Alternate Fuels

In cement industry, hazardous wastes generated from various industries like pharma, tyre etc. is co-processed in cement Kilns. These materials are used as a substitute to natural fossil fuels and minimize consumption of natural resources in manufacturing process.

The environmental policy at Vicat in India has been to deploy alternate fuels to mitigate Greenhouse Gases emissions and contribute towards a better carbon footprint. As a step towards environmental protection, the waste products are processed first to combat emissions which highly pollute the environment. The deployment of Alternate Fuels & Raw materials (AFR) is considered to be a best practice imbibed to foster a step towards a clean & green environment

The Vicat In India Group Companies – Kalburgi Cement and Bharathi Cement are authorized by Central Pollution Control Board and by State Pollution Control Boards for co-processing of hazardous waste from pharmaceutical, automobile industry as a fuel. Currently at Kadapa plant we are using organic residue, semi-solid sludge from pharmaceutical companies like Dr. Reddy’s , Mylan Laboratories etc.

For Kadapa plant, through an agreement with Ramky Enviro Associates, a set up for Municipal Solid Waste (MSW) processing plant, to convert MSW to Refuse Derived Fuel (RDF) is established. The plant is capable of extracting -- tonnes of RDF from --- tonnes of MSW per day.

Currently we utilize Pharma waste, Paint Sludge, Spent Carbon, Dolachar, Rice Husk, and RDF from pollution control board approved units. Alternate fuel substitution for Vicat India plants is one of the best in Industry.

Fly Ash & Slag Utilization

As a part of our carbon footprint reduction initiative, we continue our efforts to replace clinker with materials such as fly ash and slag from thermal power plants and steel plants.

Fly ash is a fine glass powder recovered from gases emitted by burning coal during the production of electricity. Fly ash is a major waste of coal-based thermal power plants. Fly ash disposal is a significant environmental concern as it creates huge pressures on land and water and fugitive emissions.

Both our plants put together are consuming fly ash to tune of 5.7 lakh tons per annum to produce PPC (Pozzolana Portland cement) and slag to tune of 0.8 Lakh tons per annum to produce PSC (Portland Slag Cement)

Currently such waste material is used in 55% of our cement produced at Kadapa and 25% at Kalburgi plant. This ensures conservation of natural resources and productive use of waste.