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Circular Economy

Circular economy is a concept that goes beyond just recycling. It is a restorative and regenerative process where resources are used in the first place and they are upcycled or down cycled until the complete value is derived from them. Once the value is derived, the material is used for other purposes.

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The circularity of materials is a priority for UltraTech in tackling the issue of overutilization of resources, the rising cost of natural raw materials and disposal of waste generated from it. UltraTech has developed systems at its unit locations utilize waste materials safely and efficiently following the principles of circular economy.

Alternative Fuel

UltraTech uses municipal solid waste and other industrial waste as alternative fuel in its kilns through co-processing. Dedicated teams are working constantly to procure such waste materials from Municipal Corporations.

 

Some of the key advantages of using waste as a fuel are:

  • Deviation of waste from going to landfill
  • Complete destruction of pollutants
  • Absence of any residual waste
  • No emission influenced by combustion of waste
  • No impact on the quality of cement produced
  • Preserving natural resources

Alternative Materials

UltraTech is on a constant lookout for techniques to replace natural limestone. We use waste materials like fly ash, gypsum, slag, red mud in lieu of naturally occurring limestone. We have used over 33 million tonnes of recycled and alternative raw materials in cement production in FY 24. The quantity of recycled material used has increased significantly over the past few years. Recently, our R&D teams patented the process of using aluminium industry waste into cement making. We have entered into a Memorandum of Understanding (MoU) with our Group company, Hindalco Industries Ltd., a global leader in aluminium and copper, where Hindalco will deliver 1.2 million metric tonnes of red mud (also known as bauxite residue) annually to UltraTech's plants. Red mud generated in the alumina manufacturing process is rich in iron oxides, along with alumina, silica and alkali. Our R&D team has developed the capability to process red mud as a replacement for mined minerals such as laterite and lithomarge in its process.

Resource Management

UltraTech focusses on using fewer natural resources across its value chain and promotes the same at the industry level. We vehemently support a low-carbon economy where raw materials are consumed judiciously. In our operations, we follow a dual approach for efficient waste management: First, we generate less waste by using raw materials judiciously so that the waste can be managed effectively. Second, we substitute fossil fuels and raw materials with waste material generated not only from our plants but also from other industries which helps us to reduce our carbon footprint.

Key Achievements

  • 20.85% recycled input material has been used for cement production in FY24. 
  • Achieved 5.12 % thermal substitution rate in FY24 by using waste materials in a kiln 
  • UltraTech consumes plastic waste in form of alternate fuel. We have achieved 3.40 times Plastic negative status at business level, which is assured by third party. 
  • Use of waste materials such as fly ash and slag for making blended types of cement such as PPC (Portland Pozzolana Cement), PSC (Portland Blast Furnace Slag Cement), PPC Super and composite cement 
  • Co-processing for a cleaner society- UltraTech has tied up with many municipal corporations across India to help them in destroying incinerable non-biodegradable waste in a safe and sustainable manner through co-processing. We have co-processed 5.43 lakhs tonnes of MSW as alternative fuels in our kiln operations and captive power plants. 
  • Utilized 1.58 million tonnes of alternative fuels including both kiln and TPP in FY24. We have co-processed 4.97 lakh tonnes of industrial waste, 5.43 lakh tonnes of Municipal Solid Waste and 5.41 lakh tonnes of agro-waste as alternative fuels in our kilns in FY24. 
  • Many manufacturing units have registered as plastic waste processing facilities (PWPF) under Plastic Waste Management (Amendment) Rules, 2022, to provide co-processing to various brands for fulfilling their Extended Producer Responsibility (EPR) compliances.
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