Concrete

The use of Alternative Raw Materials (ARM) is expanding.

Published

2 months ago

May 14, 2026

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Rajat Goswami, Director, Optifuel Enviro, explains how structured sourcing, process optimisation, and robust compliance frameworks are key to unlocking consistent, high TSR AFR adoption in cement plants.

As cement plants push toward higher thermal substitution rates, the challenge is no longer just adopting AFR but integrating it into a structured, scalable operating model. In this conversation, Rajat Goswami, Director, Optifuel Enviro, outlines how cement producers can move beyond fragmented sourcing to build reliable AFR ecosystems, optimise pyro processes, and align technical, commercial, and regulatory strategies for sustained performance.

How can cement plants move from fragmented AFR sourcing to a structured, high-TSR model across both hazardous and non-hazardous waste streams?
To achieve higher and consistent TSR, cement plants need a structured AFR strategy supported by a dedicated business development team. This team should be divided into focused streams-one for high-volume, TSR-positive materials like RDF and biomass, another for low-volume materials with negative cost benefits such as industrial hazardous waste and sludges, and a third for pre-processed AFR from external platforms. Quality-based sourcing is critical, with strict adherence to parameters like calorific value, ash, moisture, chlorine and particle size to ensure stable kiln performance.
From a commercial and operational perspective, companies should shift to long-term contracts of 5-10 years, especially with large waste generators, to ensure supply stability and cost efficiency. Proper AFR processing-shredding, blending, and homogenisation-is essential to convert waste into consistent, kiln-ready fuel. Strengthening pre-processing capabilities, in-house or through partnerships, is key to achieving higher TSR reliably.

What are the most critical technical bottlenecks in utilising diverse AFR materials, and how can they be systematically resolved at the plant level?
Improper AFR feeding is a major cause of kiln disturbances. Plants must invest in advanced feeding systems such as VFD-controlled screw feeders, apron feeders, and elevators for consistent feed. Selecting the correct feeding point-preferably at the calciner-is critical to ensure proper residence time; poor placement can lead to incomplete combustion and frequent CO generation. Layout constraints at preheater towers can be addressed using air-supported or pipe conveyors for efficient installation.
Another challenge is coating and ring formation due to imbalances in alkali, chlorine and sulphur, especially from AFR inputs. Maintaining optimal ratios and conducting hourly hot meal sampling
helps monitor chloride levels and enable corrective action. Blending AFR streams to control chlorine and ensuring consistent feed quality are essential for stable kiln operation.

How do you evaluate and balance calorific value, chemical composition, and risk when integrating hazardous wastes into cement kilns?
AFR evaluation must cover three dimensions: energy contribution, chemical composition, and
safety risk. Energy assessment includes NCV (as received), moisture, and ash content, which affect combustion efficiency. Chemical analysis must monitor
sulphur, chlorine, alkalis, and heavy metals (Hg, Pb, As) within CPCB limits to avoid operational and environmental risks.
Safety evaluation includes storage hazards (flash point above 55°C or suitable systems for volatile materials), emissions risks, and regulatory classification under Hazardous Waste Rules, 2016. A strong evaluation framework includes pre-acceptance lab testing, controlled trial runs with gradual AFR increase, and continuous monitoring of kiln parameters such as free lime, clinker litre weight, coating condition, emissions, and chloride in hot meal.

What role does pyro process optimisation play in enabling higher and more stable AFR substitution rates?
TSR levels above five per cent require strong kiln optimisation, as AFR directly impacts process stability. Key parameters include kiln outlet oxygen control for efficient combustion and minimising coal fluctuations through proper control systems. Stable burning zone temperature and kiln torque are essential to avoid process disruptions.
Flame shape and momentum must be optimised for proper heat transfer, while precise calciner temperature control ensures complete AFR combustion. Stable kiln draft is equally important, indicating continuous raw mix flow in the preheater. Together, these ensure stable operations and enable higher AFR usage without affecting product quality.

How can synthetic gypsum and alternative raw materials be scaled to reduce dependence on natural resources without affecting product quality?
The cement industry is increasingly using synthetic gypsum as a substitute for natural gypsum, with multiple viable sources available. Captive synthetic gypsum plants produce gypsum through the reaction of limestone with high-purity (98 per cent) sulphuric acid, delivering quality equal to or better than natural gypsum. Leading players like Shree Cement and Ambuja Cement use such systems to replace 50 per cent to 100 per cent of natural gypsum, with purity levels adjustable
between 50 per cent and 85 per cent. Another key source is Flue Gas Desulphurisation (FGD) gypsum from power plants using pet coke or high-sulphur coal, where purity typically ranges between 75 per cent to 80 per cent. In addition, chemical or industrial gypsum generated as a by-product from industries such as dyes, specialty chemicals, fertilisers, rolling mills, and water treatment is widely used due to its low cost, although purity varies between 40 per cent to 80 per cent and may include impurities like chemicals and heavy metals.

To use synthetic or chemical gypsum effectively, certain parameters must be ensured:
• Adequate purity, specifically CaSO4•2H2O content
• Low contaminants such as chlorides and organics
• Consistent quality through proper sourcing
and testing
To enhance its usage, cement plants should invest in:
• Drying and blending systems for consistency
• Long-term supply contracts with power plants and waste generators
• Quality monitoring and controlled dosing to maintain performance
Alongside gypsum, the use of Alternative Raw Materials (ARM) is expanding, driven by availability and location. Common ARMs include slag, fly ash, lime sludge, red mud and mine rejects. Fly ash is widely used in PPC cement, typically at 25 per cent to 30 per cent, while slag usage depends on proximity to steel plants. In regions like Chhattisgarh and Jharkhand, cement manufacturers use 50 per cent to 55 per cent slag in slag cement. These materials reduce dependence on natural resources while improving sustainability and cost efficiency.

What are the key regulatory and compliance challenges in AFR utilisation, and how can industry navigate them more effectively?
AFR adoption in India is governed by CPCB and SPCBs, presenting challenges such as lengthy approvals for hazardous waste, inter-state movement restrictions, extensive documentation, and strict emission compliance. These factors often slow down scaling efforts.
To navigate this, companies should secure approvals for multiple pre-approved waste categories and promote digital manifest systems for better traceability. Implementing Continuous Emission Monitoring Systems (CEMS) ensures compliance and builds regulator confidence. Proactive engagement with authorities-focused on transparency and collaboration-can significantly accelerate AFR adoption.

What practical roadmap should a cement plant follow to move from zero per cent to 20 per cent+ TSR sustainably?
Cement plants can scale AFR usage in phases. In Phase 1 (zero to five per cent), conduct kiln audits, install basic feeding systems, and start with easy AFR streams like biomass and RDF. Phase 2 (five per cent to 10 per cent) focuses on pre-processing, hazardous AFR trials, and building sourcing contracts.
In Phase 3 (10 per cent to 20 per cent), plants should implement multi-point feeding, enhance pre-processing, expand hazardous AFR usage, and strengthen QA/QC systems. Phase 4 (20 per cent+) involves advanced systems like chlorine bypass, Hot Disc, and pyrolysis, along with large pre-processing facilities, AI-based controls, and strong coordination between sourcing and plant teams to ensure sustained high TSR.

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Concrete

Nuvoco commissions Surat grinding unit

Nuvoco posts 20 per cent rise in Q1 PAT

Published

3 hours ago

July 14, 2026

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Nuvoco Vistas Corp. has announced its financial results for the quarter ended June 30, 2026, reporting growth in volumes, earnings and profitability while advancing its expansion plans in western India.

