Technology

High-efficiency SNCR Injection Systems

Published

10 years ago

February 28, 2015

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Dr Ullrich Speer elaborates on the Selective Non-Catalytic Reduction (SNCR) technology as a fundamental technique to reduce NOx emissions.
To comply with current and future emissions requirements, it is important that equipment suppliers remain ?in-the-know,? so that they can offer the most appropriate solutions. The new emission norms are already announced with due date as June 1, 2015 for new plants and January 1, 2016 for the plants currently in operation to comply with NO2 emissions in India.

NOx reduction and ammonia slip
When fuel is burned pollutants are emitted in the flue gas. One of the main pollutants is NOx. Once emitted, NOx reacts with other atmospheric components to produce ozone (O3). Other products generated during combustion, such as nitric acid (HNO3), react in the atmosphere and fall as acid rain, which negatively affects people, plants and animals.

SNCR technology currently involves the injection of ammonia (NH3) or urea (CH4N2O) solutions. The reaction of ammonia or urea with gaseous nitrous oxide (NOx) is transformed by thermal decomposition into steam (H2O) and nitrogen (N2).

When ammonia is used, a solution is injected directly into the duct in several positions/levels, at approximately 900-1,000?C. The ammonia reacts with nitrogen monoxide (NO) to produce nitrogen (N2) and steam:
4NO + 4NH3 + O2 ? 4N2 + 6H2O
Adding urea solution is simpler and safer and you don?t need explosion protection. In the SNCR application, urea reacts like ammonia but with carbon dioxide (CO2) as a byproduct:

NH2CONH2 + H2O ? 2NH3 + CO2
During the injection of ammonia or urea, ammonia slip will appear in the exhaust gas. The amount can be reduced via process adjustments, but it cannot be eliminated. At high temperatures, ammonia creates NH2 radicals. These are a result of the reaction between ammonia with hydroxyl radicals and oxygen radicals, which are usually created in hot gas streams by other reactions. The ?NH2 radicals reduce nitrogen monoxide to dinitrogen:

NH2 + NO ? N2 + H2O
In the overall reaction, the radical formation reactions appear twice and the reduction reaction four times. This results in the following overall equation:

4NO + 4NH3 + O2 ? 4N2 + 6H2O
When urea is used, it forms ?NH2 and the resulting carbon monoxide (CO) is oxidised by oxygen.
The reduction of NOx by ammonia or urea is based on many partial reactions, the balance of which is determined by the temperature and concentration of the reagents. Therefore, with a theoretical over-stoichiometric injection relationship between ammonia and NOx, the NO cannot be completely removed. Additionally, some of the reducing agent is regenerated as NH3 from the reaction.

For a maximum reduction rate of NO leading to low ammonia and NOx emissions, a temperature window must be complied with (Figure 1). In addition, nozzles are often installed at several levels throughout the whole duct. Based on temperature measurements and calculations, those nozzles closest to the injection point with the optimum reaction temperature will be activated.

Sophisticated single-nozzle control systems that offer independent injection-level sprays already exist. If they could be combined with a local and timely highly-resolving temperature calculation (like an online computational fluid dynamics – CFD), the best NOx removal results could be achieved. Furthermore, minimum ammonia slip will be achieved.

Challenges to be managed by the plant
There must be a clear strategy to meet changing NOx and ammonia emission limits, with different requirements for different plants. Some plants can proceed step-by-step with multiple small investments, but others find it better to invest in a full package.

How are such decisions made?
a)Emission limits are different in different jurisdictions. Could production costs be optimised even with tighter values?
b)Plants must determine (and understand) the complexity of the influencing variables of NO production and NOx reduction such as: flue gas temperature in the injection area; flue gas speed in the injection area; flue gas speed in other parts of the system; fuel properties; raw NOx load from the sintering zone and possibly from the calciner.
c)The process choice will influence current and future investments. There are many options at different prices with varying future adaptability. Some of Lechler?s solutions will be discussed later.
Unfortunately, the parameters listed under Point b must be controlled as well as known. Each of the influencing factors must be controlled separately and considered in the final calculation that will decide on the type of control system. Within the plant there are three different influencing groups:

Unknown variables: These include the raw NOx value, temperature, gas speed and gas composition in the injection area and must be measured to be known.

Difficulty factors: These include temperature fluctuations in the injection area, high dust loads within the system, up to five minute delays between the measurement point(s) and stack, the riser duct refractory, the gas flow and speed, fouling at the tip of the nozzles and the residence time of the gas.

Permanent process changes: Most European cement plants (many elsewhere) use alternative fuels and each of these changes the gas composition. Ongoing modifications to the kiln line, or even existing changes within the process while the kiln is running, will also permanently affect the process.

One factor that will affect NOx production is build-up in the calciner. This is because the whole process of the production line is based on theoretical calculations of an optimized new plant. With increasing build-ups in the tower, the internal diameter of the tower reduces. Assuming the same volume of gas, but travelling through a smaller diameter, we will see a higher gas velocity. A specific residence time at the optimum temperature is required to achieve the best possible NOx reduction. However, increased velocity will shorten the residence time, resulting in an incomplete reaction and higher NOx levels. To prevent this, it is necessary to have online control of the build-ups and to be able to predict the next occurrence ahead of time.

3D-temperature simulation and online CFD
Steag Powitec GmbH (Powitec) from Essen, Germany, has developed a high-efficiency SNCR (heSNCR) software system for NOx reduction in cement plants in cooperation with Lechler GmbH, due to the fact that primary measures like staged combustion will not be able to meet the 200 mg/Nm3 NOx limit. It is available as a stand-alone solution or as an upgrade to an existing SNCR plant.

The heSNCR technology enables low NOx emissions while maintaining tight limits for the ammonia slip and reduced reagent consumption. Upgrading to the heSNCR from standard SNCR is attractive because this approach almost always makes investment in an SCR system obsolete. The total costs of the heSNCR system are also lower than those of SCR technology. The system can also be supported by the advanced sintering process control system to reduce primary NOx. The system software comprises:

Online CFD for continuous generation of a highly-resolved time and spatial model of the flue gas in the rising duct between kiln and pre-heater (or calciner);
Estimation of the build-up thickness in relevant duct walls that dominate airstream issues;
Online calculation of the ideal spray amount (considering current and future levels of NOx, O2, temperature, deposition rate and slip)
Permanent adaptation of control to process changes.

An additional special characteristic of the process is that the NOx reduction efficiency and slip depend strongly on temperature and O2 distribution. To achieve the targets, the temperature window must be determined for spraying the right amount of reducing agent at the right time to the right area. However, this poses another challenge as the optimal temperature window permanently changes, influenced by:

current cement production volumes; Local fuel loads, fuel types and qualities; build-ups; local gas flow and velocity. To meet these challenges, SteagPowitec follows the sense, analyse, predict, control (SAPC) approach:

Sense: Additional temperature sensors are used to gain detailed knowledge of the conditions in the area where reagent is injected. Sensors are installed in the refractory material of influential ducts, in positions where build-ups tend to occur. At each position, two temperature sensors are used to improve the understanding of the current build-up of the deposits at this specific point. Because the sensors are of different lengths, they can measure a specific temperature difference. In the case of build-ups or a reduction of refractory wall thickness due to wear, the changes in temperature difference give information about gas flow velocity.

Analyse: The current build-up deposit situation in the rising duct is estimated using the data from the temperature sensors together with the process control system data.

Data is continuously analysed and noise removed.
Predict: The temperature distribution in the rising duct is calculated by dividing the duct into many small segments. For each segment, the physical parameters of the flue gas (mass, density, velocity and temperature) are modelled. Mutual interactions are described by mathematical equations as used in CFD analysis.

The calculated values are calibrated online with the values from the process control system. The temperature distribution is continuously calculated online with update rates of 10-30s. The permanent online CFD allows the calculation (prediction) of the load and fuel-dependent change of temperature. This enables efficient and intelligent system control.

Control: As clinker production is a non-linear process with significant reaction times and Constantly changing correlations, controlling a heSNCR system is a complex task. Different operating conditions generate different emission loads and different temperatures.

The PiT Navigator SNCR technology, part of the heSNCR system, continuously uses conventional process data, the additional temperature sensor data and the results of the online CFD calculations to find and evolve process models automatically over time. The technique is a system of neural networks, which are used to estimate important process results. Thus, the PiT Navigator automatically evaluates the presently valid model to determine the effect of certain activities. For example, it simulates slight modifications to the amount of reagent injected through the nozzles to determine the effect on NOx reduction and the ammonia slip at the stack. The best result derived from these simulations is used for the control of the lances in the actual plant.

