Minister Himanta Biswa Sarma, addressing the gathering, lauded the commitment of leading investors towards the state’s economic progress. He underscored that such projects reinforce Assam’s position as an emerging industrial hub. “The investment commitments we have received reflect Assam’s potential as a centre for industries and innovation. These projects will significantly contribute to our vision of a developed and self-reliant Assam,” he stated.

This ambitious proposal by Star Cement aligns with Assam’s broader vision of fostering large-scale industrialisation, particularly in key sectors such as manufacturing, infrastructure, and green energy. The project is expected to create significant employment opportunities and contribute to the state’s economic landscape.

Surge in Investments Across Sectors
Beyond Star Cement’s investment, the Assam government secured several other strategic MoUs during the summit. Among them was an agreement with Matheson Hydrogen Lvt Ltd, which will set up a Rs 15 billion hydrogen and steam generation facility, marking a crucial step in Assam’s transition towards clean energy.

Additionally, the state signed a Rs 5 billion MoU with Global Health Ltd to bolster healthcare infrastructure, while ITE Education Services partnered with the government to enhance educational facilities through two non-financial agreements.

Over the two-day event, Assam witnessed the signing of a record-breaking 164 MoUs spanning 15 sectors, reinforcing its status as a promising investment destination. The chief minister hinted at further agreements being finalised, underscoring the growing confidence of investors in Assam’s potential.

Market Outlook: Assam’s Industrial and Economic Trajectory
The surge in investments at the Advantage Assam 2.0 summit highlights the state’s evolving business landscape. With an emphasis on industrial diversification, infrastructure development, and sustainable energy solutions, Assam is poised to emerge as a key player in India’s economic growth story. The increasing participation of major companies across various sectors signals a robust economic trajectory, further solidifying Assam’s reputation as a preferred destination for investors seeking growth and innovation.

Concrete

Kaushalya Logistics Expands with New Varanasi Depot for Adani Cement

Kaushalya Logistics has been actively expanding its depot network to support cement manufacturers with faster turnaround times.

Published

2 weeks ago

February 27, 2025

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Kaushalya Logistics, a diversified conglomerate specializing in logistics for the cement industry, has expanded its operations with the commencement of services at the Varanasi (Uttar Pradesh) depot of ACC, a part of the Adani Cement Group. This development aligns with the company’s strategic growth objectives, aimed at enhancing supply chain efficiencies and streamlining cement distribution across key regions in India.

The Varanasi depot, established under the CCFA model, marks the company’s sixth location and eighth depot under this framework. Designed to manage over 20,000 metric tons of cement per month, the facility will contribute to improved inventory management and timely deliveries. As the cement industry experiences strong demand growth, efficient distribution networks play a critical role in ensuring seamless supply chain operations.

Kaushalya Logistics has been actively expanding its depot network to support cement manufacturers with faster turnaround times, optimized inventory management, and cost-effective logistics solutions. Through automation, digital tracking systems, and operational excellence, the company continues to enhance its service offerings, aligning with the evolving needs of the industry.

The launch of the Varanasi depot is part of Kaushalya Logistics’ aggressive expansion strategy, which has seen the establishment of 19 new depots in FY 2024-25. With this addition, the company’s total network has grown to 93 depots, significantly strengthening its market presence. This expansion further reinforces Kaushalya Logistics’ role as a key logistics partner for leading cement manufacturers, ensuring efficient and uninterrupted cement distribution across diverse regions in India.

News source: ANI