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Cement plants can add renewable electricity without interrupting production when they plan around the plant’s hourly demand, critical loads and backup arrangements—not just the annual volume of power a project is expected to generate. Options include on-site solar or wind, contracted renewable electricity and hybrid systems that combine generation with storage. The right mix depends on the site and local grid rules. A project reported by UltraTech at Sewagram Cement Works shows one possible configuration, not a template for every plant.
Power is only part of cement’s energy and emissions challenge. Renewable electricity can reduce the emissions associated with electricity use, but it does not automatically supply the kiln’s high-temperature heat or eliminate emissions released when limestone and other raw materials are processed. A continuity plan for electricity therefore belongs within a broader plant decarbonisation plan.
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Why switching power sources is not the same as switching off the grid
A cement plant needs an energy supply that follows its operations. Renewable generation, however, varies with the resource available at a given time: solar output depends on sunlight, and wind output depends on wind conditions. The operational question is not simply whether a project can produce enough electricity over a year. It is whether supply can meet demand when the plant needs it, and what happens when generation falls short.
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1Clear out junk files and repair common Windows errors2Scan for outdated or missing drivers - takes under a minute3Repair Windows errors before they cause bigger problemsContinuity must be designed into the project. Depending on the site and market, a plant might use on-site generation alongside the grid, procure renewable electricity through a contract, or combine generation with battery storage and other backup arrangements. These routes differ in ownership, operating responsibilities, grid dependence and exposure to contract or settlement rules. None is automatically available or suitable everywhere.
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UltraTech reports that its Sewagram Cement Works in Gujarat, India, has a 7.5 MW behind-the-meter hybrid renewable system combining solar modules with trackers, wind and battery storage. The company says the system is intended to provide uninterrupted clean energy for manufacturing without grid power and identifies Gentari as its project collaborator. This company-reported installation demonstrates that a combined configuration has been implemented at one cement site; it does not establish that another plant can operate without grid support, or that the same capacity, performance or economics would apply elsewhere.
Separate electricity, kiln heat and process emissions
Electricity is used for plant equipment and operations, while kiln production also depends on high-temperature thermal energy. The emissions challenge extends beyond both forms of energy: processing carbon-containing raw materials releases process emissions. These are distinct sources of emissions and need distinct measures.
The International Energy Agency (IEA) describes cement as difficult to decarbonise because of its reliance on carbon-containing raw materials and high-temperature heating requirements. Renewable electricity procurement can lower the emissions intensity of a plant’s electricity supply, subject to the source and applicable accounting rules. It does not, by itself, replace kiln heat or prevent emissions from raw-material processing.
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That distinction matters when assessing a project. A plant should identify which loads can benefit from renewable electricity and track the result as an electricity measure. It should not treat a renewable electricity contract or solar installation as proof that the plant’s thermal energy use or process emissions have also been addressed.
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Build a continuity baseline before choosing a supply option
There is no single standard audit protocol established for all cement plants in the reviewed material. A practical starting point is to assemble the operating information needed to judge supply against demand, then have plant and energy teams assess options against it.
- Map electricity use over time. Compile the plant’s electricity demand at the time intervals available, and distinguish operating periods from shutdowns or planned maintenance. Annual consumption alone cannot show whether generation will coincide with production.
- Identify critical loads. Record which equipment and systems must remain supplied to sustain safe, controlled operations, and which loads can be reduced, shifted or temporarily interrupted under an approved operating plan. Confirm the required response with the people responsible for plant operations and electrical systems.
- Document supply and outage arrangements. Record the existing grid connection, backup equipment, operating procedures and planned and unplanned outages. Identify who responds to a shortfall and how the plant manages the transition between available supply sources.
- Record kiln thermal demand separately. Track the thermal energy needs of kiln operations independently from electricity use. This prevents a power project from being credited with solving a heat requirement it does not serve.
- Set the continuity requirement for the proposal. Specify which loads must be served, the operating conditions under which they must be served, and what the plant will accept during a supply shortfall. A proposal cannot be evaluated against “reliability” unless the plant has defined what continuity means in its own operations.
This baseline is an operating tool, not a promise that renewable generation can match every load. It gives the project team a way to examine the timing of supply, the consequences of a shortfall and the role of the grid or backup systems before selecting a configuration.
Compare renewable supply routes against plant operations
On-site generation, contracted supply and hybrid systems solve different parts of the supply problem. A plant can assess more than one route, but the feasibility of each depends on site conditions and local electricity-market rules.
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One free scan finds every outdated or missing driver and matches the right update for your exact hardware.Free scan · exact hardware match| Route | What to assess | Continuity question | Evidence limit |
|---|---|---|---|
| On-site solar | Solar resource, suitable space, interconnection and whether surplus generation can be exported. | How will supply be managed when solar output does not match plant demand? | Annual energy production alone does not establish an hourly match or uninterrupted supply. |
| On-site wind | Wind resource, siting constraints, grid connection and the plant’s ability to use or export generation. | What supplies the plant when wind generation is insufficient or unavailable? | It is a site-dependent option, not a universally available one. |
| Contracted renewable electricity | Contract structure, delivery and settlement rules, counterparty, curtailment and balancing terms. | What does the contract provide when the plant needs power but contracted generation is low? | Contract terms and renewable-electricity accounting depend on the jurisdiction and agreement. |
| Hybrid generation with storage | Generation mix, storage power and duration, grid connection, operating controls and backup arrangements. | Which shortfalls is storage intended to cover, and what happens when its available energy is insufficient? | A hybrid installation at one plant does not establish a standard design, cost or performance for others. |
On-site solar and wind
On-site projects can place generation close to plant loads, but proximity alone does not guarantee continuous supply. The team still needs to compare expected generation timing with the plant’s demand and determine how the electrical system handles surplus and shortfalls. Space, resource quality, connection capacity and export permissions may affect whether a project is feasible.