Unlike standard control systems, the PiT Navigator SNCR system is self-calibrating and auto-optimising closed-loop control software. Consequentially, extensive and permanent manual reconfigurations are not necessary. Additionally, statistical models do not rely on subjective expert knowledge; they learn from existing process data automatically and select the best control strategy. The system is also fault-tolerant: If a single measurement fails, it will rely on others.

The heSNCR technology is equipped with a self-learning adaptive process controller that adjusts itself automatically to process changes and thus injects the optimal quantity of reagent, at the right time, in the right area. This has the effect of continuously achieving significantly lower NOx levels with the lowest possible reducing agent consumption at the lowest possible slip. In places where NOx limits are not yet low, the system still offers significantly lower reagent consumption rates and protects against further investment costs when NOx limits are lowered.

SNCR solutions
Lechler GmbH and Powitec provide a variety of NOx reduction systems. The differences between each system and the anticipated NOx and ammonia reagent reductions are outlined.

SmartNOx
?: The Lechler SmartNOx system is a standard valve skid for de-NOx using ammonia. Customisation options are limited and the lances (Figure 2) are not individually controllable. The system was designed for those that want to gain experience with de-NOx and is also useful for meeting more relaxed NOx emission limits.

Basic level SCNR: Basic SNCR is recommended for customers seeking long-term equipment that are willing to upgrade later on. It includes a twin fluid valve skid with a conventional control system and four Laval nozzles and lances on one injection level. It is possible to individually adjust the volume and droplet size delivered by each lance. Typical reductions in NOx emission levels are from 700 mg/Nm? to 500 mg/Nm?.

Efficient SNCR (eSNCR): This includes two additional lances with Laval nozzles, giving six lances on two levels, as well as a second small control rack. Beside the existing control system, the eSNCR system offers a special NOx prediction. The system can reduce NOx emissions from 1,000 mg/Nm? to 500 mg/Nm?, using 15 per cent less ammonia than the basic SNCR.

High-efficiency SNCR (heSNCR): The heSNCR consists of the eSNCR system, the build-up detection and the online CFD. Two additional Lechler twin fluid Laval nozzles are included and the injection takes place on three levels in the calciner. All outstanding and currently available technologies are included, like the NOx prediction, the PiT deposit detectors and the PiT online CFD tool. A reduction from 1,000 mg/Nm? to 200 mg/Nm? NOx is typically achieved, as well as a saving of approximately 30 per cent of ammonia reagent.

The author is Global Division Leader (Environmental Division) at Lechler GmbH.

Concrete

Optimising plant performance

Published

5 days ago

June 17, 2025

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As India’s cement industry heads for unprecedented growth, the importance of smart, sustainable and strategic lubrication is gaining ground. From reducing downtime and enhancing energy efficiency to enabling predictive maintenance, lubricants are transforming plant performance. ICR explores how advanced lubrication solutions are becoming critical enablers of reliability, resilience and environmental stewardship in the cement sector.

The Indian cement industry, a cornerstone of the nation’s infrastructure development, is experiencing significant growth. In 2023, India’s cement production reached 374.55 million tonnes, marking a 6.83 per cent year-on-year growth. Projections indicate that the market size will expand from 3.96 billion tonnes in 2023 to 5.99 billion tonnes by 2032, reflecting a compound annual growth rate (CAGR) of 4.7 per cent during 2024-32. This expansion underscores the increasing demand for efficient and sustainable operations within the sector.
In cement manufacturing, equipment such as kilns, crushers, vertical mills, ball mills, conveyors and fans operate under extreme temperatures, heavy loads and high dust exposure. These demanding conditions make proper lubrication not just essential, but mission-critical. Selecting the right type of lubricant and maintaining an effective lubrication regime can drastically improve machine uptime, reduce maintenance costs, and enhance plant safety. In many cases, lubricant-related failures account for a significant proportion of unplanned downtime, underscoring the value of a well-structured lubrication strategy.
The Indian cement sector is also undergoing a technological transformation, with increasing emphasis on automation, predictive maintenance and energy efficiency. In this evolving landscape, lubricants are no longer just consumables—they are enablers of performance, longevity and sustainability. With the growing availability of advanced lubricants and condition-monitoring technologies, Indian cement plants have the opportunity to optimise their lubrication practices in line with global standards. Additionally, tightening environmental regulations and sustainability goals are driving the shift toward eco-friendly lubricants and responsible usage practices, making lubrication management a key factor in both operational and environmental performance.
As the industry moves forward, there is a growing realisation that lubrication excellence can be a competitive differentiator. This article explores the critical role of lubricants in cement manufacturing, the latest technological advancements, the environmental considerations shaping lubricant use, and the challenges and opportunities for cement producers in India aiming to maximise equipment reliability and operational efficiency.

