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A Perspective: Technology and Future Development

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We in India often hear of the green revolution and the milk revolution but few recognise that we also have a real success story in the cement industry. Prior to the introduction of partial decontrol by the government in 1982, a bag of cement could be purchased in the black market at about Rs 150 when the controlled price against permit was a mere Rs 25. The fact that cement is freely available today at almost the same price per bag as it was 30 years ago is indeed also a revolution.Jayaram K Nambiar is associated with design, manufacture, supply, project planning and implementation of cement projects for the past 45 years. He currently serves as Director on the Board of Pfeiffer (India).With an installed capacity of 300 million tonne a year in 2011, India is the second largest cement producer in the world. The level of technology, processes and design of the plants is comparable to the best globally. The competence and knowledge of the people within the industry is second to none and the capacity utilisation, operating efficiencies and energy consumption results at the plants prove the same.Although substantial technology transfer has taken place in the period of growth, no real or worthwhile R&D in process technology or design development of equipment for cement manufacture is being undertaken in India. In not ploughing back returns – whether in terms of funding or knowledge gained – into R&D, the private sector cement producers and plant suppliers betray a short-sightedness that will in time erode the gains made over the last 30 years.Evolution of TechnologyUntil the 1980s, technology developments introduced were chiefly concerned with the reduction of thermal energy consumption – The pre-calcinator technology with the short kiln, pre-heater and high efficiency grate cooler developed at that time still remains the basic process of the top of the line clinker plants that are being constructed today.Subsequent developments emphasised savings in electrical energy. For example, new types of grinding equipment – vertical roller mills (VRM) and high pressure grinding rolls (HPGR) – are used in the three energy intensive operations, ie, preparation of raw materials and coal for the clinkerisation plant and for the grinding of the clinker into cement. Progressive improvements in the grinding circuits have been done to achieve further small gains in electrical energy by refinement of system engineering and streamlining of airflows. In clinkerisation the low pressure drop cyclones of the pre-heater and the high efficiency separators in grinding are outstanding examples of such development of streamlining of gas flows.The early 2000’s (2001-10) witnessed the commencement of a new trend – sharp increase in the capacity of the unit plant being installed from 6,000 tpd to 10,000 tpd – to take advantage of economies of scale by way of reduced investments.In view of the trend of installing high capacity plants a single grinding machine VRM with power as high as 12,000 KW transmitted through girth gear and multi-drive with variable speed motors was introduced in 2010 by Gebr Pfeiffer AG. The machine power of the VRM was earlier limited by the power transmittable by the VRM gearbox of around 7500 KW and this barrier now seems to have been overcome. In the future we can expect very large single unit VRMs of high capacity being installed for raw and cement grinding in plants of large capacity.The FutureAfter power, cement industry is the largest producer of CO2 waste accounting for 5 per cent of the total CO2 emitted worldwide. The Kyoto Protocol also applies to the cement industry and it gets, by way of subsidy, carbon credits for implementing CO2 reduction measures in the production process. The trend therefore from year 2000 was increasingly towards the production of blended cements (PPC and PBFS) which resulted in higher production capacity of cement being without the corresponding increase of CO2 emissions.Recent improvements being implemented in the cement Industry are environmental-friendly like waste gas heat recovery and production of blended cements described earlier will continue at more plants in the current decade. With the increasing acceptance of blended cement by consumers and with new power and steel plants being commissioned additional fly ash and slag would be available and the production of PPC and PBFS cement shall further increase.Future dust emissions norms set by the government are likely to be more stringent for the cement industry. The industry in anticipation has from the early 2000s started installing bag house filtration in place of ESP. Baghouses have reduced emission than the prescribed regulatory norms. Baghouses can be further enlarged quite easily and the technology will be able to match the tighter norms when next prescribed by the government.Cement companies in India have experimented with alternative fuels but sufficient headway has still to be made. The capability is available within the industry to handle successfully the process changes and develop the sustained utilisation of alternative fuels – wastes, biomass, etc but greater efforts has to put in this area. The situation in this regard can be expected to change as costs of coal go up and the collection and handling and thereby availability of waste materials improve, through collaboration across industry sectors and local government institutions. It has to be emphasised that the cement kiln with pre-calcinator is an ideal incinerator and by identifying specific available waste material and organising the long term use of it as an alternative fuel, the industry as well as society shall benefit. The importance of CO2 reduction for the cement industry cannot be under estimated and more developmental efforts have to be undertaken by the Indian cement companies in this direction.ConclusionsThe new plants coming up during this decade will have to consider new technological developments in the reduction of CO2 and other harmful emissions and in being environmentally-friendly. The design of these plants may well have to take into account new directions and regulations for the cement industry.Cement industry has been identified as one of the industries contributing to green house gases responsible for drastic climate changes. Global attention is focussed on climate change and international agreements on joint action for reduction of green house gases exist. What form such joint action will ultimately take will depend on the progress of technological developments underway (eg CCS), but before the end of the current decade some directions to the cement industry in relation to action required for a more environmental-friendly industry can be expected. Indian cement industry being the second largest will be required to be in the forefront of implementing these changes. Unfortunately, all the research and development which will decide the future direction is being undertaken in the developed countries and our Industry will continue to be dependant on technology transfer from others for implementing the required future changes and developments.

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Concrete

We consistently push the boundaries of technology

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Swapnil Jadhav, Director, SIDSA Environmental, discusses transforming waste into valuable resources through cutting-edge technology and innovative process solutions.

SIDSA Environmental brings decades of experience and expertise to the important niche of waste treatment and process technologies. As a global leader that is at the forefront of sustainable waste management, the company excels in recycling, waste-to-energy solutions and alternative fuel production. In this conversation, Swapnil Jadhav, Director, SIDSA Environmental, shares insights into their advanced shredding technology, its role in RDF production for the cement industry and emerging trends in waste-to-energy solutions.

Can you give us an overview of SIDSA Environmental’s role in waste treatment and process technologies?
SIDSA is a leading innovator in the field of waste treatment and process technologies, dedicated to delivering sustainable solutions that address the growing challenges of waste management.
SIDSA is a more than 52-year-old organisation with worldwide presence and has successfully realised over 1100 projects.
Our expertise is in the engineering and development of cutting-edge systems that enable the conversion of waste materials into valuable resources. This includes recycling technologies, waste-to-energy (W2E) systems, and advanced methods for producing alternative fuels such as refuse derived fuel (RDF). The organisation prioritises environmental stewardship by integrating energy-efficient processes and technologies, supporting industrial sectors—including the cement industry—in reducing their carbon footprint. Through our comprehensive approach, we aim to promote a circular economy where waste is no longer a burden but a resource to be harnessed.

How does SIDSA Environmental’s shredding technology contribute to the cement industry, especially in the production of RDF?
SIDSA’s shredding technology is pivotal in transforming diverse waste streams into high-quality RDF. Cement kilns require fuel with specific calorific values and uniform composition to ensure efficient combustion and operational stability, and this is where our shredding systems excel. In India, we are segment leaders with more than 30 projects including over 50 equipment of varied capacity successfully realised. Some of the solutions were supplied as complete turnkey plants for high capacity AFR processing. Our esteemed client list comprises reputed cement manufacturers and chemical industries. Our technology processes various types of waste—such as plastics, textiles and industrial residues—breaking them down into consistent particles suitable for energy recovery.

Key features include:

  • High efficiency: Ensures optimal throughput for large volumes of waste.
  • Adaptability: Handles mixed and heterogeneous waste streams, including contaminated or complex materials.
  • Reliability: Reduces the likelihood of operational disruptions in RDF production. By standardising RDF properties, our shredding technology enables cement plants to achieve greater energy efficiency while adhering to environmental regulations.

What are the key benefits of using alternative fuels like RDF in cement kilns?
The adoption of RDF and other alternative fuels offers significant advantages across environmental, economic and social dimensions:

  • Environmental benefits: Cement kilns using RDF emit fewer greenhouse gases compared to those reliant on fossil fuels like coal or petroleum coke. RDF also helps mitigate the issue of overflowing landfills by diverting waste toward energy recovery.
  • Economic savings: Alternative fuels are often more cost-effective than traditional energy sources, allowing cement plants to reduce operational expenses.
  • Sustainability and resource efficiency: RDF facilitates the circular economy by repurposing waste materials into energy, conserving finite natural resources.
  • Operational flexibility: Cement kilns designed to use RDF can seamlessly switch between different fuel types, enhancing adaptability to market conditions.

