Enhancing energy efficiency
Through continuous monitoring and maintenance of equipment and machineries, Prism Johnson strives towards attaining better energy efficiency across all business divisions.
Use of Renewable Energy:
Over the last few years, the Company has ramped up its investment in renewable energy. At present, Prism Cement has an installed capacity of 22.5 MW of solar power and 22.4 MW of WHRS. In 2023-24, around 29.2% of the Prism Cement’s power consumption requirements were met through green and renewable sources. The Division has also adopted a target to increase the share of renewable power to 50% by 2024-25. To achieve this target, we (the Company) have/has made an investment in 8 MW of additional solar power, which is likely to get commissioned during 2024-25. Additionally, the Company is investing in setting up 24 MW of captive wind power which is likely to get commissioned by March 2025.
Additionally, HRJ has a total installed capacity of 4.5 MW of solar energy across its own plants. The division also leverages the waste heat generated from its kilns for spray drying reducing fossil fuel consumption.
Water Conservation
The Company has constructed rainwater-harvesting structures across different plants and locations to reduce reliance on virgin sources of water. During 2023-24, around 20% of HRJ’s water requirements were met through rainwater harvesting. Through these harvesting structures, the Company has recharged ~ 23 Lakh m3 to ground. Prism Cement was 3.4 times water-positive during 2023-24.
Reduction of Clinker Factor and use of Alternative Materials:
The calcination of limestone into clinker is responsible for about 50% of the Company’s carbon emissions. Therefore, substituting clinker with alternative low-carbon raw materials is a key component of the Company’s decarbonisation strategy. Prism Cement and Prism RMC use alternative raw materials such as fly ash, Ground Blast Furnace Slag (GGBS), copper slag, and Pulverised Fuel Ash (PFA).
During 2023-24, Prism Cement Division used 17%, Prism RMC used 5% and HRJ used 8% of alternative raw materials.
Alternative fuels:
To reduce dependence on conventional fossil fuels, Prism Cement uses alternative fuels in its kilns and has developed a well-defined plan to boost the Thermal Substitution Rate (TSR) of its operations. Through further investments in AFR capabilities, the Company leveraged alternative fuels to meet 7% of its energy requirements in the fourth quarter of 2023-24 and 3% for the full year 2023-24. Moreover, the HRJ Division of the Company effectively leverages fuels derived from waste from local industries, including cashew husk, sludge waste and many more. Overall, the Company met 6% of its fuel requirements through alternative fuel sources during 2023-24.
Carbon Sequestration and Carbon Capture and Storage (CSC):
As a part of the Company’s decarbonisation agenda, it aims to explore different CCS technologies. Prism Johnson’s ambition is to experiment with different technologies and reach cost-effective solutions.