Economy & Market

With WHRS, power requirement can be reduced by about 20-25per cent

Published

12 years ago

August 31, 2014

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O P Puranmalka Managing Director, UltraTech Cement

UltraTech a leader in cement industry has made considerable investments in captive power generation. Apart from generating power from coal fired captive plants, the company satiates a large portion of its power demand through renewable sources. O P Puranmalka elaborates on some of the initiatives in an interaction with ICR. Excerpts from the interview.

What is your current requirement of power and how much of it is met through captive power production?
Our pan-India presence with 12 integrated plants, 12 grinding units and five bulk terminals demands a focused approach towards captive power production to meet our requirements. Our captive power plants with a combined capacity of 707 MW and Waste Heat Recovery System (WHRS) based power plants with a capacity of 55 MW ensure smooth and efficient operations at our units.

We have further extended the wheeling of power to some of our cement grinding units. These measures have resulted in UltraTech being able to meet over 80 per cent of its power consumption through captive sources.

Are you using renewable resources for power generation?
In our quest to explore more options for reducing our dependence on fossil fuels, our unit at Awarpur Cement Works has installed 6 solar arrays in a parallel combination through channel partner Tata BP Solar. The Awarpur unit constitutes an ideal location for a solar power plant installation because it has sufficient shadow-free land area. In addition, the intensity and clarity of light rays in the area are optimal to generate maximum power through the installation of solar arrays. Since 2009, a wind farm has been installed at our Reddipalayam unit. In 2013-14, we generated 2.9 million units from solar power panels and 2.05 million units from wind power.

Brief us about the latest investments made in the captive power generation at your plant.
UltraTech recently invested in brownfield capacity expansion projects in Karnataka, Chhattisgarh, and Rajasthan. These projects include commissioning a clinkerisation plant of 3.3 MT capacity at Rawan Cement Works, Chhattisgarh; a clinkerisation plant of 3.3 MT capacity at Rajashree Cement Works, Karnataka; grinding unit of 1.6 MT capacity at Hotgi, Maharashtra; grinding unit of 1.6 MT capacity at Jharsuguda, Orissa, and grinding unit of 1.5 MT capacity at Rajashree Cement Works, Karnataka.

Further, UltraTech acquired an integrated unit and a grinding unit from Jaypee Cement in Gujarat in June 2014. The integrated plant at Sewagram and grinding unit at Wanakbori in Gujarat together have added 4.8 million tonnes to our capacity, taking our installed capacity to 62 million tonnes.

Recently, UltraTech commissioned captive power plants incorporating latest technologies at three location; Rawan Cement Works in Chhattisgarh 1 x 30 MW, Rajashree Cement Works at Karnataka 2 x 25 MW, and Andhra Pradesh Cement Works 1 x 25 MW (commissioned) + 1 x 25 MW (commissioned).

The two captive power plants at our Sewagram Cement Works plant include a total capacity of 57.5 MW (CPP-I: 35 MW and CPP-II: 22.5 MW). The power requirement of the plant is around 57 MW. The plant also has a standby source of power of around 35 MW.

As part of its commitment to reduce its carbon footprint, UltraTech Cement commissioned a Waste Heat Recovery System (WHRS) producing 13.2 MW of electricity at Awarpur Cement Works in Maharashtra. UltraTech also has a 3.5 MW waste heat recovery plant operational at Andhra Pradesh Cement Works, Tadipatri. We are in the process of installing a WHRS at Rawan Cement Works in Chhattisgarh, Aditya Cement Works in Rajasthan, and Rajashree Cement Works in Karnataka. Post the commissioning of these three plants, UltraTech Cement will be the leader in WHRS in India with a combined capacity of 55 MW. With WHRS, power requirement can be reduced by about 20-25 per cent of total requirement for cement manufacturing. The cost of electrical power for the cement plant gets reduced to a considerable extent.

Are you facing any issues in availability of the raw materials of appropriate quality/price or any kind of logistical challenges?
Majority of our products originate from minerals extracted from quarries, such as limestone, gypsum rock and clay. We have made the use of alternative materials a strategic priority in order to reduce the consumption of natural resources and to extend the life of the quarries.

One of the raw materials used in the manufacture of cement is gypsum. Gypsum can be sourced naturally from quarries or from chemical gypsum, which is a by-product of the process used to treat flue gas from fuel or coal-fired power plants. Chemical gypsum generated during this process is an industrial waste, and depositing it in landfills could be toxic to the environment.

This chemical gypsum is now being used as a part replacement of natural gypsum in cement manufacturing at UltraTech, resulting in effective use of industrial waste as an alternative to a natural raw material, a step ahead in our sustainability journey.

India has huge potential to tap solar and wind energy. What can be done to ensure that these resources are utilised effectively?
After the two oil shocks that our country suffered in the 1970s, a lot of interest has been evinced in new and renewable forms of energy. Solar and wind energy with their "clean energy" tag have received their fair share of research and investment. At the end of last calendar year, it is estimated that India had 20,140 MW of wind power and 2,200 MW of solar power. These numbers are low considering that India generates over 967 TWh (Terra Watt-hour) of energy from non-renewable sources. To give a push to renewable energy sector in the country, we need friendly policies that will incentivise businesses to invest in such forms of thinking. We also need innovative ideas, plans and the will to implement them, even on a pilot basis. For example, the offshore wind farm is one such idea. Our country is blessed with a lot of sunshine and geographical areas like the Thar desert that lend itself to solar power generation.

With governmental will, access to suitable capital and cost effective distribution policies, there is good opportunity to become a world leader in this space, especially as there are still about 300 million people in India who have no access to electricity.

Concrete

Wonder Cement appoints Mahesh Singh as VP Corporate Brand Communication

Published

1 week ago

October 9, 2026

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Singh brings 20+ years of brand and marketing experience, and will lead integrated corporate brand communication initiatives at Wonder Cement

New Delhi

Wonder Cement, a leading cement manufacturer, has appointed Mahesh Singh as Vice President – Corporate Brand Communication. In his new role, he will oversee corporate brand strategy and communication, including digital and performance marketing, public relations, trade, events, exhibitions, sports and experiential marketing.

Singh brings over two decades of experience across marketing and communications, with roles spanning the automotive industry, agencies and entrepreneurship. He spent more than a decade with Honda Motorcycle & Scooter India, working across integrated communication, media, digital, retail and consumer engagement. His stint also included helping build the company’s digital marketing capabilities.

He moved to dentsu X India as Vice President – Strategy & Planning, working across categories such as automotive, auto components, electric vehicles, FMCG, consumer electronics, BFSI, apparel and brand consulting. His responsibilities included media and marketing strategy, product launches, content, performance marketing and consumer activations.

Singh subsequently took an entrepreneurial route with Radiant Brands before joining Shriram Ltd (SPR Autotech) as Head – Marketing & Communications. There, his remit included brand and corporate strategy, communications, PR and ORM, retail identity, loyalty programmes and events.

At Wonder Cement, Singh will be responsible for bringing together the company’s corporate brand communication initiatives across digital, performance marketing, PR, trade, sports and experiential platforms. The role will focus on creating an integrated approach to communication across consumers, trade partners and other key stakeholders.

The appointment brings to Wonder Cement a marketer whose career has spanned the brand, agency and entrepreneurial sides of the communications ecosystem.

Wonder Cement, part of the RK Group, is a cement manufacturer with roots in Rajasthan and a focus on quality, trust and transparency. The company has grown to six manufacturing plants, and a cement capacity of 21.5 MTPA. With more than 2,000 employees and a network of over 5,000 dealers, its operations span manufacturing, distribution and customer engagement, with a focus on consistent product quality and efficient execution.

Concrete

JSW Cement commissions additional 1 MTPA grinding unit at Nagaur

Published

1 week ago

October 8, 2026

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With this commissioning, JSW Cement’s total cement grinding capacity has increased to 25.10 MTPA,
Mumbai

JSW Cement, one of India’s leading green cement producers and part of the diversified JSW Group, today announced the successful commissioning of an additional 1.00 MTPA cement grinding unit at Nagaur, Rajasthan. The commissioning marks another significant milestone in the Company’s growth strategy.

With this commissioning, JSW Cement’s total cement grinding capacity has increased to 25.10 MTPA, while its total clinker manufacturing capacity, including clinker capacity at its joint venture, JSW Cement FZC, stands at 9.74 MTPA.

JSW Cement had commenced operations in North India in March 2026 with the Nagaur Integrated Plant, comprising a 3.30 MTPA clinkerisation unit and 2.50 MTPA cement grinding unit. With the commissioning of the additional 1.00 MTPA cement grinding unit, the plant’s total cement grinding capacity has increased to 3.50 MTPA, enhancing the company’s ability to cater to the growing cement demand across Rajasthan, Haryana, Punjab and the National Capital Region (NCR). The expansion has been funded through a strategic mix of equity and long-term debt.

During the quarter ended 30th September 2026, JSW Cement has also commissioned the Alternate Fuel Handling System and the Waste Heat Recovery system (WHRS) at the Nagaur Integrated Plant.

Nilesh Narwekar, CEO, JSW Cement, said: “The commissioning of additional 1.00 MTPA grinding capacity at Nagaur is a key strategic priority for us and will accelerate JSW Cement’s expansion into North India. We look forward to servicing the growing needs of the region and contributing to the economic growth of Rajasthan, Haryana, Punjab and the NCR area. I am delighted to share that the company has commissioned this grinding unit within the expected timeline, showcasing our project execution capabilities. Further, the Alternate Fuel Handling System and the Waste Heat Recovery system (WHRS) are expected to substantially reduce our production costs going forward.”

Concrete

UltraTech becomes first Indian cement firm to cross 2 GW green energy

Published

1 week ago

October 7, 2026

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UltraTech Cement has crossed 2 GW of captive green energy capacity, with renewables and waste heat recovery meeting 48 per cent of its power needs.

Mumbai

UltraTech Cement Limited has surpassed 2 GW of installed green energy capacity for captive use, becoming the first cement company in India to achieve the milestone. The Aditya Birla Group company commissioned 116.55 MW of wind capacity at its Inter-State Transmission System-connected wind-solar hybrid project in Barmer, Rajasthan, along with 10 MW of Waste Heat Recovery System capacity at Sarlanagar Cement Works in Karnataka.

With these additions, UltraTech’s cumulative installed green energy capacity has reached 2,024 MW. This includes 1,580 MW of renewable energy capacity and 444 MW of waste heat recovery capacity, together meeting around 48 per cent of the company’s current power requirements.

The company said the milestone reflects the progress of its long-term energy transition strategy. In FY27 so far, nearly one-third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements, while five units have crossed 95 per cent.

K C Jhanwar, Managing Director, UltraTech Cement Limited, said, “Crossing the 2 GW green energy milestone is the result of a strategy we have pursued consistently over the past decade. Cement is an energy-intensive, hard-to-abate sector, and showing that reliability and growth can go hand in hand with a rapid shift to green energy sets a benchmark for the industry. With nearly half of our power needs now met through green energy, we are significantly less exposed to fossil fuel supply constraints and power price volatility. As we scale up renewables, waste heat recovery and battery storage across our operations, we are building an energy foundation for stable, long-term growth.”

UltraTech commissioned 430 MW of green energy capacity in FY26 and continues to expand its renewable energy and waste heat recovery portfolio.

The company is also progressively integrating Battery Energy Storage Systems across its operations to improve renewable energy utilisation and supply reliability.

In 2025, UltraTech operationalised what it described as India’s first on-site hybrid round-the-clock renewable energy project at Sewagram Cement Works in Gujarat. The project combines solar, wind and battery storage.

As part of its decarbonisation strategy, UltraTech said it has not invested in new captive thermal power capacity for either greenfield projects or brownfield expansions at its integrated units for more than a decade.

The company said its expanding green energy portfolio is helping reduce dependence on conventional grid electricity and fossil fuel-based power, while lowering exposure to fluctuations in coal and electricity prices.

UltraTech aims to increase green energy’s share in its total power mix to 85 per cent by 2030. As a member of RE100, it has also committed to meeting 100 per cent of its electricity requirement through renewable sources by 2050.

UltraTech Cement, the cement flagship of the Aditya Birla Group, has a total grey cement capacity of 210.1 MTPA and white cement and putty capacity of 3.5 MTPA. The company is also a signatory to the GCCA Climate Ambition 2050 and has committed to the GCCA Net Zero Concrete roadmap.