What innovations have been introduced in waste-to-energy (W2E) and recycling solutions?
SIDSA’s machinery is meticulously engineered to handle the complex requirements of processing hazardous and bulky waste.

This includes:

  • Robust construction: Our equipment is designed to manage heavy loads and challenging waste streams, such as industrial debris, tires and large furniture.
  • Advanced safety features: Intelligent sensors and automated controls ensure safe operation when dealing with potentially harmful materials, such as chemical waste.
  • Compliance with standards: Machinery is built to adhere to international environmental and safety regulations, guaranteeing reliability under stringent conditions.
  • Modular design: Allows for customisation and scalability to meet the unique needs of various waste management facilities.

How does your organisation customised solutions help cement plants improve sustainability and efficiency?
We consistently push the boundaries of technology to enhance waste management outcomes.
General innovations and new product development focus on:

  • Energy-efficient shredders: These machines consume less power while maintaining high throughput, contributing to lower operational costs.
  • AI-powered sorting systems: Utilise advanced algorithms to automate waste classification, increasing material recovery rates and minimising errors.
  • Advanced gasification technologies: Convert waste into syngas (a clean energy source) while minimising emissions and residue.
  • Closed-loop recycling solutions: Enable the extraction and repurposing of materials from waste streams, maximising resource use while reducing environmental impact.

What future trends do you foresee in waste management and alternative fuel usage in the cement sector?
Looking ahead, several trends are likely to shape the future of waste management and alternative fuels in the cement industry:

  • AI integration: AI-driven technologies will enhance waste sorting and optimise RDF production, enabling greater efficiency.
  • Bio-based fuels: Increased use of biofuels derived from organic waste as a renewable and low-carbon energy source.
  • Collaborative approaches: Strengthened partnerships between governments, private industries and technology providers will facilitate large-scale implementation of sustainable practices.
  • Circular economy expansion: The cement sector will increasingly adopt closed-loop systems, reducing waste and maximising resource reuse.
  • Regulatory evolution: More stringent environmental laws and incentives for using alternative fuels will accelerate the transition toward sustainable energy solutions.

(Communication by the management of the company)

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Concrete

FORNNAX Technology lays foundation for a 23-acre facility in Gujarat

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FORNNAX Technology, a leading manufacturer of recycling equipment in India, has marked a major milestone with the Groundbreaking (Bhoomi Pujan) ceremony for its expansive 23-acre manufacturing facility in Gujarat. Specialising in high-capacity shredders and granulators, FORNNAX is strategically positioning itself as a global leader in the recycling industry. The new plant aims to produce 250 machinery units annually by 2030, making it one of the largest manufacturing facilities in the world.
The foundation stone for this ambitious project was laid by Jignesh Kundaria, CEO and Director, alongside Kaushik Kundaria, Director. The ceremony was attended by key leadership members and company staff, signifying a new chapter for FORNNAX as it meets the growing demand for reliable recycling solutions. Speaking on the occasion, Jignesh Kundaria stated, “This marks a historic moment for the recycling sector. Our high-quality equipment will address various waste categories, including tyre, municipal solid waste (msw), cables, e-waste, aluminium, and ferrous metals. this facility will strengthen our global presence while contributing to India’s Net Zero emissions goal by 2070.”
FORNNAX is actively expanding its footprint in critical markets such as Australia, Europe and the GCC, forging stronger sales and service partnerships. The facility will house an advanced Production Department to ensure seamless manufacturing.

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Concrete

Decarbonisation is a focus for our R&D effort

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Dyanesh Wanjale, Managing Director, Gebr. Pfeiffer discusses the need to innovate grinding technologies to make the manufacturing process more efficient and less fuel consuming.

Gebr. Pfeiffer stands at the forefront of grinding technology, delivering energy-efficient and customised solutions for cement manufacturers worldwide. From pioneering vertical roller mills to integrating AI-driven optimisation, the company is committed to enhancing efficiency and sustainability. In this interview, we explore how their cutting-edge technology is shaping the future of cement production.