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The Global Cement and Concrete Association’s 2024/25 progress-report excerpt describes UltraTech installing 3,600 m² of floating solar panels at Awarpur Cement Works in India in 2024. It is an example of solar being used in a cement-sector setting, not evidence that floating solar is suitable at every site. The physical space, water-body requirements and approvals for a project must be assessed locally.
Contracted renewable electricity
A power purchase agreement (PPA) is a time-defined contract for electricity supply, as described in the IEA Photovoltaic Power Systems Programme’s 2025 report excerpt. A PPA may let a plant procure renewable electricity without owning the generating asset, but the contract does not remove the need to understand how physical supply and market settlement work where the plant operates.
The same IEA PVPS excerpt identifies low generation and off-taker insolvency as PPA risks. In practical terms, a plant should examine what the contract says about underproduction, the buyer’s obligations and remedies, and which party carries relevant balancing or settlement exposures. Grid capacity, curtailment rules and local accounting treatment also matter. No savings or emissions outcome should be assumed without checking the specific contract and local rules.
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Hybrid supply and storage
Storage can form part of a continuity design, but the label “battery storage” does not reveal what the system can support. The proposal should state the battery’s power capability and intended duration of support, which loads it is meant to serve, what controls govern discharge, and how it is recharged. It should also show how the system responds to a longer renewable shortfall or an outage affecting the grid connection.
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For grid-connected systems, clarify whether the plant expects to remain connected during normal operations and how it behaves during a grid disturbance. If islanded operation is proposed, establish which equipment can support it and what operating limits apply. These are design questions for the plant’s electrical and project teams; a case study cannot substitute for site-specific engineering.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.Use the Sewagram project as a case, not a specification
UltraTech’s reported Sewagram installation combines solar, wind and battery storage in a 7.5 MW behind-the-meter system. The company describes it as a round-the-clock hybrid renewable project co-located at the site and intended to supply uninterrupted energy during cement manufacturing without grid power. The configuration illustrates the kind of integration an operator might investigate when continuity is central to the project.
The report is company-attributed evidence about one installation. It does not provide a transferable design rule for storage duration, plant load coverage, cost, outage reduction or performance at other sites. Those values are not established for comparable options in the available source material. A plant considering a similar approach needs a proposal tied to its own load data, grid conditions and operating requirements.
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The IEA’s 2023 Cement: Net Zero Emissions Guide includes scenario milestones for kiln thermal energy intensity and the share of low-emissions fuels in thermal energy use. The values below are scenario figures, not forecasts for a particular plant or engineering targets to apply without site analysis.
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| IEA cement-pathway indicator | 2022 scenario value | 2030 scenario value | 2035 scenario value | 2050 scenario value |
|---|---|---|---|---|
| Kiln thermal energy intensity (GJ per tonne of clinker) | 3.6 | 3.4 | 3.3 | 2.9 |
| Low-emissions fuels’ share of thermal energy use | 5% | 30% | 49% | 86% |
| Electricity contribution shown in the pathway table | 0% | 0% | 0% | 8% |
The electricity row is presented as a contribution in the IEA pathway table; it should not be read as a share of total plant energy without checking the table’s category and context. These scenario figures describe a sector pathway, not a required renewable-electricity percentage for an individual cement works. Their relevance here is that the pathway includes changes in thermal energy as well as electricity, reinforcing the need to keep the two questions separate.
Integrate power procurement with the wider decarbonisation plan
The IEA’s 2023 cement guide places renewable electricity within a wider set of measures. Near-term measures include energy efficiency and lower-emissions fuels; deeper reductions involve alternative materials and carbon capture, utilisation and storage (CCUS). The appropriate mix and timing depend on the plant and its operating context.
For an operator, that means keeping separate workstreams connected. An electricity project should be evaluated for its effect on power supply and emissions, while efficiency measures address energy use, fuel choices address thermal demand, and material or CCUS measures address process emissions. A plan that measures only renewable electricity can miss emissions sources that the power project does not affect.
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Decision checklist for a plant proposal
- Does the proposal use the plant’s demand over time and identify critical loads?
- Does it distinguish electricity demand from kiln thermal energy demand and process emissions?
- Are solar or wind resource, site suitability, interconnection and surplus-export conditions assessed?
- Does the continuity design explain the role of the grid, storage, backup and operating controls?
- For contracted supply, are generation shortfalls, counterparty credit, curtailment, balancing, settlement and local accounting rules addressed?
- Are performance, cost and reliability claims supported for this plant and jurisdiction rather than inferred from a different installation?
- Is renewable electricity placed alongside efficiency, lower-emissions fuels, alternative materials and CCUS in the plant’s broader decarbonisation plan?
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