Connect with us

Environment

Water transport is the largest cost reduction opportunity in cement logistics

Published

on

Shares

SUMIT BANERJEE, former Vice Chairman, Reliance Cement and Ex MD&CEO, ACC Ltd, says it is only a matter of time before cement companies evince interest in waterways and coastal transportation for competitively moving cement.

How has inland or coastal water transportation evolved over time?
From the early days of human civilisation, habitats and trade centres developed around rivers. This was no accident. Rivers provided a source of water, the elixir of life; helped irrigate lands for farming and provided an easy solution for sanitation (although unacceptable by today?s standards). On top of all that, rivers gave humans an avenue for transportation of people and merchandise. However, as newer modes of transport were invented, we favoured railways and roadways over riverine carriage of goods, evidently because we wanted to move things faster, and also away from rivers deeper into the hinterland.

As we started neglecting our traditional waterways, they deteriorated in terms of navigability, due to a variety of reasons such as indiscriminate construction of barrages, bridges and dams and consequent siltation, reclamation of river banks, inadequate investments in de-silting and in terminals, geopolitical controversies regarding sharing of waters between countries, etc.

Altogether, the effect of all these factors has been to push the concept of inland water transportation (IWT) into oblivion, at least in our country. Some other countries have fared better. The Fjords in Norway or the waterway systems in Pittsburgh/Great Lakes area in USA have excellent infrastructure for water transportation. In Germany, IWT constitutes 20 per cent [WB, 2005] and in Bangladesh it is 32 per cent [Rahman Mushfequr, 1994] of the total domestic goods movement. In Norway, it is reported to be 42 per cent. However, in India, it has become a very marginal part indeed (0.15 per cent) [Raghuram G, 2004]. Evidently, we have a lot to do.

How is inland water transport relevant today?
Water transport is the largest cost reduction opportunity in cement logistics. Empirically, we say that rail transport costs half of road transport, on per ton – km basis. Water transport, in turn, would cost half of rail transport, simply because it consumes substantially lesser amount of fossil fuel. So, clearly, IWT is highly relevant from a cost perspective, and as the cost of energy goes up, this cost differential is going to go up. It obviously makes business sense for a nation to focus on IWT, from cost or resource conservation points of view. This is single largest opportunity in front of cement companies to make a dent in their transportation costs, and thereby improve their competitiveness. But there is another dimension to this – that of climate change.

Out of all the global greenhouse gases emitted, 13-14 per cent are caused by transportation. If we can make a sizeable dent in this component of GHG, we can, as nations, contribute more to the global effort in climate mitigation. After the recent Paris Agreement (CoP 21), it has become more important for countries like China and India to evolve development-friendly strategies for CO2 management. IWT has suddenly become doubly more meaningful in this context.

Which industries can benefit from IWT/coastal transport?
To determine this, we have to first acknowledge the weaknesses of IWT, which are its relative slow speed and limited reach, restricted to regions adjoining riverine routes. There will be many products (electronic items, white goods, semi-precious metals) whose prices are high enough to afford faster and costlier modes of carriage like road or even air. Contrast these with bulk commodities like coal, steel, cement, fertilisers, food grains, iron ore and such other items which are comparatively lower in prices, volumetric and bulky in size, heavy in weight, and large in quantity. In these cases, one will be ready to allow it to spend a few days more in transit, if that saves significant amount of freight. I think it is only a matter of time before cement companies will get interested in exploiting this route for competitively transporting coal, cement, gypsum, clinker, and similar commodities.

However, for this to happen meaningfully, the cement companies will need to plan their footprint keeping in mind water routes, coastal positions and terminals, and most importantly, the location of target markets. Companies like Ambuja Cement and Ultratech have done this well on the western coast.

What steps should the government take to popularise water transport?
This will not move without improved and all-year round navigability and availability of terminals and storage facilities. This is where government investment will have to come in by way of continuous dredging, in addition to building terminals and warehouses along the waterway routes. The move to announce more waterways as National Waterways is most welcome, but this has to be followed through with effective development of infrastructure, which will definitely pay back by way of user fees, over time, as IWT becomes popular with commodity players. We have seen that the last budget has provided for raising Rs 800 crore by way of tax-free infrastructure bonds, specifically for inland waterways, and this is a commendable beginning. In due course, it may be a good idea to allow companies accelerated depreciation (or some such incentive) for investments in barges and riverside godowns, terminals, material handling equipment and similar infrastructure needed for inland water transportation. Andhra Pradesh took a step forward, when the CM recently announced an incentive of Rs 0.25/ton of water borne cargo, with the aim to achieve a 5 per cent share for IWT in the state.

Minister of Roads and Transport, Shri Gadkari said that at present there are only 5 inland waterways and his government has identified 106 more, and now these 111 waterways are being developed as National Waterways. He said that his government plans to construct 2000 water ports.

I feel that is the way to go!

Continue Reading
Click to comment

Leave a Reply

Your email address will not be published. Required fields are marked *

Concrete

India donates 225t of cement for Myanmar earthquake relief

Published

on

By

Shares

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.

Continue Reading

Concrete

Reclamation of Used Oil for a Greener Future

Published

on

By

Shares

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.

Continue Reading

Concrete

Charting the Green Path

Published

on

By

Shares

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.

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds