Economy & Market

Optimising plant utilisation

Published

10 years ago

July 31, 2015

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Developments in pyro processing optimisation and technologies have made it possible to improve existing plants with high energy efficiencies and low emissions, while simultaneously reducing operating costs and preserving the environment and optimal use of fast depleting natural resources.

Kiln is said to be the heart of a cement plant, comparing the cement plant with that of human body. It is a continuous operation and the performance of a plant is judged by the number of days; the kiln runs without any stoppages. In the present economic scenario on an average, the plant utilisation is close to 70 per cent. For the operational function, it is much more challenging because if the production level further goes down for want of demand, then within no time, the plant operation runs into red. Therefore, it is extremely important to decide the equipment capacities precisely since it is a part of design. There is a tendency to go for higher capacity plants for the simple commercial considerations, but in the present situation, such plants in no time will turn into stressed asset if they are running below the bench mark level. Every unit knows its benchmark level to run it into profits. This is exactly the situation in few of the cement plants in the country as they were set up when there was a boom time for cement business which did last for few years but no further.

New approach
A few cement producers in the industry have been smart to decide on the capacities of the plant. Generally at design stage, while deciding on preheater it is preferred to have a single string of operation as a starting phase. Then after stabilisation and proper understanding of the market conditions, it is better to add another string. But then the kiln in the first phase must have been designed with sufficient margins. This has been the case with a few of plants in our country. The plant capacities have been enhanced over a period of time. Our design engineers along with FLSmidth, ThyssenKrupp, KHD Humboldt etc, have done wonderful jobs to add to the capacities of the plant in the country without diluting the performance of the kiln on any count like gaseous pollution or compromising on operational part. However, we strongly feel this has created tremendous load on the coolers and to some extent compromised its performance. The cooler as a hardware has limitations to enhance its capacity or either have modifications in the given space. In many cases, it has been noticed that it is the cooler which throttles the production and not the kiln or grinding.

Use of alternate fuels
Regarding the technology front, there is not much to say on the pyro process per se specifically that has happened in the last decade except more and more players in our country have been experimenting on alternate fuels or industrial waste which is encouraging. With more support coming from the government departments like Central Pollution Control Board (CPCB) and State Pollution Control Boards, the number of usage is only going to grow. There are some changes required in the kiln burner design before the fuels are changed or replaced. Plant would prefer to have a common burner for conventional fuel like coal and for alternate fuels like industrial waste and petcoke. The plants need to address the issue of safety while using hazardous waste since our experience in doing jobs in a safe manner is far below expectations.

Waste Heat Recovery (WHR) can reduce the operating costs and improve EBITDA margins of cement factories by about 10-15 per cent. On average, electric power expenses account for up to 25 per cent of total operating costs of a cement factory. However, to realise the full potential of WHR as of now $1,400 million is required, which is too high.

The other major advantage for Indian cement industry is minuscule presence of volatile matters like sulphur, chlorine, potassium etc. Therefor a majority of plants in India do not have bypass system as a part of design whereas the plants in Gulf countries have this as an additional system. In future as more and more plants will go for alternate fuels in the country they may have to go for by pass system as additional feature.

Focus emission
In pyro processing, the area of focus has been, reduction of NOX and SO2 emissions, and increase of production throughput without compromising on energy consumption but with flexible options on fuel.

Safety in pyro processing is extremely important since coal is used as a fuel. Generally, it is pulvisised at the plant and then fed into the kiln through burner. The conditions in the coal mill area are extremely hazardous and need more attention to reduce the number of unsafe incidences. Inertisation of coal mill is yet to be executed in many plants. There is a lot of scope for improvement here in the industry. Considering the capabilities exhibited till date, we feel Indian cement industry will fulfill this aspiration as well.

Conclusion
According to Kumar, developments in pyro processing optimisation and technologies have made it possible to improve existing plants with high energy efficiencies and low emissions, while simultaneously reducing operating costs and preserving the environment and optimal use of fast depleting natural resources. Process optimisation and performance improvement has become inevitable in cement industry. "Although every situation must be analysed carefully to evaluate real gains that can be achieved, most cement plants can achieve improved performance by implementing suitable modifications," he concludes.

