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Better Waste Management: Alternative Fuels & Raw Materials

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Daily 0.2 million tonnes of waste is generated in India. Waste collection efficiency ranges between 20 and 25 per cent out of municipal waste collected. Of this 94 per cent is dumped in land and 5 per cent composited. Waste will increase between at phenomenal rate. between 2005 and 2025. This can be recycled to generate new products, such as cement and not just a waste incineration.Alexander Koshi is a chemical engineer with 39 years experience in cement industry in India, Saudi Arabia, UAE, Oman, Bahrain, Bangaladesh and Kuwait. He is a major international conference speaker.Cement manufacturing is a large scale industrial process with high energy consumption and a potential for co-processing of high quantities of alternate fuel and raw material (AFR). AFR can be recycled to generate new products, such as cement. It is not just a waste incineration. The co-processing of AFR in the clinker manufacturing process is environmentally-friendly.Evaluation Of AFRCharacteristics:

  • Thermal substitution of coal with waste up to 40 per cent in 1 million tonne cement plant will reduce the CO2 emission by 100,000 tonne.
  • Saves fossil fuel considering India’s kiln capacity of about 300 million tonnes 5 per cent substitution will save 2.5 million tonnes of coal annually.
  • It is the most environment-friendly way to dispose hazardous waste as it recovers energy from waste and leaves no residue.
  • Saves money. There is no need to invest in incinerators and landfills to dispose the hazardous waste that India generates. India’s present cement kiln capacity is good enough for the next decade or more.

Advantages of the clinker manufacturing using waste fuelsFirst of all, a utilisation of secondary or waste derived fuels, so called WDF?s in the clinker manufacturing process is a real recycling. It is not just an incineration. Moreover, due to the strict alkalinity of the process practically all inorganic compounds, like heavy metal elements are immobilised in the clinkers minerals without negative influence on the quality of the product as those compounds are diluted below as significant values. In addition these elements are not re-mobilised during the hydration process of the cement and hence no pollution, for example of the ground water is possible, as this is a serious problem of landfills.As proven by intensive investigations, the organical compounds of WDF’s are completely ed down to a methane-like base molecule by an extreme high temperature profile of the thermal system of up to 1550 ?C. This methane-like compound is easy to ignite and to combust.Furthermore, due to the high gas velocities and the related short retention time in the thermal system the window of de novo synthesis of dioxins and furans is very short and no significant reformation of those hazardous compounds takes place. In waste incineration plants, tremendous technical provisions are necessary in order to cover this problem.Liquid Waste Firing Through Burner

  • Injection of the liquid waste should be done through the centre of the burner and coal as a primary fuel can be injected through the outer annulus. Higher velocity at the burner tip is required in case of multi fuel firing and hence necessity of an axial blower is envisaged in case the primary air quantum is low.
  • Two phase injection nozzle for hazardous liquid waste firing is recommended to achieve sufficient fineness of the droplets
  • Atomisation of the primary air is envisaged and hence any kind of compressor along with an air vessel is necessary to assure stable injection of the liquid waste. Air pressure of the compressor should be in the range of 6-8 bar for an atomisation viscosity of 25-40 cSt.
  • Opening size of the nozzle diameter is of prime importance for firing of liquid waste due to its solid content (possibility of the nozzle to get plugged). Hence, required opening would be determined after having the detailed analysis of the solid content in the hazardous liquid waste.
  • Precautions are to be taken to avoid any damage due to back pressure generating from the system during upset condition of the kiln, if any.

The Indian Waste Management ScenarioIndian population is 1.2 billion in roll and increasing. Daily 0.2 million tonnes of waste is generated around in 28 states and 7 union territories with total 38 million tonnes annually. Waste collection efficiency ranges from 20-25 per cent out of municipal waste collected 94 per cent is dumped in land and 5 per cent composited. Waste will increase between 2000 and 2025 at phenomenal rate. In 2009, about 67 million tonne of hazardous waste was generated.The waste collection will undergo the following changes.

  • Organic waste will go up from 40 to 60 per cent.
  • Plastic will rise from 4 to 6 per cent
  • Metal will escalate from 1 to 4 per cent
  • Glass will increase from 2 to 3 per cent
  • Paper will climb from 5 to 15 per cent
  • Others (ash, sand, grit) will decrease from 47 to 12 per cent

Action To Improve AFR

  • India emerging as developed country must consider use of AFR in cement industry to improve quality of life of its growing population.
  • The conditions in rotary kilns guarantee that the use of AFR is ecologically safe.
  • The hazardous waste, more than 1,80,000 tpa is available. This can be used in cement kiln to produce 38 x 105 GJ of heat energy. This will help to reduce CO2 emission and solve land filling problem. Use of AFR in cement plants is both ecologically and economically justified.
  • The barriers to AFR use in India are technological and economical barriers. But the critical issue who pays and globally it is found that the polluter pays. There is complete disconnect between the user and giver. The government has to setup laws and regulations followed by integrated solid waste management hierarchy (ISWM) with a strong legal frame work. Economical incentives have to be provided for RDF production and utilisation such as offering tax free and soft loan for machinery lower taxes for companies, those use RDF. The cement manufactures association with National Council of Building materials and central pollution control board (CPCB) with central and local governments must work in synergy to solve the problem.

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Economy & Market

Power Build’s Core Gear Series

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

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Economy & Market

Conveyor belts are a vital link in the supply chain

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Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

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Economy & Market

Impactful Branding

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Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.

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