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We are exploring opportunities for installation of WHRS at other plants

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KN Rao Director – Energy & Environment, ACC Limited

ACC Ltd-one of India?s leading manufacturers of cement and concrete with operations spread throughout the country with 17 modern cement factories, more than 50 RMC plants, 21 sales offices, and several zonal offices-successfully installed a waste-heat recovery system (WHRS) at its Gagal cement plant in Bilaspur district of Himachal Pradesh, with an investment of Rs 100 crore in 2013.

"WHRS are the requirement of waste heat for drying of raw material, fuel as well as additives. Most of our plants have been optimised for heat recuperation in the preheater as well as clinker cooler," says KN Rao, Director – Energy & Environment, ACC Limited, during an exclusive interview with the ICR team. He speaks at length about how to reduce energy consumption and ACC?s future plans.

As one of the important players of the industry, how do you assess the scope of upgrade of your existing pyro-processing system in your plant?
A robust and technically strong in-house team reviews, identifies and implements actions to continually improve thermal efficiency of the plants. Besides, close monitoring of operational measures like reduction of infiltration of air through continuous focus, burner momentum, raw-mix, etc. are taken to sustain/reduce thermal energy consumption.

Computatation Fluid Dynamics (CFD) studies are carried out on a continuous basis through in-house expertise to improve heat recuperation in preheater cyclones, besides reduction of pressure drop.

Please elaborate on your initiatives/improvements taken in terms of optimisation. Plants took up various debottlenecking/optimisation activities to improve the kiln productivity. Some of the activities are mentioned below:

a)Kiln improvement:

  • The kiln and calciner coal firing systems were upgraded for consistency and accurate coal feeding
  • Modificationon in preheater cyclones
  • Re-routing of coal injection and reduction of calciner outlet temperature with optimisation of degree of calcinations (DOC)
  • Controlling fine coal residue and moisture(grinding media change and taking hot air directly from kiln

b)Use of high efficiency coolers:

  • Control Flow Grate (CFG) to reduced fall through (RFT) conversion in clinker cooler and compartment modification fan replacement
  • Modification of cooler inlet with addition of new fans to improve rate and recuperation, which resulted in reduction in average PH tower O/L temp by 50C

c)Upgrade in process fans:

  • Replacement of process fans (preheater fan, raw mill fan, etc) with high efficiency fan and installation of medium voltage drives for speed control of major process fans
  • Replacement of impellers to improve operating efficiency
  • Modification in fan circuit to reduce pressure drop
  • Replacement of existing PA fan by high pressure turbo blower along with burner tip modification to improve burner momentum, reduce primary air and Nox and improve combustion.

d)Improved refractory technology:

  • Focussed monitoring of radiation and prompt action for any abnormality.

If you have already gone ahead with the improvements could you brief us on the results in terms of reducing energy consumption, and bringing down cost of operation?
The various initiatives, some of which have been detailed above resulted in reduction of 16 MJ of specific thermal energy/tonne of clinker to 3,050 MJ in 2014 as compared to 3066 MJ in 2013. In terms specific CO2 emissions per tonne of cement, the same reduced to 526 kg CO2/tonne of cement from 538 kg CO2/tonne of cement.

A significant portion of the energy requirement can be sourced through utilisation of waste heat from the pre-heater and cooler. Could you brief us on the initiatives (installing WHR system) taken by your company?
ACC has commissioned WHRS system at Gagal, during 2013. The potential for generation of WHRS depends on the thermal efficiency of the clinker cooler and the pre-heater. Other factors influencing WHRS are the requirement of waste heat for drying of raw material, fuel as well as additives. Most of our plants have been optimised for heat recuperation in the preheater as well as clinker cooler. We are exploring opportunities for installation of WHRS at other plants where waste heat is available for recovery through economically viable WHRS.

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Concrete

India donates 225t of cement for Myanmar earthquake relief

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On 23 May 2025, the Indian Navy ship UMS Myitkyina arrived at Thilawa (MITT) port carrying 225 tonnes of cement provided by the Indian government to aid post-earthquake rebuilding efforts in Myanmar. As reported by the Global Light of Myanmar, a formal handover of 4500 50kg cement bags took place that afternoon. The Yangon Region authorities managed the loading of the cement onto trucks for distribution to the earthquake-affected zones.

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Concrete

Reclamation of Used Oil for a Greener Future

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In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.

The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.

The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.

Circular economy in lubricants
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.

Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.

Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)

The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.

On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:

  • Kinematic Viscosity
  • Flash Point
  • Total Acid Number
  • Moisture / Water Content
  • Oil Cleanliness
  • Elemental Analysis (Particulates, Additives and Contaminants)
  • Insoluble

The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.

Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.

About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

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Concrete

Charting the Green Path

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The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.

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