The company inaugurated a 2-million-tonnes-per-annum (MTPA) grinding unit at its Limla Cement Plant in Surat on July 11, 2026, ahead of schedule. The facility, part of the Vadraj Cement assets, is expected to strengthen Nuvoco’s presence in western India while freeing up capacity at its Rajasthan plants to cater to demand in northern markets.

Progress at the Kutch project remains on track, with phased commissioning scheduled to begin in the third quarter of FY27. The company has also commenced work on a bulk cement terminal at Viramgam, Sachana, Gujarat, featuring a dedicated railway siding. The terminal is expected to become operational by the second quarter of FY28 and will support distribution across Gujarat. These projects form part of Nuvoco’s capacity expansion programme, which is expected to increase its total cement capacity to 35 MTPA by FY28.

During Q1 FY27, the company recorded cement sales volumes of 5.3 million tonnes, up 5 per cent year-on-year. Consolidated total income rose 9 per cent to Rs 31.29 billion, while EBITDA increased 7 per cent to Rs 5.72 billion, marking the company’s highest-ever first-quarter EBITDA. Profit after tax grew 20 per cent year-on-year to Rs 1.60 billion.

Commenting on the results, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp., said the company delivered improved business performance despite macroeconomic and geopolitical challenges. He attributed the results to disciplined execution, cost optimisation and operational efficiencies, while highlighting the early commissioning of the Surat grinding unit as a key milestone in the company’s expansion strategy.

He added that the company remains focused on prudent procurement, supply chain efficiency and cost discipline while monitoring geopolitical developments that could affect industry supply chains and input costs.

Concrete

Cement Sector Faces Sluggish Growth in First Half of FY27

April Price Hikes Unlikely To Offset Margin Decline

Published

1 day ago

July 13, 2026

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Nuvama Institutional Equities has warned that India’s cement industry is expected to record subdued volume growth in the first half of fiscal year 2026-27 before a recovery in the second half. The brokerage assessed that price increases implemented in April 2026 will be insufficient to offset an overall decline in sector profitability. It attributed the outlook to weak demand and fresh capacity additions scheduled during fiscal years 2026-27 and 2027-28 that are likely to keep prices under pressure.

The report noted that demand was sluggish in April and May 2026 owing to global uncertainty, labour shortages, heatwaves, constraints in raw materials and unseasonal rainfall. Producers raised prices across regions in April to mitigate rising petcoke costs and higher packaging expenses, but the increases proved short lived. Nuvama reported that standard petcoke prices rose to USD153/t, around USD41/t higher than in the third quarter of fiscal year 2025-26.

Price correction followed weaker demand, limiting the net increase to about Rs 10-12 per bag by the end of the quarter. Imported petcoke prices have since fallen to USD132/t from a recent peak of USD168/t, although they remained roughly USD20/t higher quarter on quarter. The brokerage expected the higher input cost impact to begin reflecting from late quarter one of FY27 and to continue into early quarter two.

Nuvama also estimated that crude linked increases were likely to raise packaging costs by about Rs 120-150/t and to exert upward pressure on freight. It warned that soft demand combined with significant new supply coming on stream in FY27-28 would keep pricing under strain and constrain near term margin recovery. The report concluded that volume growth was likely to be sluggish in the first half of FY27 before recovering in the second half.

Concrete

Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint

Published

1 day ago

July 13, 2026

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Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.

Surat (Gujarat)

Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.

Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.

Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.

The Limla Cement Plant is expected to support a phased increase in sales volumes across Gujarat. It will also help Nuvoco supply neighbouring markets in Western Maharashtra and release cement capacity from its northern plants, which can consequently be redirected towards markets in North India. The plant will manufacture a full portfolio comprising Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. It will additionally produce the complete Nuvoco Duraguard range, including the premium Nuvoco Duraguard Microfibre product. The acquisition is also expected to generate operational synergies with Nuvoco’s existing plants at Nimbol and Chittorgarh in Rajasthan, improving logistics optimisation and market reach across important regional markets.

The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.

Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”

He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”

Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.

Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.