Concrete

Cash for trash

Published

5 years ago

March 5, 2021

admin

India faces major environmental challenges associated with waste generation and inadequate waste collection, transport, treatment and disposal. Current systems in India cannot cope with the volumes of waste generated by an increasing urban population.

It is estimated that the Mumbai region alone generates one-third of the total waste generated in Maharashtra and it also tops the list of metros in terms of solid waste generated every day. The municipal solid waste generated by the Mumbai region includes all kinds of waste including biodegradable, non-biodegradable, construction, metal, plastic and other kinds of waste.

INCENTIVE FOR LESS WASTE

Stalin Dayanand, a conservationist and activist with Mumbai-based environmental NGO Vanashakti, said issues like waste management have been overlooked by governments deliberately because there is so much money involved in waste management budgets. ??he budget gets bigger and bigger when more waste is generated. There is no incentive to reduce it. Instead, the municipal corporations hand out contracts. So, why will someone stop it? Whether it is Delhi or Mumbai, there is no ward-wise estimation of waste. A waste audit has to be done in every ward to understand what are the problems of that ward. There needs to be an incentive for less waste. There needs to be a carrot and stick policy,??Stalin said.

??he landfill sites as per the rules should have been kilometres away from the nearest human habitation but there they are next to housing colonies. The entire area is enveloped in the stench. People are being treated like pigs and made to live in horrible conditions. The money involved in waste management in Mumbai itself is in the range of Rs 80-100 billion and that kind of money has its own power play,??Dayanand added.

In September 2019, a group of citizens of Pune had released an environment manifesto that was submitted to all political parties and their candidates seeking votes. Apart from other environmental issues, the citizen manifesto demanded a push for ensuring the segregation of waste at the user level and a clear policy regarding the responsibility of waste on its generator.

Stalin explained that people are aware of the problem of waste and know about the importance of segregating it but the problem is when the segregated waste is collected and they see the garbage truck taking all of it together to a dumping ground, where it is mixed again, they feel their effort is futile.

Waste management infrastructure has an important role in delivering sustainable development. Rapid population growth in India has led to depletion of natural resources. Wastes are potential resources and effective waste management with resource extraction is fundamental to effective SWM (Solid WasteManagement). Value extraction from waste can be materials, energy or nutrients, and this can provide a livelihood for many people. The transition from wastes to resources can only be achieved through investment in SWM as this depends on a coordinated set of actions to develop markets and maximize recovery of reusable/recyclable materials.

WASTE CHARACTERISATION DATA

Estimating the quantity and characteristics of municipal solid waste (MSW) in India and forecasting future waste generation is fundamental to successful waste management planning. The quantity of MSW generated depends on living standards, the extent and type of commercial activity, eating habits and season. The local economy impacts on waste composition, as high-income groups use more packaged products, resulting in higher volumes of plastics, paper, glass, metals and textiles. Changes in waste composition can have a significant impact on waste management practices.

The average composition of MSW produced by Indian cities is approximately 41 wt.% organic, approximately 40 wt.% inert, with approximately 19 wt.% potentially recyclable materials. Most organic waste is generated from households, and inert waste is generated from construction, demolition and road sweeping. Waste samples collected from Delhi, Ahmadabad and Bangalore indicate that MSW composition varies between cities.

FUTURE WASTE GROWTH

World waste production is expected to be approximately 27 billion tonnes per year by 2050, one-third of which will come from Asia, with major contributions from China and India. Waste generation in urban areas of India will be 0.7 kg per person per day in 2025, approximately four to six times higher than in 1999. The problems associated with waste become more acute as the size of communities increase. Urban India generated 31.6 million tonnes of waste in 2001 and is currently generating 47.3 million tonnes. By 2041, waste generation is predicted to be 161 million tonnes, a fivefold increase in four decades.

COLLECTION & TRANSPORT

Waste collection, storage and transport are essential elements of any SWM system and can be major challenges in cities. Waste collection is the responsibility of the municipal corporations in India. Improvements to waste collection and transport infrastructure in India will create jobs, improve public health and increase tourism . Local bodies spend around Rs 500 to Rs 1,000 per tonne on SWM with 70 per cent of this amount spent on collection and 20 per cent spent on transport. It is to be noted by the waste generators that in order to have successful model of waste utilisation the waste user would like to have a seamless supply and his consumption point. Any unreliable supply will jeopardise the success.

SOLUTIONS: WASTE TO ENERGY, WASTE TO FUEL

Source separation of inert and high moisture content fractions would maximise the potential for thermal recovery and other treatment options in India. The waste processed in thermal recovery is residual waste. The most widely used waste-to-energy technology for residual waste uses combustion to provide combined heat and power. Adopting maximum recycling with waste-to-energy in an integrated waste management system would significantly reduce dumping in India. Waste-to-energy technologies are available that can process unsegregated low-calorific value waste, and industry is keen to exploit these technologies in India. Several waste-to-energy projects using combustion of un-segregated low-calorific value waste are currently being developed. Alternative thermal treatment processes to combustion include gasification, pyrolysis, production of refuse derived fuel and gas-plasma technology.

CII WASTE MATERIAL EXCHANGE

Confederation of Indian Industry (CII) is working on an initiative to facilitate use of urban and industrial waste as alternate fuel and raw materials (AFR) in Indian cement Industry, the main objective of the initiative is to facilitate waste exchange and promote sustainable waste management practices and circular economy concepts in India. This initiative will support the nation in reducing its overall carbon emissions.

