Environment

Co-processing of waste in cement kilns can become an arm of Swachh Bharat

Published

8 years ago

December 30, 2017

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To incorporate co-processing of waste in cement kilns in the ‘Swachh Bharat’ initiative, KN Rao, Director, (Energy & Environment), ACC Ltd wants support from the society and munici?palities. He thinks that once regular supply of waste material is ensured, cement industry will definitely invest further to utilise this.
What are your observations on fuel mix optimisation currently being practiced by the industry and by your own plants? Considering there is any restriction put on use of pet coke, where are we headed?
With the introduction of PAT targets for cement sector, most of the cement plants are trying to increase alternative fuels like biomass, industrial waste (hazardous and non-hazardous) in cement kilns. Subsequently, the government for the first time introduced emission norms for SOX and NOX for cement kilns, which need to be complied by August 2018.
In mid 2017, based on the NGT directive, restrictions were imposed on usage of pet coke in various industries. However, the cement kilns were permitted to use pet coke by MoEF and various State Pollution Control Boards. Some states permitted the use of pet coke in the fluidised bed boilers. With many changes mentioned above happened during the last one year, the pet coke usage has come down substantially in CPPs and cement kilns. The biomass availability for cement kilns also reduced as majority of biomass is currently being used by biomass-based captive power plants.
Cement plants desire to use low ash fuels like pet coke instead of high ash coal to produce high quality clinker with slightly lower grade of limestone, which is prevalent in India. The high grade clinker helps in absorbing more fly ash and slag in cement. This will help us to reduce the carbon footprint of the cement production and also mineral gypsum required for cement production.
In the long term, we expect increased use of pet coke and other alternative fuels like RDF, industrial waste (hazardous and non-hazardous) and biomass. Even in the last five years, Indian cement industry had progressed from 0.6 per cent to 4 per cent TSR (thermal substitution rate). The industry had a roadmap to increase TSR to 25 per cent by 2050. TSR do not include pet coke, which is considered as a fossil fuel like coal.
Since there is a restriction of pet coke usage in other industries, we expect pet coke prices to come down in the longer term. What kind of savings one can expect after second level of PAT audit?
In PAT 2 cycle, we expect that many designated consumers (DCs) will find it difficult to meet the reduction targets given to them. Most of the low cost and quick payback project got implemented in the PAT-1 cycle and the industry DCs have to implement high capex and long payback projects. Due to lack of growth in various sectors and low profitability and compliance, capex required for meeting the new emission norms for various industries for installation of Pollution control system, these high capex projects are not implemented by DCs.
Most of the DCs are going to use the surplus Escerts of PAT-1 cycle to meet the PAT-2 cycle reduction obligations. Even the discount price of Escerts is not attractive to justify high capex projects.What incremental changes could be done for benchmarking power consumption, fuel consumption? How are you placed on both these parameters?
The cement manufacturing technology has not changed for last couple of decades. Whatever has happened is small incremental changes, which is planning to give a reduction of 5-10 per cent in the electrical energy and 3-5 per cent in thermal energy. Since most of the Indian installed capacity built with modern technology, the opportunities for improvement are minimal.
Currently, as per WBCSD-CSI roadmap data, Indian cement industry stands number one in energy efficiency. The only major levers available are reducing the clinker factor, increasing the alternative fuels and raw materials, installation of waste heat recovery and use of renewable energy for operating the cement plant. For old plants, which commissioned before 1980, there are many opportunities like increase in the number of stages of pre-heater, cooler upgradation, waste heat recovery, grinding technology upgradation, process automation upgradation, installation of variable speed drive and energy efficient fans, compressors, motors, lighting, air conditioning system, etc. However, at the current Escerts prices, large capex projects will be difficult to justify as payback periods will be long. The only area where India can progress on energy efficiency is only through new products like composite cement where we can reduce the clinker factor.Is WHRS a fashion statement in cement plants? Please comment.
WHRS offers an environment-friendly option of generating power at the cement plant, thereby reducing the dependency on fossil fuel. Though WHRS provides a greener solution, this has several hurdles. Technology such as steam Rankine cycle becomes economical only with sufficient waste gas is available at reasonably higher temperatures. Other technologies such as Organic Rankine Cycle found to be expensive and Kalina cycle technology has two working installations. Both these technologies have a higher capex cost per MW compared to Rankine cycle.