Can you tell us about the grinding technology your company offers and its role in the cement industry?
We are pioneers in grinding technology, with our company being based in Germany and having a rich history of over 160 years, a milestone we will celebrate in 2024. We are widely recognised as one of the most efficient grinding technology suppliers globally. Our MBR mills are designed with energy efficiency at their core, and for the past five years, we have been focused on continuous improvements in power consumption and reducing the CO2 footprint. Innovation is an ongoing process for us, as we strive to enhance efficiency while supporting the cement industry’s sustainability goals. Our technology plays a critical role in helping manufacturers reduce their environmental impact while improving productivity.

The use of alternative fuels and raw materials (AFR) is an ever-evolving area in cement production. How does your technology adapt to these changes?
Our vertical roller mills are specifically designed to adapt to the use of alternative fuels and raw materials. These mills are energy-efficient, which is a key advantage when working with AFR since alternative fuels often generate less energy. By consuming less power, our technology helps bridge this gap effectively. Our solutions ensure that the use of AFR does not compromise the operational efficiency or productivity of cement plants. This adaptability positions our technology as a vital asset in the industry’s journey toward sustainability.

What are some of the challenges your company faces, both in the Indian and global cement industries?
One of the major challenges we face is the demand for expedited deliveries. While customers often take time to decide on placing orders, once the decision is made, they expect quick deliveries. However, our industry deals with heavy and highly customised machinery that cannot be produced off the shelf. Each piece of equipment is made-to-order based on the client’s unique requirements, which inherently requires time for manufacturing.
Another significant challenge comes from competition with Chinese suppliers. While the Indian cement industry traditionally favoured our technology over Chinese alternatives, a few customers have started exploring Chinese vertical roller mills. This is concerning because our German technology offers unmatched quality and longevity. For example, our mills are designed to last over 30 years, providing a long-term solution for customers. In contrast, Chinese equipment often does not offer the same durability or reliability. Despite the cost pressures, we firmly believe that our technology provides superior value in the long run.

You mentioned that your machinery is made-to-order. Can you elaborate on how you customise equipment to meet the specific requirements of different cement plants?
Absolutely. Every piece of machinery we produce is tailored to the specific needs of the customer. While we have standard mill sizes to cater to different capacity requirements, the components and configurations are customised based on the client’s operational parameters and budget. This process ensures that our solutions deliver optimal performance and cost efficiency. Since these are heavy and expensive items, maintaining an inventory of pre-made equipment is neither practical nor economical. By adopting a made-to-order approach, we ensure that our customers receive machinery that precisely meets their needs.

The cement industry is focusing not only on increasing production but also on decarbonising operations. How does your company contribute to this dual objective, and how do you see this evolving in the future?
Decarbonisation is a key focus for our research and development efforts. We are continuously working on innovative solutions to reduce CO2 emissions and improve overall sustainability. For example, we have significantly reduced water consumption in our processes, which was previously used extensively for stabilisation. Additionally, we are leveraging artificial intelligence to optimise mill operations. AI enables us to monitor the process in real-time, analyse feedback, and make adjustments to achieve optimal results within the given parameters.
Our commitment to innovation ensures that we are not only helping the industry decarbonise but also making operations more efficient. As the cement industry moves toward stricter sustainability goals, we are confident that our technology will play a pivotal role in achieving them.

Can you provide more details about the use of digitalisation and artificial intelligence in your processes? How does this improve your operations and benefit your customers?
Digitalisation and AI are integral to our operations, enabling us to offer advanced monitoring and optimisation solutions. We have developed three distinct models that allow customers to monitor mill performance through their computer systems. Additionally, our technology enables real-time feedback from our German headquarters to the customer. This feedback highlights any inefficiencies, such as when a parameter is outside the optimal range,
and provides actionable recommendations to address them.
By continuously monitoring every parameter in real time, our AI-driven systems ensure that mills operate at peak efficiency. This not only enhances production but also minimises downtime. I am proud to say that our mills have the lowest shutdown rates compared to other manufacturers. This reliability, combined with the insights provided by our digital solutions, ensures that customers achieve consistent and efficient operations. It’s a game-changer for reducing costs and enhancing overall productivity.

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