The role of lubricants in cement manufacturing
Cement manufacturing involves heavy-duty machinery operating under extreme conditions—high temperatures, heavy loads and continuous operations. Lubricants are essential in minimising friction, reducing wear and tear, and preventing equipment failures. Proper lubrication ensures that components such as kilns, crushers and grinding mills function optimally, thereby reducing downtime and maintenance costs.
Moreover, the integration of advanced lubrication technologies has enabled predictive maintenance strategies. By monitoring lubricant conditions, operators can anticipate equipment issues before they escalate, allowing for timely interventions and uninterrupted production cycles.
“Lubricants play a crucial role in enhancing the efficiency and reliability of cement plant operations. High-performance lubricants reduce friction and wear in critical machinery such as crushers, kilns, mills, and conveyors, ensuring smoother operation and extending equipment life. By minimising mechanical breakdowns and unplanned downtime, they contribute to consistent production and lower maintenance costs. Additionally, specialised lubricants designed to withstand high temperatures, heavy loads, and dusty environments help maintain optimal performance under demanding conditions. Proper lubrication also improves energy efficiency by reducing power loss due to friction. In essence, the right lubrication strategy not only enhances equipment reliability and operational uptime but also supports overall cost-effectiveness and productivity in cement manufacturing,” says Hiten Ved, Sales Head, Royal Petro Specialities.
In addition to enhancing equipment longevity, lubricants are pivotal in ensuring uninterrupted production cycles. Cement manufacturing is a 24/7 operation, and any unexpected downtime due to mechanical failure can lead to significant financial losses. Lubricants with high thermal stability and oxidation resistance prevent the breakdown of oil films under intense heat, especially in applications like rotary kilns, vertical roller mills and clinker coolers. By reducing the likelihood of equipment seizures or breakdowns, these lubricants act as silent enablers of plant reliability and uptime.
Gaurav Mathur, Director and Chief Executive Officer, Global Technical Services, says, “Wall paintings in tombs show workers using water to move statues, indicating early recognition of lubrication. By 1400 BC, animal fat was used to lubricate chariot axles, ever since then mankind has been relentlessly working to improvise the efficiency of lubricants. Tribological advancements have propelled industrialisation in the world. Machines working in demanding environment need better performance, however merely just better lubricant that is made from highly refined base oils is not good enough. Mineral and synthetic base oils and advanced additives chemistry have given birth to advanced lubricants. These lubricants have better performance characteristics and longer service life.”
“However, the way lubrication is done is more critical and if lubrication is not performed in a proper way, highest performing lubricants would also under perform compared to the lowest specification product. Total Lubrication Management has to be implemented for better machine reliability, equipment availability and lower down time. Implementation of TLM has paid rich dividends in the industry. Pillars of TLM being, contamination free lubrication, regular testing of lubricants to access the lubricant and machine condition and regeneration of lubricants,” he adds.
Lubricants contribute directly to energy efficiency. Friction losses within rotating equipment can account for up to 30 per cent of the total energy consumption in certain plant areas. Advanced synthetic lubricants, with low traction coefficients and superior film strength, reduce this internal resistance, thus improving mechanical efficiency and lowering the plant’s overall energy footprint. As Indian cement plants pursue energy benchmarking and ISO 50001 certifications, the use of high-performance lubricants becomes an integral strategy in achieving energy conservation goals.
“The cement industry has many lubrication points that require NLGI Grade 2 grease that can be used in high temperature applications. These may include bearings on vibrating screens and roller mills; rotating joints on grinding units; and various shafts, pivots, and metal to metal contact points found throughout the plant. CorrLube™ VpCI® Lithium EP Grease has a dropping point of 360 °F (182 °C), allowing it to be used in a broad range of temperatures. For areas that need a slightly harder grease of NLGI Grade 3, EcoLine® Biobased Grease offers a
similar dropping point of 365 °F (185 °C), explain Julie Holmquist, Marketing Content Writer,
Cortec Corporation.

