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Circular Economy

Circular economy is a concept that goes beyond just recycling. It is a restorative and regenerative process where very few 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. Only when the material fully degrades, it is recycled into another form.

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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
  • Self-cleaning combustion gas due to the alkaline atmosphere
  • 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 more than 28 Million Tonnes of recycled material for making cement. The quantity of recycled material used has increased significantly over the past few years. Recently, our R&D teams patented the process of making cement from aluminium industry waste. 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

  • Alternate material constitutes 20.60% of our total raw material used
  • Achieved a 5.2% thermal substitution rate by using waste materials in a kiln 
  • UltraTech consumes plastic waste in form of alternate fuel. We have achieved 2.44 times Plastic negative status at business level, which is certified 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 more than 80 municipal corporations across India to help them in destroying incinerable non-biodegradable waste in a safe and sustainable manner through co-processing.
  • Total consumption of alternative fuels: approximately 0.6 million tons in FY23.
  • Co-processed 4.1 lakh tonnes of industrial waste as an alternative fuel and 1.59 lakh tonnes of segregated Municipal Solid Waste from municipalities across India in FY 22-23.
  • In a first-of-its-kind initiative in India, inland and coastal waterways were leveraged by UltraTech to transport 57,000 metric tons (MT) of phosphogypsum in a bulk cargo carrier from Paradeep port in Odisha to the jetty of UltraTech's integrated cement unit, Gujarat Cement Works.
  • 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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