TECHNOLOGY TRENDS IN PYRO PROCESSING

Kilns

Redefinition of operating parameters – volumetric loadings up to 7.5 tpd/cu m
Thermal loadings up to 5.5 Gcal/ sq m/kg clinker
Filling % of 14-16 and kiln speeds up to 5.5 rpm
2-pier installations with a drop in L/D ratios to 10-11
Low primary air, low NOx multi-channel burners

Pre-calciners

Degree of calcination up to 95 per cent
Calciner to kiln fuel ratio of 70:30
Increased residence time up to 5.5 sec to improve combustion efficiency specially in case of petcoke
Low NOx systems Pre-heater
6-stage, twin string preheaters with clinkering capacities up to 10,000 tpd
Increased cyclone efficiency up to 96 per cent
Reduction in L/D ratio in cyclones resulting in a pressure drop reduction from 700 to 400 mm WG and a tower height reduction of 10-15 m
Reduction in the total sp. air requirement from 1.6 to 1.45 Nm3/kg clinker Improvement in fan efficiencies.

Coolers

New generation (eg, walking-floor) coolers resulting in increased cooler recuperating efficiency from 68-76 per cent resulting in increase of secondary/tertiary air temperature to 1,000oC
Drop in air requirement from 2.2 to 1.6 Nm3/ kg clinker
Increase in cooler loading up to 50 t/d/sq m

Bypass system
Raw materials and fuels used for the manufacture of clinker generally contain some volatile constituents. These are mainly the compounds of potassium, sodium, sulphur and chlorine. Volatiles may also originate from water, refractory and wearing parts of equipment. These volatile constituents generally have low melting points. Hence, condensation of the volatile matters takes place on raw meal particles and the surrounding walls in the colder zones of the kiln. This causes build-ups on the cyclone walls and riser ducts that lead to blockages in the passage areas in the cyclones. The bypass system allows a high proportion of volatiles to be removed through the kiln gas stream and improves the performance and product quality.

Fuel solutions
Alternative fuels such as lignite, petcoke, tyres, bagasse, rice husk, industrial wastes etc, are being in use for sometime now. Several plants are using/ investigating hospital refuse and municipal waste as workable alternatives. The current reported thermal substitution rates (TSR) in the Indian cement industry is about one per cent. However, TSR levels as high as 60 per cent have been achieved in some of the developed nations. Action plans are needed to overcome technical, financial and regulatory barriers to the growth of alternate fuel (AF) usage. Technical solutions are in place for storage, handling and dosing the AF to the system.

– Kamal Kumar, Chief General Manager, Holtec

Diagnosis
Based on process measurements conducted following observations were made:

The PH system is operating with about 28% leakage air. This is resulting in higher PH fan power consumption.
The cooler vent gas volume of 1.63 Nm3/kg clinker and temperature of 369oC.
High clinker temperature of 165oC value against the normal value of around 100oC.
The heat balance of the pyro processing system indicated that the total heat consumption works out to 888 kcal/kg clinker.

Implementations
Following suggestions were implemented:
Area	2,000 t/d
Kiln size	3.95 m dia x 56 m L
Preheater (PH)	Single string 5-stage suspension preheater with in line calciner (ILC)
Kiln burner	Duoflex
Fuel used	Furnace oil
Preheater fan	7,000 m³/min at 900 mm WG, 320^oC
Cooler vent fan	5,133 m³/min at 190 mm WG, 300^oC
Clinker cooler	Reciprocating grate cooler
Cooler effective area	52.8 m²
No. of grates	2
Specific heat consumption
(A mass and heat balance conducted jointly)	854 kcal/kg clinker

Implementations
Following suggestions were implemented:
Area	Recommendations	Result
Fuel firing	Conversion of oil firing to coal firing in kiln and PC	Reduction in operation cost
Preheater	Reducing preheater exhaust gas quantity to 1.60 Nm³/kg clinker by arrest false air leakage, reduce the PH outlet draft	Reduction in heat consumption
	PC primary air fan volume reduced, smaller capacity fan motor installed	Reduction in power consumption
	Coal transport air quantity to PC was reduced in phases	Reduction in heat consumption
	Maintaining PC outlet temperature as 840^oC.A PID loop was provided for the PC firing.	Reduction in heat consumption
Kiln	Increase the kiln speed from 3.0 to 3.3 rpm	Increased kiln output
	Coal transport air to quantity to kiln was reduced in phases	Reduction in heat consumption
	Position of the inner burner pipe was retracted by 30 mm and pressure at burner pipe was increased by 10 per cent	Sharp and intense flame resulting in saving in heat consumption
Clinker cooler	To reduce the cooler vent air temperature	Reduction in heat consumption.
	Optimisation of cooler operation, commissioning of water spray system.	Reduction in clinker temperature
	First grate of the cooler is to be modified with the new generation static grate plates/grate systems.	Improved heat recuperation to handle increased clinker production
		Stable cooler operation

