Technology

Optimising Plant Performance

Published

9 years ago

July 4, 2016

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The Rietveld method of quantitative analysis of amorphous materials has gained importance in the light of the BIS issuing specifications for composite cement.
Nowadays, many industries are looking for possibilities to reduce CO2 emissions, energy consumption and increase the reuse of waste materials, These demands are enforced by various regulations and international agreements, and in the long term, they will cause cost reductions. In the cement industry, this can be achieved by using modern techniques in production and by an optimisation of the burning process, by fuel substitutions, alternative clinker compositions or by the production of blended cements with different additives. A variety of completely or partly amorphous materials are used as additives, like slag, fly ash, silica, pozzolana and others. Controlling these additives quantitatively is essential in order to guarantee the cement norms.

Since the mineralogy strongly influences the reactivity of the cement as well as the physical properties of the hydrated product, the need for a direct mineralogical assessment by X-ray diffraction is more important than ever before. X-ray diffraction (phase analysis) opens enormous possibilities for process and quality control. Moreover, the recent development of ultra-high-speed X-ray detectors and of the software for quantitative X-ray diffraction analysis allows truly interactive process control. The quantitative Rietveld analysis is an important tool to control raw materials as well as industrial products, hence offering significant benefits in terms of cement production. Cluster analysis in combination with Automatic Program Selection increases the reliability of quantification results.

The examples presented in this paper will show how X-ray diffraction is being used to quantify blended cements with a complex mineralogy containing crystalline and amorphous phases.

Production and quality control using XRD
Nowadays X-ray fluorescence (XRD) and X-ray diffraction (XRF) analyses are standard tools for process and quality control in cement plants. XRD analysis in combination with Rietveld refinement is a reliable, precise and very reproducible way to quantify the relative phase abundances in building materials. The whole process from sample preparation, through measurement to Rietveld evaluation can be implemented in existing laboratory automation systems and takes approximately 10 minutes. Due to the completely automated operating principle, no additional staff are required and the results are user-independent. The Rietveld method is now being applied in industrial laboratories and also in various cement plants as the standard method for quantitative analyses of raw materials, Portland cement clinkers, Portland cements (OPC) and all types of blended cements.

For clinker, the Rietveld method is the only option to determine the phase content in an accurate and fast way, because the Bogue calculation is usually not correct due to the incorporation of higher amounts of minor and trace elements in the clinker phases, especially when alternative fuels are used. The quantitative mineralogical composition of the cement is directly linked to the hardening behavior and the compressive strength after 28 days. Blended cements are classified under different norms. In order to fulfill these norms and to guarantee the quality of the product, it is necessary to determine the exact amount of added blending materials which is only possible by Rietveld quantification.

Figure 1: Contribution of crystalline and amorphous phases to
an XRD pattern

Figure 2: Rietveld quantification of a pure fly ash, containing
mullite, quartz and around 45 per cent amorphous material..

Figure 3: Rietveld quantification of a fly ash
cement with separate

Figure 4: Cluster analysis of different slag cements with low
(blue), medium (grey) and high (green) amounts of slag
quantification of the fly ash components, including amorphous content

Application of Rietveld analysis for blended cements
The Rietveld analysis uses the whole XRD pattern for quantification and not only single peaks like the classical free lime determination. All peaks from the pattern are used for the refinement and the crystalline compounds are normalised to 100 wt.-%. The Rietveld analysis requires information on the structure data of all crystalline phases in the material and other crystallographic parameters. The quantification of amorphous material requires special procedures. Amorphous material doesn?t give clear diffraction peaks; the pattern may just show a higher background or a hump in a certain region. This hump is not always discernible, especially for low concentrations of the amorphous phases. The background noise strongly influences the quantification results for the amorphous material. Figure 1 illustrates the contribution of crystalline and amorphous phases to a XRD pattern.

Different approaches to determine the amorphous content are described in the literature. The addition of an internal standard is a common method for the determination of the amorphous content.

A defined amount of a standard (like corundum or rutile) is added to the material, and the amorphous content can be calculated from the obtained standard amount from the Rietveld quantification. Influences on the quantification resulting from mixing of the sample with the standard, from possible amorphous content in the standard (Whitfield & Mitchell, 2003) or from crystallographic parameters (De La Torre et al., 2001) were studied. Westphal et al. (2009) showed that the calculation of the amorphous content via Rietveld analysis using an internal standard follows a nonlinear function. For an industrial application, especially for automated systems, the internal standard method is not suitable.

Figure 5: Cluster analysis of different limestones rich in quartz, dolomite
or mica. Outlier in red was a damaged sample.
Figure 6: Working scheme of the Automatic Program Selection
based on Cluster Analysis.

For industrial applications, other methods for quantification of the amorphous material were developed. One possibility is the external standard method. In this case a crystalline standard material is prepared only once and measured separately on a weekly basis. Via mathematical procedures the data obtained from this scan are used for the determination of the amorphous content in the cement. The advantage of this method is that no mixing of standard material and cement sample is necessary. Another possibility is to calculate the area or the intensity of the amorphous contribution to the powder diffraction pattern. This approach is known as the ?HKL? method. The amorphous part is considered as an additional phase and included in the Rietveld calculation. The final result including all crystalline and amorphous phases is again normalised to 100 wt.-%.

Table 1 shows typical ranges of reproducibility and repeatability for different slag cements containing slag from 8 wt.% to 65 wt.%. Table 2 shows typical ranges of reproducibility and repeatability for different fly ash cements with fly ash contents from 10 wt.% to 30 wt.%. For the reproducibility sets of 10 separately prepared samples of the same material were measured. The variation of the results is mainly caused by sample inhomogenities and preparation effects. For the repeatability values one prepared sample was measured 10 times.

Some blended cements have a very complex composition containing more than 20 crystalline phases and one or more amorphous components, introduced by the addition of materials like fly ash or other compounds. Fly ashes used in the cement industry contain usually 30 – 70 per cent amorphous material and as main crystalline phases quartz and mullite. Different feldspars, magnetite, hematite, anhydrite or other phases may also occur.

A Rietveld refinement of an example of a fly ash containing quartz, mullite and amorphous material is shown in Figure 2.

The described quantification methods including amorphous contents can easily be integrated into automation systems. The output file can be defined according to the needs, either all crystalline phases are shown separately (as depicted in Figure 3), or a total value for the amount of slag, fly ash, pozzolana or other added material is given.

A Rietveld refinement of a cement sample containing 20 per cent fly ash is shown in Figure 3.

Cluster Analysis
Statistical analysis techniques are necessary for the data interpretation.
Cluster analysis is a useful tool, as it greatly simplifies the analysis of large amounts of data. This application can be used for simple pass/fail analyses of raw materials, characterisation of blended cements, and automatic selection of control files for Rietveld analysis (APS).

Powder diffraction scans or other data sets are sorted automatically into separate clusters, with closely related scans in a cluster. The most representative as well as the most different scans or data sets can be identified. Outliers are clearly visible as they do not fit into any of the defined classes. Outliers represent deviations or problems in the production process, like changes in the composition, instabilities in a kiln or others. They can be also a result of problems with the sample itself, resulting from sample preparation or transport, like uneven surface or a broken sample. An example of cluster analysis of different slag cements is shown in Figure 4. In Figure 5 an example for an outlier produced by a damaged sample is given.

Automatic Process Control (APS)
The quality of the control files for the Rietveld quantification is decisive for the accuracy of the results and therefore also for the whole process control. A control file can work over a large range of compositions, e.g. from very low to very high amounts of slag in a cement, with good results. For smaller ranges, the control files can be designed with an optimised accuracy. Separate control files are also recommended if different fly ash types are used. Special designed refinement strategies, different background treatment and an optimised fitting for other parameters can be implemented to achieve higher accuracy for the quantification. The selection of a control file can be done automated by cluster analysis. After a measurement, the scan is compared with a pool of scans, the master scans. These scans define separate clusters, representing clinkers or cements with different compositions, like slag cements with low, mid, and high amounts of slag. The variability of each cluster, represented by the diameter of the spheres in the PCA (Principal Component Analysis) plot, is defined by the allowed range of composition for each material. Every measured scan is classified into an existing cluster, if it is within the allowed range, or rated as an outlier.

To each cluster, an optimised control file for the automated quantification is assigned. Each scan can then be processed by a special control file designed for this material. The results of the quantification can be handled by a LIMS (Laboratory Information Management Solution) system. Outliers have to be treated in a special way. The scan can be processed with the control file of the nearest cluster, accompanied by a warning message, that the quantification is of limited reliability. In any way, human interaction is necessary or recommended. The process scheme of the Automatic Program Selection is shown in Figure 6.

Conclusion
Phase analysis by X-ray diffraction opens enormous possibilities for process and quality control in the cement industry especially for blended cements. Moreover, the development of fast X-ray detectors allows fast quantitative X-ray diffraction analysis and truly interactive process control. The Rietveld method allows precise and reproducible quantitative analysis of all types of blended cements. It can be performed in an automated, stable and accurate way. Using an external standard or HKL fit, the determination of the amorphous content can be done directly on the cement sample. The result output includes the quantitative analysis of the crystalline and amorphous phases as well as the total amount of added cementitious material. Nowadays the Rietveld method is being applied in many cement plants worldwide as the standard method for quantitative phase analyses of all types of blended cements. The integration of the cluster analysis into the Rietveld quantification allows fully automated selection of an optimised control file for each material. This increases the accuracy of the quantification and allows an easy identification of outliers.

References
1.Rietveld, H. M. (1969): A profile refinement method for nuclear and magnetic structures, J. Appl. Cryst. 2, 65-71
2. Young, R. A. (1993): The Rietveld Method, Oxford University Press
3.De La Torre, A. G., Bruque, S., and Aranda, M. A. G. (2001): Rietveld quantitative amorphous content analysis, J. Appl. Crystallogr. 34, 196-202.
4.Westphal, T., F?llmann, T., and P?llmann, H. (2003): Rietveld quantification of amorphous portions with an internal standard-mathematical consequences of the experimental approach, Powder Diffr. 24, 239-243
5.Walenta, G., Gimenez, M., and F?llmann, T. (2008): Quantitative analyses of blended cements in industrial applications.- International Cement Review, July 2008, 67-71
6.Whitfield, P. S. and Mitchell, L. D. (2003): Quantitative Rietveld analysis of The amorphous content in cements and clinkers, J. Mater. Sci. 38, 4415-4421.
7.Westphal, T., F?llmann, T.: Quantifying Amorphous Portions in Blended Cements – A Comparative Study.
8.F?llmann, T., Meier, R., and Witzke, T.(2012): Use of X-ray techniques to optimize the efficiency of cement and concrete characterization.
Fuellmann, T., Witzke, T., van Weeren, H. PANalytical B.V., Lelyweg 1, 7602 EA Almelo, The Netherlands

Concrete

Optimising plant performance

Published

5 days ago

June 17, 2025

admin

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

admin

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.