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Powering sustainable production in Pali

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World Cement,

S. K. Gupta, UltraTech Cement Ltd, and Ashok Kumar Dembla, KHD Humboldt Wedag India Pvt Ltd, offer some details on their collaboration at Ultratech’s Pali plant, outlining the facility’s sustainability goals and the equipment that will help it reach them.

Powering sustainable production in Pali

Long-term prospects for the Indian economy continue to be robust. Various initiatives, including the privatisation of public sector enterprises, the monetisation of assets, the implementation of National Infrastructure Pipeline projects, and targeted foreign investment incentives through production-linked incentives schemes, are likely to spur a positive cycle of investment and growth in the medium term.

At UltraTech Cement, a clear roadmap has been put in place to implement low-carbon technologies across the value chain and thus to reduce the carbon footprint across the lifecycle of its products. Every year, the group sets new benchmarks on this journey, while contributing to global sustainable development goals. Progress made on sustainability commitments includes the following:

  • The company currently returns nearly four times the amount of water it consumes compared to local communities and has a target to be five times water-positive by 2024.
  • Progress has been made in efforts to increase the use of alternative fuels (AF) and raw materials in its manufacturing processes.
  • The company is scaling up its contribution to the circular economy by utilising 28 million t of recycled material for cement manufacturing in fiscal year 23 alone.
  • Energy conservation efforts have gained momentum, as waste heat recovery system capacity and the share of green power in the total energy mix for operations are increasing year on year, leading to a significant reduction in CO2 emissions.

As a founding member of the Global Cement and Concrete Association (GCCA), UltraTech is also committed to achieving net zero by 2050. This includes a commitment to lowering Scope 1 GHG intensity by 27% by 2032 from the base year of 2017.

In 2020, UltraTech announced CAPEX to increase its total capacity by 12.8 million tpy via a mix of brownfield and greenfield expansions in the fast-growing markets of south, east, central, and north India.

This will take UltraTech’s capacity to 132.45 million tpy, further solidifying the company’s position as India’s leading building solutions company and forming part of its overall growth plan to reach manufacturing capacity of 200 million tpy.

UltraTech Pali: a benchmark greenfield plant

One such expansion project is the construction of a new 8 000 tph greenfield clinker production line in Pali, Rajasthan, in northwest India. UltraTech appointed KHD as its technology partner for the project, via KHD’s Indian subsidiary, Humboldt Wedag India. KHD has a long history as a leading technology supplier to the cement industry, developing many of the key innovations that define the modern cement plant. Against a background of resource depletion, concerns over greenhouse gas emissions, and the need for more sustainable practices, the Germany-based company is committed to providing cutting-edge solutions that improve the long-term sustainability of cement production.

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