Economy & Market

Fornnax launches world’s biggest secondary/fine shredder for AFR pre-processing

Published

1 week ago

November 7, 2025

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Fornnax has introduced its latest breakthrough – the R-MAX3300, for handling low-density waste streams, offering a powerful solution for cement AFR plants.

Fornnax Technology has launched its latest breakthrough – the R-MAX3300, the biggest secondary shredder in its class. The unveiling took place on 14th October, 2025 at IFAT India 2025 in Mumbai, one of the most prestigious events for environmental technologies, waste management, and sustainable resource innovation.

The launch ceremony was graced by esteemed industry leaders and dignitaries. The guest list included Md Fahim Sopariwala, CEO, GEPIL India; Sridhar Jagannathan, Vice President, Zigma Global; Priyesh Bhatti, CEO, GEPIL India; Shailendra Singh, Deputy General Manager, Prism Johnson (Cement Division); Ulhas Parlikar, Global Consultant, Waste Management, Circular Economy, Policy Advocacy and Co-processing; Saurabh Palsania, Joint President (Strategic Sourcing), Shree Cement; Rajeev Patel, DGM (Process), Mangalam Cement; and Anumodan Kumar Dubey, Mangalam Cement.

This state-of-the-art equipment represents a significant advancement for India’s recycling and waste processing landscape, offering a powerful solution for cement AFR plants and waste-to-energy facilities.

Building on the proven performance and legacy of the R Series secondary shredder, which has long been trusted for high-density materials like tyres and cables, the newly introduced R-MAX3300 is specifically engineered for handling low-density waste streams. These include Municipal Solid Waste (MSW), Commercial and Industrial (C&I) waste, Bulky waste, Legacy waste, Wood waste, and Construction & Demolition (C&D) waste.

By incorporating advanced shredding technology, the R-MAX3300 enables seamless and highly efficient production of Refuse Derived Fuel (RDF) and Solid Recovered Fuel (SRF) within the ideal particle size range of 30 to 50 mm. Its design prioritises versatility, durability and superior performance, directly supporting industrial operations that demand consistency and scale.

“The R-MAX3300 represents a monumental leap forward in our vision to become a global leader by 2030 in recycling technology through innovation,” said Jignesh Kundaria, Director and CEO, Fornnax Technology. “With the rising challenges of waste management in India and globally, this machine is not just a product; it’s a powerful tool for change. We engineered it to handle the most difficult waste streams with unparalleled efficiency, turning what was once considered unusable waste into a valuable resource. It directly addresses the urgent demand for effective, large-scale shredding technology that can support cement kilns and waste-to-energy facilities in achieving the desired output,” he added.

The launch of the R-MAX3300 arrives at a pivotal moment. India currently generates over 160,000 tons of municipal solid waste daily, while government-led initiatives such as Swachh Bharat Mission and Smart Cities are accelerating the demand for RDF and waste-to-energy solutions. Simultaneously, the global industrial shredder market is expected to grow at a 5–6 per cent CAGR, driven by stricter recycling regulations and increasing waste generation.

Kundaria further emphasised, “Our commitment goes beyond just selling machinery; it’s about empowering our customers to achieve lasting efficiency, sustainability, and growth. We see ourselves as a trusted partner who stands beside them at every step – from technology deployment to ongoing support, ensuring they can rely on Fornnax not only for performance but also for consistency, dependability, and long-term value.”

The R-MAX3300 is equipped to handle high-throughput processing of pre-shredded or coarse materials, making it ideal for SRF/RDF production, composting pre-treatment, and volume reduction for logistics optimisation. It is expected to play a crucial role in Integrated Waste Management Projects (IWMP) and bio-mining operations both within India and globally.