Market dynamics: growth and trends
The Indian industrial lubricants market was valued at $13.05 billion in 2024 and is projected to reach $ 20.72 billion by 2033, growing at a CAGR of 4.12 per cent. This growth is driven by the expanding industrial sector, increased mechanisation, and the adoption of advanced machinery requiring specialised lubricants.
In the cement sector specifically, the demand for high-performance lubricants is rising. The lubricants for cement market are estimated to be $ 2.5 billion in 2024 and is expected to reach $ 3.9 billion by 2033, at a CAGR of 5.3 per cent from 2026 to 2033. This surge is attributed to the need for lubricants that can withstand harsh operating conditions and enhance equipment reliability.

Advancements in lubrication technology
Recent years have witnessed significant advancements in lubrication technology tailored for the cement industry. Synthetic lubricants, known for their superior thermal stability and longer service life, are increasingly being adopted. These lubricants perform effectively under extreme temperatures and heavy loads, common in cement manufacturing processes.
Additionally, the development of bio-based lubricants offers environmentally friendly alternatives without compromising performance. These lubricants, derived from renewable sources, reduce the environmental footprint and align with global sustainability goals. Their biodegradability and low toxicity make them suitable for applications where environmental considerations are paramount.
Smart lubrication systems are another breakthrough in the cement industry. These systems use IoT-enabled sensors and controllers to monitor lubricant condition in real time—tracking parameters such as viscosity, temperature, contamination levels and usage. This data is integrated into plant maintenance software to automate lubricant replenishment and alert operators to potential failures. Predictive lubrication ensures that each component receives the right amount of lubricant at the right time, minimising waste, reducing manual intervention, and extending machinery life.
“Many VpCI® products can be applied to surfaces with minimal pre-cleaning, and the protective VpCI® layer typically does not need to be removed before equipment is put back into service. VpCI® ‘s save significant labor, time, and associated costs compared to methods that require extensive surface preparation (e.g., sandblasting) and post-application cleaning or degreasing. This allows for faster startup after maintenance,” elaborates Ana Juraga, Content Writer, Cortec Corporation.
Furthermore, Original Equipment Manufacturers (OEMs) and lubricant suppliers are collaborating to develop application-specific lubricants tailored to the unique operating conditions of cement manufacturing units. For example, gear oils designed for high-load kilns or open gear systems now come with superior Extreme Pressure (EP) additives and anti-wear properties to cope with shock loading and variable speed operations. These co-developed solutions not only enhance mechanical reliability but also ensure compatibility with diverse materials used in modern cement equipment, ensuring peak performance in both greenfield and brownfield plants.

Sustainability and environmental considerations
The cement industry is under increasing pressure to reduce its environmental impact. Lubricants contribute to this goal by enhancing energy efficiency and reducing emissions. High-quality lubricants decrease friction, leading to lower energy consumption and, consequently, reduced greenhouse gas emissions.
Furthermore, the use of long-life lubricants minimises the frequency of oil changes, thereby reducing waste generation and disposal issues. The shift towards bio-based and recyclable lubricants also supports circular economy principles, promoting resource efficiency and environmental stewardship.
A report by Klüber Lubrication India suggests that sustainability continues to be a key focus for industries, the Securities and Exchange Board of India (SEBI) has mandated Business Responsibility and Sustainability Reporting (BRSR) for the top 1,000 listed companies. This framework requires organisations to disclose their environmental, social and governance (ESG) initiatives, including energy conservation, emission reductions and resource optimisation. Beyond compliance, BRSR reporting allows companies to showcase their sustainability leadership and build investor confidence. Organisations that proactively address sustainability challenges are better positioned to attract long-term investors, secure financing, and maintain a competitive advantage in an evolving regulatory landscape.
The report also states that their high-performance synthetic lubricants play a crucial role in helping cement manufacturers meet these regulatory requirements by enhancing energy efficiency and reducing CO2 emissions in critical machinery such as vertical roller mills (VRMs) and main gearboxes. By adopting our energy-efficient solutions, companies can strengthen their BRSR compliance while achieving tangible operational benefits.
An emerging trend in the lubricant industry is the formulation of biodegradable lubricants specifically tailored for heavy industries like cement manufacturing. These eco-friendly alternatives are made from renewable base stocks and are designed to degrade naturally without leaving behind harmful residues. In environmentally sensitive zones or operations with high spill risk, such as open gear applications or hydraulic systems exposed to the elements, biodegradable lubricants offer a sustainable solution that aligns with stricter environmental regulations and the growing emphasis on corporate social responsibility (CSR) in India’s industrial sector.
KB Mathur, Founder and Director, Global Technical Services, says, “In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.”
Lubricant manufacturers are increasingly focusing on circular economy principles, offering oil analysis, filtration and recycling services that extend lubricant life and minimise waste. Used oil regeneration programs not only reduce disposal costs but also help cement plants meet regulatory norms under the Hazardous Waste Management Rules of India. This closed-loop approach not only lowers the environmental burden but also enhances economic efficiency—making sustainability a dual benefit for operational and ecological performance. As cement companies work towards science-based targets and carbon neutrality, lubricant selection and management play a more strategic role in meeting these broader sustainability commitments.

