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History Rewritten

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Indian Railways have scripted history by quietly conducting a trial run of the country?s first Dedicated Freight Corridor (DFC) which will come up between two districts in rural Bihar.

The train carried 5,265 tonnes of clinker, an intermediate product for cement manufacturing, loaded on 58 wagons on the 56-km new stretch between Durgawati and Sasaram, the bastion of late Dalit leader Babu Jagjivan Ram.

The trial run brought India a step closer to joining the select club of nations, including the US, China, Australia and South Africa, with operational dedicated freight-specific lines.The double line electrified Durgawati-Sasaram section is being commissioned with an investment of Rs 1,000 crore entirely funded by Indian Railways? equity. The pilot stretch on the eastern arm of the DFC project would divert largely coal freight from the existing rail network. The DFC has eliminated 18 level-crossings on the 56-km stretch by building road over-bridges.

The section is being constructed with an average investment of Rs 20 crore per km. The Dedicated Freight Corridor Company (DFCC), entrusted with the task, is currently building more than 3,350 km of double-track freight-specific lines from Ludhiana in Punjab to Dankuni in West Bengal as the Eastern DFC, and from Dadri in Uttar Pradesh to Jawaharlal Nehru Port Trust (JNPT) in Navi Mumbai as the Western DFC.

The DFCC has acquired more than 89 per cent of the 11,550 hectares of land required for the project and has tied up funding from the World Bank for the Eastern DFC and Japan International Cooperation Agency for the Western DFC.

Contracts worth Rs 24,102 crore were awarded in 2015-16 as against contracts worth Rs 13,000 crore finalised in the previous six years.

?The DFCC has finalised civil contracts for 2,138 km (76 per cent), electrical contracts for 1,786 km (63 per cent) and signalling & telecom contracts for 1,356 km (48 per cent) of the length of the project,? an official said.

The DFCC will purchase 200 locomotives for the western arm of the project from Japan and that order is being finalised at the Board level.

When commissioned, the eastern and the western arms of the DFCC will divert up to 40 per cent of freight traffic from Indian Railways and push the rail?s share of freight from the existing 36 per cent to 45 per cent.

JK Cement stops clinker production from Karnataka plant
JK Cement has informed stock exchanges that it has stopped clinker production at its Muddapur, Taluka Mudhol, Dist. Baglakot, South site (in Karnataka) on account of cracks being developed in its CF silo. This is the raw meal feeding silo to the kiln and as a measure to avoid collateral damage, the company has stopped kiln production temporarily. No material clinker inventory being currently present, volumes are likely to be impacted for the next 30-40 days. JK Cement dispatches nearly 5,000 tonnes of daily production of cement from this facility. This is the second instance when damage is being observed in a silo at its southern site.

Further, JK Cement has also said that power connectivity has been commissioned at its UAE site. Till date the plant was operating on diesel generating sets.

Cement prices cut in Himachal
Cement producers have decided to cut prices by Rs 10 per bag in Himachal Pradesh with immediate effect, the state government has said.
Cement companies had recently announced a price hike, forcing the state government to intervene in the matter.
State Industries Minister Mukesh Agnihotri asked Principal Secretary R D Dhiman to take up the matter with cement manufacturers.
Consequently, a high-level meeting was held here under the chairmanship of Dhiman. The meeting was attended by Director-Industries Amit Kashyap and representatives of ACC, Gujarat Ambuja and JP Cements.
It was decided in the meeting that all cement producers would slash prices of cement by Rs 10 per bag with immediate effect, an official spokesman said.
It was agreed in the meeting that rates of cement in the bordering areas of Himachal Pradesh would be at par or lower than the rates in the neighbouring states.

Adulterated cement selling racket busted
The Khour police (in Jammu) have busted an illegal cement selling racket by arresting three persons.
As per police sources, a complaint was lodged by Gittan Sharma, son of Daya Ram, a resident of Camp Khour with police station Khour on April 20 regarding illegal trade of cement.
Acting on the complaint, a case was registered at Khour police station and an investigation was started.
During the investigation, the accused disclosed that he along with his associates used to buy inferior quality cement from the mini plants of Kathua, and after procuring original used bags of Ambuja Cement, they used to refill the cement in these branded bags at rented shops and godowns at Rara Ramnagar.
After packing the cement in these ?branded? bags, the accused used to sell the cement bags at Akhnoor and Khour. They were engaged in this business for the last several months.
A total of 445 bags of spurious and substandard cement have been seized by the police.

RMC trucks emit cloud of dust
While citizens across Mumbai have been complaining of worsening air quality, residents of Sion?s Everard Nagar are particularly at risk because of constant movement of trucks from a nearby RMC plant.
The cloud of dust and pollutants that the trucks leave behind has already landed some residents and compelled a senior citizen to relocate to Goa.
?A ready mix truck passes by our society almost every minute. They go to the ACC plant located on KJ Somaiya grounds and use the same service road on the way back. There are two speed breakers on the stretch and every time a truck stops, it releases some dust and cement that enters our homes,? said Saraswathi Sundareswaran, who has been leading the society?s fight against the polluting vehicles.
Saraswathi has taken up the issue with the BMC, police, Maharashtra Pollution Control Board (MPCB), ACC Limited, and KJ Somaiya, but RMC trucks continue to ply on the service road.
?An MPCB official came to our society a few weeks ago. He just stood near the gate and asked us, ?Where is the cement? I don?t see anything?,? she said.
The in-charge at the ACC concrete batching plant said the company had deployed five men to clean the road regularly.?We use water to clean the road to ensure the dust does not rise. Lately, there has been a water shortage in the city, so it has been difficult to wash the road,? said Rohan from the plant.
According to one of the five workers, around five to six sacks of cement is collected from the service road. V Rangnathan, secretary of KJ Somaiya, said he had held several meetings with residents to try and solve the problem.

ASTM award goes to BASF?s Goodwin
ASTM International?s Committee on Concrete and Concrete Aggregates (C09) has presented its top annual award – the Award of Merit – to Fred Goodwin of BASF Construction Chemicals in Beachwood, Ohio, U.S.A. The prestigious award, which includes the accompanying title of Fellow, is ASTM?s highest recognition for individual contributions to developing standards.
The committee honored Goodwin for his dedicated work to develop standards in a number of areas, including hydraulic cement grouts, packaged dry combined materials, and polymer modified concrete and mortars. He has been a member of ASTM since 1991 and received the Award of Appreciation from the same group in 2011.
Goodwin is head of the BASF Construction Chemicals Global Corrosion Competency Center, providing technical expertise and driving research and development on grouts, adhesives, concrete materials, and more. He previously served as a principal scientist with Degussa Construction Chemicals, a technology manager with ChemRex, a plant chemist with Mapei Corporation, and a chief chemist for River Cement Company.

Restart of RMC units in Mumbai
In the last week of April 2016, the Member-Secretary of the Maharashtra Pollution Control Board has given permission to restart the closed Ready Mixed Plants in Mumbai on certain conditions. The conditions laid down are for arresting the emission of dust from these RMC plants either during the movement of trucks or while transferring materials like sand, aggregates etc. All the conditions have to be complied by 30th June 2016. Out of 12 plants closed, 3 are still waiting to restart. This is a big relief to RMC operators in Mumbai.

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Economy & Market

TSR Will Define Which Cement Companies Win India’s Net-Zero Race

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Jignesh Kundaria, Director and CEO, Fornnax Technology

India is simultaneously grappling with two crises: a mounting waste emergency and an urgent need to decarbonise its most carbon-intensive industries. The cement sector, the second-largest in the world and the backbone of the nation’s infrastructure ambitions, sits at the centre of both. It consumes enormous quantities of fossil fuel, and it has the technical capacity to consume something else entirely: the waste our cities cannot get rid of.

According to CPCB and NITI Aayog projections, India generates approximately 62.4 million tonnes of municipal solid waste annually, with that figure expected to reach 165 million tonnes by 2030. Much of this waste is energy-rich and non-recyclable. At the same time, cement kilns operate at material temperatures of approximately 1,450 degrees Celsius, with gas temperatures reaching 2,000 degrees. This high-temperature environment is ideal for co-processing, ensuring the complete thermal destruction of organic compounds without generating toxic residues. The physics are in our favour. The infrastructure is not.

Pre-processing is not the support act for co-processing. It is the main event. Get the particle size wrong, get the moisture wrong, get the calorific value wrong and your kiln thermal stability will suffer the consequences.

The Regulatory Push Is Real

The Solid Waste Management (SWM) Rules 2026 mandate that cement plants progressively replace solid fossil fuels with Refuse-Derived Fuel (RDF), starting at a 5 per cent baseline and scaling to 15 per cent within six years. NITI Aayog’s 2026 Roadmap for Cement Sector Decarbonisation targets 20 to 25 per cent Thermal Substitution Rate (TSR) by 2030. Beyond compliance, every tonne of coal replaced by RDF generates measurable carbon reductions which is monetisable under India’s emerging Carbon Credit Trading Scheme (CCTS). TSR is no longer a sustainability metric. It is a financial lever.

Yet our own field assessments across multiple Indian cement plants reveal a sobering reality: the primary barrier to scaling AFR adoption is not waste availability. It is the fragmented and under-engineered pre-processing ecosystem that sits between the waste and the kiln.