CII in partnership with European Union – Resource Efficiency Initiative for India (EU-REI) developed a unique website, which acts as a platform to facilitate material exchange and enable network between buyers and sellers, thereby promoting resource efficiency among the stakeholders of waste management in the country. This website will offer a platform for waste generator (non-hazardous and hazardous waste) to register and share the details of waste generated with quantity and quality. Also, offers waste users to access the information on waste generation and policy framework for managing the waste in the country. This website will facilitate significant synergies among large industries, Government, ULB’s and SMEs, where the waste/by-product of one may be used as a resource in other, thereby reducing the use of natural resources and overall carbon emissions.

CII will make the documents on waste inventory in various states and list of co-processing units approved by the Central Pollution Control Board (CPCB). Procedures to be followed for co-processing approvals in cement plants and transportation of Hazardous waste were listed in this section.

Moreover, official estimates report that out of the 26,000 tpd of plastic waste generated across India, only 60 per cent of it is recyclable. ??he association of cement manufacturers has assured us that they will take necessary steps to ensure that all cement plants use plastic waste fuel,??said Durga Shankar Mishra, Urban Affairs Secretary, Government of India. ??hat will help us in a big way to get rid of the garbage that can’t be processed.” The Ministry of Housing and Urban Affairs (MoHUA) has approached the cement industry to see how it can increase the dispatches of processed waste to cement plants. The current estimates are that plastic waste needs to be transported up to 200 km before reaching a cement plant for co-processing. The MoHUA and CMA collectively conducted the plastic waste initiative across five cities in India, including Delhi, Noida, Lucknow, Raipur and Ahmedabad.

Jharkhand cement plant in West Singhbhoum district is one of the first cement plants in India to adopt plastic waste co-processing. The cement producers in Gujarat are among the leaders for co-processing plastic waste, which makes up five per cent of their total fuels, and it could soon be made mandatory for producers in the state to increase this to 10 per cent of their fuel use. ?? few plants have already started setting up some infrastructure so that they can dispose of plastic waste,??added Mahendra Singhi, MD and CEO of Dalmia Bharat.

WHO PAYS?

Meanwhile, there are several issues up for discussion. These will include who will bear the cost of any investments required and how soon the country can make the switch to burning plastic waste. It is estimated that the capital expenditure required to install the necessary equipment to burn the waste will be between Rs 150 to Rs 300 million per plant.

??he model implemented in Europe and worldwide is for the polluter to pay,??added Singhi. ??f India implements this scheme, then the producers of single-use plastics will pay to dispose their waste. The cement industry should either get paid or the plastic should at least be free for us.??/p>

Another issue to be addressed is about the continuous supply of waste as the industry is expected to invest in capital expenditure.

MEGHALAYA INITIATIVE

However, initial projects have not always been free for the cement plants. In Meghalaya, where around 10 per cent of the country?? limestone reserves are found and home to many cement plants, cement companies pay for the plastic waste. One initiative has ragpickers and volunteers collecting plastic waste to be used as fuel in cement plants. To benefit from this service, cement producers have to pay the scrap dealers Rs 30/kg of plastic as part of the government?? ??lastic Challenge??initiative. The scheme enables tribal bodies and local organisations in Meghalaya to play their part in reducing plastic waste in the province, which has had a plastic ban on many items since 2018. (Source: CemNet.com)

The fuel mix of cement manufacturers is going through a churn. The last decade saw cement companies partially substitute coal with pet coke. However, the fuel mix now includes plastics and tyres, as companies look to rejig their sourcing. ??ur fuel mix currently comprises alternative fuels at 7 per cent. According to Geocycle (a waste management solution), the estimated amount in the long-term will be 13 per cent as disclosed by Ambuja Cements. The company has adopted Geocycle as a co-processing technique for industrial and other wastes at its kilns.

Co-processing refers to the use of waste materials in industrial processes as alternative fuel or raw material. Due to the high temperature in the cement kiln, different types of wastes can be effectively disposed of without harmful emissions, according to CPCB. Others like UltraTech, Nirma?? Nuvoco, JK Lakshmi and Madras Cement are among companies that are burning waste ranging from tyre chips, rubber dust to rice husk and cashew nut shells in their kilns to generate heat. At Dalmia Cement?? Responsible Industrialisation initiative, around 18.9 tonnes of plastic waste was collected from residential areas, the plant and neighbouring villages and used in the kiln to save a good 56 million kilo calories of energy.

For the country?? largest cement maker UltraTech, alternative fuels contribute eight to 18 per cent to the total fuel mix. In an investor presentation in February, the company said it is targeting 10 per cent contribution from alternative fuels by the end of the current financial year.

Companies like Shree Cements have also extended the fuel mix to sources like automobile sludge, waste water with high ammonia levels as well as medical waste. ??lternative fuel now contributes four to five per cent to our total fuel mix,??said HM Bangur, managing director of Shree Cements.

Anumita Roy Chowdhury, executive director at Centre for Science and Environment or CSE, said, ??o ensure such processes do not cause environmental hazards, there is a need for stringent monitoring of stack and process emissions as well as profiling of emissions.??She added, ??ement companies will have to invest in effective emission control systems to stay within the permissible limit and reduce toxic emissions. Adequacy of emission standards will have to be reviewed from time to time.??/p>

– VIKAS DAMLE

Concrete

The primary high-power applications are fans and mills

Published

2 days ago

October 10, 2025

admin

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

2 days ago

October 10, 2025

admin

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

2 days ago

October 10, 2025

admin

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