The capex cost for WHRS has not come down in the last few years whereas renewable energy projects (wind and solar) cost have substantially come down with many incentives applicable for renewable energy making WHRS projects less attractive. WHRS projects will not be viable if the plant is running at lower capacity utilisation. Most of the Indian cement kilns are operating between 50 to 80 per cent capacity utilisation due to lack of cement demand growth which is making WHRS less attractive.
If WHRS has been given the deemed renewable energy status, the cement plant can install WHRS to fulfill the RPO obligation. If the cement plant already has a CPP and if the power generated by WHRS is surplus, the State of Electricity Board should agree to import the surplus power at the same price what State Grid charges. If this gets implemented, WHRS in every cement plant will be a reality.How do you rate the progress in AFR and use of bio fuels? Do you think investments in AFR are adequate to reach the targeted numbers?
Cement industry has advocated for long for utilisation of AFR and biomass in cement kilns through co processing. It is heartening to note that, the Government has understood the positives of AFR and the regulatory processes have become supportive to certain extent. There have been good progress so far in waste utilisation and ACC has installed pre-processing facilities in Wadi, Kymore and Madukkarai and carrying out co-processing in most of the plants. Out of our three pre-processing platforms, our Wadi pre-processing platform is receiving good amount of industrial and municipal waste and we are in the process of expanding its capacity. Currently, ACC is operating with TSR of 3.8 per cent, which we are planning steep growth.
Co-processing of waste in cement kilns can become an extended arm of Swatch Bharat initiative if support is extended from society and municipalities. Once regular supply of waste material is ensured, cement industry will definitely invest further to utilise this. Some of the cement plants in Europe run fully on waste derived fuels. So there exists huge potential.
In 2016 only, the Government of India has recognised co-processing as one of the waste management solution under Hazardous and Other Wastes Management Rules for the purpose of energy or resource recovery or both. After this regulatory change, more and more cement kilns have started using AFR and also investment will be keep coming in phased manner. If the municipalities enforce segregation and processing of waste to make cement grade "RDF", then there will be
large availability of AF for consumption in cement kilns.What should be the ideal payback period for energy efficiency improvement programmes undertaken by a typical plant?
Ideal payback period for energy efficiency improvement programs are typically less than two years. Above two years it becomes difficult to justify its business case under current market dynamics.
Capacity utilisation of the cement Industry is very low at present; moreover they need to invest huge capex to meet new pollution control norms for Kilns as well as for captive power plants.
After PAT 1 cycle, the potential projects for intensity reduction need considerable capex and most of the plants may not be in a position to invest in this front. Implementing energy saving projects through ESCO companies has not progressed in private sector. ESCO companies in China are implementing approximately of $2 billion of energy saving projects annually whereas in India it is almost insignificant.What has been the progress on use of alternate energy in cement plants?
Till now, approximately 250 MW of WHRS has got implemented in Indian cement sector. Similarly, more than 200 MW wind and solar projects are implemented till now. Many cement plants are buying renewable bilaterally from third party to meet the RPO obligation for wind and solar. Some of the cement plants are buying solar and non solar RECs from the energy exchange to meet their RPO obligation.
Cement plants have surplus mine and plant land and also have large amount of covered roof space to produce solar PV power of 4-5 MW in each plant.
Approximately 500-750 MW solar PV power generation potential is available in the Indian Cement Industries within the plant boundary. If PAT regulations are modified and benefits are given captive generation status for the installations of RE installed outside the plant boundary and importing into the plant for self consumption.

Concrete

India donates 225t of cement for Myanmar earthquake relief

Published

5 months ago

June 17, 2025

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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.

Concrete

Reclamation of Used Oil for a Greener Future

Published

5 months ago

June 16, 2025

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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.

Concrete

Charting the Green Path

Published

6 months ago

May 13, 2025

admin

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.