Why Indian Waste Is a Different Engineering Problem

Indian municipal solid waste is not the material that imported shredding equipment was designed for. Our waste streams frequently exceed 40 per cent to 50 per cent moisture content, particularly during monsoon cycles, saturated with abrasive inerts including sand, glass, and stone. Plants relying on imported OEM equipment face months of downtime awaiting proprietary spare parts. Machines built for segregated, low-moisture waste fail quickly and disrupt the entire pre-processing operation in Indian conditions.

The two most common failures we observe are what I call the biting teeth problem and the chewing teeth problem. Plants relying solely on a primary shredder reduce bulk waste to large fractions, but the output remains too coarse for stable kiln combustion. Others attempt to use a secondary shredder as a standalone unit without a primary stage to pre-size the feed, leading to catastrophic mechanical failure. When both stages are present but mismatched in throughput capacity, the system becomes a bottleneck. Achieving the 40 to 70 tonnes per hour required for meaningful coal displacement demands a precisely coordinated two-stage process.

Engineering a Made-in-India Answer

At Fornnax, our response to these challenges is grounded in one principle: Indian waste demands Indian engineering. Our systems are built around feedstock homogeneity, the holy grail of kiln stability. Consistent particle size and predictable calorific value are the foundation of stable kiln combustion. Without them, no TSR target is achievable at scale.

Our SR-MAX2500 Dual Shaft Primary Shredder (Hydraulic Drive) processes raw, baled, or loosely mixed MSW, C&I waste, bulky waste, and plastics, reducing them to approximately 150 mm fractions at throughputs of up to 40 tonnes per hour. The R-MAX 3300 Single Shaft Secondary Shredder (Hydraulic Drive), introduced in 2025, takes that primary output and produces RDF fractions in the 30 to 80 mm range at up to 30 tonnes per hour, specifically optimised for consistent kiln feeding. We have also introduced electric drive configurations under the SR-100 HD series, with capacities between 5 and 40 tonnes per hour, already operational at a leading Indian waste-processing facility.

Looking ahead, Fornnax is expanding its portfolio with the upcoming SR-MAX3600 Hydraulic Drive primary shredder at up to 70 tonnes per hour and the R-MAX2100 Hydraulic drive secondary shredder at up to 20 tonnes per hour, designed specifically for the large-scale throughput that higher TSR ambitions require.

The Investment Case Is Now

The 2070 Net-Zero target is not a distant goal for India’s cement sector. It starts today, with decisions being made on the plant floor.

The SWM Rules 2026 are already in effect, requiring cement plants to replace coal with RDF. Carbon credit markets are opening up, and coal prices are not going to get cheaper. Every tonne of coal a cement plant replaces with waste-derived fuel saves money on one side and generates carbon credit revenue on the other. Pre-processing infrastructure is no longer just a compliance requirement. It is a business investment with a measurable return.

The good news is that nothing is missing. The technology works. The waste is available in every Indian city. The government has provided the policy direction. The only thing standing between where the industry is today and where it needs to be is the commitment to build the right infrastructure.

The cement companies that move now will not just meet the regulations. They will be ahead of every competitor that waits.

About The Author

Jignesh Kundaria is the Director and CEO of Fornnax Technology. Over an experience spanning more than two decades in the recycling industry, he has established himself as one of India’s foremost voices on waste-to-fuel technology and alternative fuel infrastructure.

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Concrete

WCA Welcomes SiloConnect as associate corporate member

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The World Cement Association (WCA) has announced SiloConnect as its newest associate corporate member, expanding its network of technology providers supporting digitalisation in the cement industry. SiloConnect offers smart sensor technology that provides real-time visibility of cement inventory levels at customer silos, enabling producers to monitor stock remotely and plan deliveries more efficiently. The solution helps companies move from reactive to proactive logistics, improving delivery planning, operational efficiency and safety by reducing manual inspections. The technology is already used by major cement producers such as Holcim, Cemex and Heidelberg Materials and is deployed across more than 30 countries worldwide.

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Concrete

TotalEnergies and Holcim Launch Floating Solar Plant in Belgium

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TotalEnergies and Holcim have commissioned a floating solar power plant in Obourg, Belgium, built on a rehabilitated former chalk quarry that has been converted into a lake. The project has a generation capacity of 31 MW and produces around 30 GWh of renewable electricity annually, which will be used to power Holcim’s nearby industrial operations. The project is currently the largest floating solar installation in Europe dedicated entirely to industrial self-consumption. To ensure minimal impact on the surrounding landscape, more than 700 metres of horizontal directional drilling were used to connect the solar installation to the electrical substation. The project reflects ongoing collaboration between the two companies to support industrial decarbonisation through renewable energy solutions and innovative infrastructure development.

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