With this grand launch, Fornnax continues to set global benchmark and move decisively towards the vision of becoming global leader in recycling technology by 2030 that is state-of-the-art, innovative, economical, efficient reliable and eco-friendly.

Concrete

Fornnax wins Top Domestic Sales Award 2024-25 by AIRIA

Published

1 week ago

November 7, 2025

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Fornnax bags the Excellence in Top Domestic Sales Award 2024–25 by the All India Rubber Industries Association (AIRIA).

The company has been honoured with the Excellence in Top Domestic Sales Award 2024–25 by the All India Rubber Industries Association (AIRIA) under the Rubber Machineries and Equipment category. The award recognises Fornnax’s exceptional market leadership, strong sales performance and continued commitment to sustainable innovation.

With over a decade of specialised expertise, Fornnax has emerged as a transformative force in India’s tyre recycling sector, commanding nearly 90 per cent of the domestic market while steadily expanding across Europe, Australia, the GCC, and other global regions.

Fornnax’s advanced recycling systems—comprising the SR-Series Primary Shredders, R-Series Secondary Shredders, and TR-Series Granulators—are engineered for durability, efficiency, and high-output performance. These technologies are widely deployed in end-of-life tyre (ELT) processing and other waste management applications, reinforcing Fornnax’s reputation as a trusted industry partner.

Expressing his gratitude, Jignesh Kundaria, Director & CEO, Fornnax, said, “We are incredibly proud to receive this recognition from AIRIA. This award validates the trust that our customers and partners have placed in us over the years. I would like to extend my heartfelt gratitude to all our clients and partners who have been an integral part of this journey and our continued success. At Fornnax, our goal has always been to empower the recycling industry with innovative, high-performance solutions that make sustainability both achievable and profitable.”

The award also underscores Fornnax’s pivotal role in promoting circular economy practices by enabling the conversion of end-of-life tyres and rubber waste into reusable raw materials. Through ongoing R&D, new product innovation, and a solutions-driven approach, the company continues to help industries worldwide adopt eco-conscious, scalable recycling models.

As India’s recycling landscape evolves to meet global sustainability benchmarks, Fornnax stands at the forefront with internationally certified technology, a proven track record, and a clear vision for environmentally responsible growth.

Concrete

Pacific Avenue Completes Acquisition of FLSmidth Cement; Rebrands as Fuller Technologies

Published

2 weeks ago

November 4, 2025

admin

The acquisition of FLSmidth Cement by Pacific Avenue Capital Partners marks a new phase of focused growth and innovation.
Rebranded as Fuller® Technologies, the company will continue delivering world-class solutions with renewed investment and direction.

Pacific Avenue Capital Partners (“Pacific Avenue”), a global private equity firm, has completed its acquisition of FLSmidth Cement following the fulfillment of all customary closing conditions and regulatory approvals. The transaction includes all of FLSmidth Cement’s intellectual property, technology, employees, manufacturing facilities, and global sales and service organizations.

As Fuller Technologies, the company will continue to seamlessly support its customers while advancing its robust portfolio of capital equipment, digital solutions, and service offerings. With a sharpened focus on Pyro and Grinding technologies, alongside core brands such as PFISTER®, Ventomatic®, Pneumatic Conveying, and Automation, Fuller Technologies aims to deliver enhanced value and reliability across the cement and industrial sectors.

Under Pacific Avenue’s ownership, Fuller Technologies will benefit from increased investment in people, products, and innovation. The dedicated management team will work to optimize operations and strengthen customer relationships, ensuring continuity and excellence during this exciting transition.

“We are proud to be the new owner of FLSmidth Cement, now Fuller Technologies, a global leader with a rich history of providing mission-critical equipment and aftermarket solutions in the cement and industrial sectors. We will continue to build upon the Company’s legacy of being at the forefront of technological innovation, service delivery, and product quality as we support our customers’ operations,” says Chris Sznewajs, Managing Partner and Founder of Pacific Avenue Capital Partners.

Pacific Avenue’s deep experience in executing complex industrial carve-outs and guiding standalone businesses into their next growth phase will be instrumental in shaping Fuller Technologies’ future. With a proven track record in building products and capital equipment industries, Pacific Avenue is poised to help Fuller Technologies optimize performance, accelerate growth, and create long-term value for its customers and stakeholders worldwide.