Product Development
There is huge scope for utilising alternative fuels
Published
12 years agoon
By
admin
Madhavkrishna Singhania, Special Executive, JK CementThe Indian Cement Industry has witnessed a sea change in its outlook towards environmental consciousness over the last three decades. The industry has taken significant strides towards transforming itself from one of the most polluted industries to a ?Green? one. Madhavkrishna Singhania outlines the initiatives taken by the industry and the challenges on the way towards a sustainable manufacture.
What is the overall impact of the various environmental acts that are binding on the cement industry in India? Are these observed both in letter and spirit?
The various environmental acts are derived, based on international practices and in consultation with the cement industry representatives. These are followed in both letter and spirit.
What operational measures have you taken to improve sustainability of your plant?
We have a mix of old as well as new units. Some were installed 3 decades ago while some have been installed in the last 5 years. Our new plants installed in 2008 and 2013 are equipped with the latest technology. We have installed vertical roller mills and roller presses for raw mills and cement grinding and have very efficient pre-heater kilns with fuel consumption between 700-710 kcal/kg clinker. There has been constant upgradation at our old plants. We have undertaken many projects to increase the capacity of the older kilns, installed high efficiency motors and fans and reduced fuel and power consumption, which has led to improved efficiency. We have installed waste heat recovery power plants (WHRP) at our Nimbahera and Mangrol units. While WHRPs are a must even for new plants, they have made our old units more efficient. WHRP installation addresses the inefficiency in the old plant in terms of fuel consumption owing to old pre-heaters.
Have you done any modifications in the plant lately to reduce emissions?
We have installed bag houses for the kiln and raw mill circuit at our new unit at Mudhol, Karnataka and Mangrol, Rajasthan. The emission levels meet international standards. The flagship plant at Nimbahera has ESP and the controller of ESP has been upgraded to maintain high efficiency. We are continuously working towards reducing the emissions in our old plants.
What are your views on upgrading old cement plants?
In India, all cement plants using the wet process of manufacturing have shut down as these have become uneconomical to operate. The old dry process plants can be upgraded to modern technology of raw material grinding, pyro-process/calcination, keeping the same kiln if the layout and space permits and depending upon the condition of the existing infrastructure. The current trend of setting up a new facility is to build a plant of capacity not less than 1.5 million TPA with a waste heat recovery power plant of the latest technology to ensure power consumption of not more than 75 kwh/tonne of cement and fuel consumption under 700 kcal/kg clinker.
How much is the scope for using fly-ash in the cement manufactured at your plant?
At all our units, we are producing PPC (Portland Pozzolana Cement) with fly ash usage in the range of 26-27 per cent. At JK Cement we educate the consumer on the benefits of blended cement and encourage its consumption through consumer awareness programmes.
What is your view about the emerging technologies in raw material substitution?
Today, the cement industry uses wastes generated by power plants and steel plants as alternative raw materials. Fly ash generated by power plants and slag generated by steel plants is used to produce Portland Pozzolana Cement (PPC) and Portland Slag Cement (PSC) respectively, which are more durable and application friendly. As per CII?s Cement Vision 2025, the Indian cement industry will have a capacity of 600 MTPA of cement and has the potential to consume almost 200 million tonnes of fly ash and 10 million tonnes of slag generated annually by 2025. However, the government needs to put in place, a structured policy on the principles of ?polluter pays.? Cement plants have also undertaken initiatives to use various types of wastes as alternative fuels. Pet coke, which is a by-product of the petroleum industry, is already being used by the cement industry as a fuel to the extent of 70 per cent to 80 per cent. Further, use of pet coke in white cement production has helped in saving huge quantities of fuel oil.
Substantial volumes of fossil fuels can be saved and associated CO2 emissions mitigated, by co-processing several wastes as Alternative Fuel Resources (AFRs). Based on the generation/availability of these wastes as per the table given below, the cement industry consumes a significant quantum, hence solving the problem of disposal and making the environment safer.
Several cement plants in India are using alternative fuels. In India, Thermal Substitution Rate (TSR) is within 2 per cent on an average whereas in countries like The Netherlands, Switzerland, Germany, France, etc., the TSR is above 30 per cent. Thus, there is huge scope for utilising alternative fuels and the same may be achieved if the availability is ensured through a more sincere collective effort. Industry for Industrial Productivity (IIP) has initiated a project aimed at developing an action plan to mainstream AFRs and facilitate its implementation, thereby helping the industry realise higher TSR levels with accompanying societal benefits.
How can IT be harnessed to reduce emissions and or improve sustainability?
Better control and instrumentation systems over the years have ensured improved productivity of equipments resulting in optimised power and fuel consumption. Stack emissions are monitored in the central control room to ensure adherence to standards and corrective action. IT has become a lifeline in the modern age, without which information sharing and communication is difficult. It has helped improve inventory management reducing inventory levels. We are also working on vehicle management within the plant, which should optimise vehicle movement and waiting time. Sharing of ideas and information is key and IT makes this possible.
What is the ratio of alternative fuel to conventional fuel used at your plant?
At present we are using 70-80 per cent pet coke and 1-2 per cent alternative fuels.
What are the challenges in switching to alternative fuels?
The basic challenge in switching over to alternative fuel is lack of continuous availability. Depending on homogeneity, it may pose problems in smooth running of the plant and hence there must be some cost advantage in using alternative fuels over the use of coal/pet coke.
WHRP installation addresses the inefficiency in the old plant in terms of fuel consumption owing to old pre-heaters.
At JK Cement we educate the consumer on the benefits of blended cement and encourage its consumption.
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Economy & Market
Conveyor belts are a vital link in the supply chain
Published
9 months agoon
June 16, 2025By
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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?
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What trends do you foresee shaping the future of the conveyor belt industry?
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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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