Circular economy: Using blast furnace slag for cement manufacturing at all plants

In our efforts to run an inherently circular business, we are increasing the content of Ground Granulated Blast Furnace Slag (GGBS) in Portland Slag Cement (PSC) to more than 50%. This helps in decreasing clinker factor along with reduction in carbon emissions by 12-15%. We are using polymer additive to reduce the clinker factor. To start this application, we purchased the polymer additive and developed it in-house.

We have developed the in-house additive, which is used in cement grinding and which helps in reduction of clinker consumption in every tonne of cement produced. By this initiative we were able to reduce our clinker consumption of ~ 45,890 tonnes at our Salboni and Jajpur plants.

Co-processing hazardous and non hazardous waste

Nandyal plant commenced co-processing in 2015 and have since co-processed different types of waste streams like hazardous waste, liquid effluent, industrial waste, biomass, dolachar, plastic waste, among others. This helps us avoid landfill of these wastes from different sources through eco-friendly co-processing. By using other wastes, we are not only providing waste management solutions but also reducing our dependence on traditional fossil fuels and overall CO₂ emissions from our manufacturing process

Usage of waste heat from cooler and coal mill for slag drying

Nandyal plant began using waste heat from cooler and coal mill stacks since 2017 for drying of slag. Before this initiative was operationalised, we used to fire coal to generate hot gases, which were in-turn used for slag drying in the mill. Following this initiative, we eliminated the usage of coal for generating hot gases, thus reducing our overall CO₂ emissions.

Installing solar power plants at our units

We currently have 9 MW capacity solar power plants, of which 5.5 MW was installed at Nandyal and 3.5 MW at Salboni. Through this, we are currently able to meet 3.15% of our overall electrical energy consumption. As we are using solar power, the equivalent of grid power consumption is has been brought down.

Rainwater harvesting at all our plants and the Nandyal Mines

All our plants are equipped with rainwater harvesting systems within our plant premises. At Nandyal, we do harvest rainwater in our worked out mine pit. The rain water harvested in a worked out mine pit will act as a water reservoir and also helps in improving the ground water table in & around our plant premises.

Developing green belts in and around our plants and mines

Our plants are surrounded by fully developed greenbelt and we take the utmost care in selecting the native species for effective green belt development. Wherever feasible saplings were purchased from nearest forest department. Once the sapling is planted, necessary steps were taken to maintain, grow the sapling with maximum possible survival rate. In our plant premises drip irrigation was adopted for watering the sapling or plantations.

Keeping the air clean

All our plants are equipped with air pollution control equipment (APCE) that are in the form of bag houses or bag filters depending upon the requirement. All our APCE were designed for outlet emissions greater than 10 mg/Nm3 against the regulatory requirement of greater than 30 mg/Nm3. Through this initiative we keep our immediate surrounding cleaner and safer. It also helps us elevate the quality of life in the plant premises.

Replacing natural resources with alternative raw materials

Across our operations we are using alternative raw materials in place of natural resources in cement manufacturing. Chemical gypsum is being used instead of natural or mineral gypsum thus maximising the life of natural resources. Fly ash is used in-place of clinker for manufacturing PPC, thus avoiding the usage of natural limestone for clinker production. This is enabling us to bring down mining activity CO _{emissions from the overall product footprint.}