Challenges and opportunities
Despite the benefits, the adoption of advanced lubricants in the Indian cement industry faces challenges. These include the higher initial costs of synthetic and bio-based lubricants and a lack of awareness about their long-term benefits. Additionally, the integration of lubrication management systems requires investment in training and infrastructure.
However, these challenges present opportunities for innovation and collaboration. Manufacturers
can work closely with lubricant suppliers to develop customised solutions that meet specific operational needs. Moreover, government incentives and regulatory frameworks promoting sustainable practices can accelerate the adoption of advanced lubrication technologies.
Another key challenge is the limited awareness and technical training available at the plant level regarding proper lubrication practices. Many maintenance teams still rely on outdated methods such as manual greasing or fixed-interval lubrication schedules, which often lead to over-lubrication, under-lubrication or lubricant contamination. This results in premature equipment wear and higher operating costs. There is a growing need for skill development programmes and collaboration with lubricant suppliers to train technicians on best practices, condition-based monitoring, and the use of smart lubrication systems.
“Oil in the machine is like blood in the human body. There is no rotating machine that works without lubricants (liquid, semi liquid or solid). Based on the machine component, type of lubricant is used to minimise the mechanical changes in the machine. Lubricant being the product that separates two or more materials under movement. With modern machines being more and more sophisticated and tolerances being finer than before, cleanliness of Lubricants is critical, would the source of contamination be internal wear or external contamination. These contaminations rupture and compromises lubricant film, contamination particles when come in-between the fine tolerances, become cause of catastrophic failure,” expounds Gaurav Mathur.
At the same time, the industry is witnessing an opportunity to leverage digitalisation in lubrication management. Advanced lubrication tracking tools, coupled with ERP and maintenance software, can now offer real-time visibility into lubricant consumption, scheduling and health diagnostics. Integration of AI-powered analytics helps predict equipment failure based on lubricant data, enabling a shift from reactive to predictive maintenance. For Indian cement manufacturers aiming to digitise plant operations as part of Industry 4.0, lubrication is an ideal entry point that delivers immediate ROI and long-term gains in efficiency, asset life and sustainability.

Conclusion
As the Indian cement industry continues its trajectory of growth, the role of high-performance lubricants in ensuring operational reliability, energy efficiency and cost savings cannot be overstated. From kilns and crushers to ball mills and gearboxes, modern lubrication solutions are critical in
reducing downtime and maximising equipment lifespan. With rising demand and increased production pressures, cement plants must adopt a proactive approach to lubrication management—viewing it not as a routine maintenance task, but as a strategic pillar of plant performance.
Recent advancements in lubricant technology, such as synthetic formulations, nano-additives, and smart dispensers, have opened new avenues for boosting equipment efficiency and longevity. Digital tools and IoT-based systems now allow plant operators to monitor lubricant condition in real time, enabling predictive maintenance and minimising the risk of failure. As cement manufacturers increasingly pursue digital transformation and automation under Industry 4.0 frameworks, lubrication systems must be seamlessly integrated into broader asset management strategies.
At the same time, sustainability imperatives are reshaping lubrication choices. There is growing emphasis on biodegradable lubricants, optimised lubricant consumption, and environmentally responsible disposal practices. Overcoming challenges such as limited awareness, inconsistent maintenance practices, and cost sensitivity will require collaboration between lubricant manufacturers, OEMs and cement producers. The opportunities, however, are substantial—by aligning lubrication strategies with efficiency, digitalisation and sustainability goals, the Indian cement industry can significantly enhance its competitiveness and resilience in the years ahead.

– Kanika Mathur

Concrete

We consistently push the boundaries of technology

Published

2 months ago

April 18, 2025

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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)

Concrete

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

Published

3 months ago

March 17, 2025

admin

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.