Technology

Advancements in fabric filtration technology

Published

7 years ago

February 28, 2018

admin

The article highlights the new emission standards and online reporting protocol for cement plants and captive power plants. It also covers the advancements in filtration technology to reduce dust, SOx, NOx, Mercury, Dioxins and Furans, heavy metals from the Kiln gases and also dust and SO2 from CPP.
Stringent dust emission regulations are introduced in early 1980s where the emission standards were 250mg/Nm3. During this period, most of the cement plants adopted electrostatic precipitators (ESP) for all applications. Subsequently, when the emission standards were reduced to 150mg/Nm3, Cement plants have upgraded the ESP with modern controllers, additional fields, change of electrodes. When dust emission standards have reduced to 50 mg/Nm3, cement kilns have shifted to reverse air baghouses with fibre glass bags and other applications like coal mill, cement mill, raw mill etc., shifted to low temperature bags like polyester/acrylic bags with or without antistatic treatment. However, the clinker cooler and captive plants continued with ESP technology.
In 2014, first time in India, gaseous emission standards (SO2, NOx, VOC, Mercury, NH3, heavy metals, dioxins and furans) for cement kilns and simultaneously dust emissions standards reduced to 30mg/Nm3 instead of 50mg/Nm3, which are on par with the global best practices. Apart from the emission standards, CPCB issued a direction on 5th February 2014 about the online reporting of emissions (both Stack and ambient air) and effluents from 17 categories of industries. Further, CPCB released guidelines for continuous emission monitoring system during July 2017.
The notification calls for online reporting of emissions from all process stacks and ambient air quality stations to SPCB and CPCB on 24 X 7 basis and stringent reporting and compliance standard. In 2015, CPPs emission reduction standard (Dust, Sox, NOx & Mercury) were introduced with varied emissions based on the vintage of the plant and also size of the plant.
Compliance timelines in both the cases i.e., Cement Plants, March 31, 2017 and for CPPs up to December 7, 2017. In both the cases, industry faced many technical as well as financial challenges to complete these projects. Based on the industry request, the Cement plants have been given time line extension up to August 31, 2018 and for the power plants, time line extension is not yet finalised.
The monitoring reporting protocol also is a major challenge in terms of technology option. As per the standard the emissions are measured on a 15 minute average and non-compliance alerts has been given to the companies. By design, emission from ESP varies with the process conditions and also emissions goes up while cleaning system of the electrodes takes place, especially in the outlet field. This becomes a big challenge when complying with the 15 minute duration constant emission from any ESP. Global compliance standards takes 1 day average or 3 day emissions average or 30 days rolling average to issue compliance alert and also to action of noncompliance. Indian standard on monitoring reporting protocol is the toughest standard at this moment.
The reporting issues posed biggest challenge for the technology selection for the control equipment. From early 1980s, there is a rapid advancement in terms of fabric filtration technology and currently newer fabrics and membranes have been developed to reduce the emissions to below 5 mg/Nm3 with a lower pressure drop and guaranteed longer life of up to 6 to 8 years. Apart from dust, the current advanced filter media is capable of reducing heavy metals, Dioxins, Furans, Mercury removal. Latest environmental regulations
Cement Plant: MoEF&CC has issued notification on revised emission norms to cement plants on August 25, 2014 against various parameters such as PM, SO2 & NOX emissions with varied compliance timelines for various parameters from January 1, 2016 to June 1, 2016. Final compliance timelines extension is further extended August 31, 2018.Filtration technologies adopted by cement
Indian cement industry is very progressive and is continuously adapting to the latest technologies to make the Cement Industry more efficient and green with less environment footprint. In the same spirit, Cement Industry is first one to adopt filtration technologies like Pulse Jet Bag House (PJBH), reverse air bag house and hybrid filters for controlling of dust emissions from stack.
Advent of new fabrics which can withstand higher temperatures and tough working conditions, controls and advance electrical systems provided the opportunity to reduce the dust emissions to very low levels. Cement Industry embraced these technologies that helped industry today in achieving consistent and lower stack emissions of 30 mg/Nm3.
To meet the online reporting requirements, cement plants have installed Continuous Emission Monitoring Systems (CEMS) and continuous ambient air quality monitoring stations (CAAQMS). Among various Industrial sectors, Cement Industry is the first one to move ahead with on line reporting of their dust emissions performance. This has demonstrated the willingness of Cement Industry to be more transparent in disclosure of their dust emissions performance.Advancement in filtration technologies in fabric filters
There are several conditions like change in process/raw material, wrong selection of fabric, and other design issues, abrupt changes in process operational parameters, poor diagnosis including lack of automation, improper maintenance, operational incompetency etc. resulting in poor performance of bag filters.
To address these issues, various advancements took placed in fabric filter technology and details of these developments are as given below:

Advancements in filter fabrics w.r.t., temperature with stand ability, chemical resistance, etc., giving an opportunity to select application specific fabric
Higher fabric area weight (density) fabrics
Economic viability of Polytetrafluoroethylene (PTFE) lamination technology
Low pressure filtration
Technological innovation in Pulse valves
Pulse valve failure detection system
Automation in back leak detection through Invention of bag leak detection systems along with latest controls
Remote diagnostics
Computational Flow Dynamics (CFD) studies of the bag house to correct the flow distribution and prevent the bag failure
Constant Pressure drop based bag cleaning system
Tall bags of 10-15 metres
Mandatory precoating of bags
Operating bag house at least 20 deg C above Water / acid dew point temperature
Residual analysis
Mandatorily adopting all seasons weather enclosure

Advancements in filter fabrics: Greater advancement took place in Filter fabrics w.r.t., temperature and tough working conditions with stand ability, filtration efficiency improvement etc., giving an opportunity for fabric manufacturers to develop various fabrics with different surface finishes and characteristics. Notable advancements in this direction are advent of Polyimide (P 84) fibres and micro denier fibres. Fabrics made out of polyimide fibres are having temperature with stand ability of approximately 260 degree and being a felt fabric can withstand rough handling and working conditions. This has helped Cement Industry to consider these fabrics in place of glass with/without PTFE membrane which are very fragile and delicate fabrics for Kiln application which has resulted improved operational efficiency of Kiln Bag Houses.
Similarly, PANOX and PYRON fibersare Oxidised Polyacrylonitrilefibers do not burn nor melt nor char. These fibres in blend with Nomex can bring in extra heat protection in Clinker cooler bag filter application.
Advent of micro denier fibres which are light in weight and high bulk, water repellent helped in developing fabrics which are more efficient with respect to filtration efficiency and more durable. The most common types of microfibres are made from polyesters, polyamides (e.g., nylon, Kevlar, Nomex), or a conjugation of polyester, polyamide, and polypropylene. This has resulted in achieving better permeability with better dust dislodgement characteristics, thereby enhancing the bag filters / bag houses performance.
Apart from dust filtrations, recent trends are towards use of Catalyst powder along with PTFE Powder during the manufacture of the felt. The resultant bag with membrane lamination can be effective in controlling the particulate emissions besides controlling Dioxins and Furans. This is also self-regenerated catalyst and is effective at temperature above 200 degree C.Fabrics with high fabric area weight (density): With the advent of finer fibres like micro denier fibres gave an opportunity to develop higher density fabrics with same / lower thickness than the traditional fabrics. Currently fabrics are available with 600 to 750 grams / sq m fabric density with the similar thickness, flexural characteristics as against traditional fabrics with density of 500 grams / sq m. These high density fabrics are more robust are able to give higher bag life even in touch working conditions.
Economic viability of PTFE membrane technology: Both the PTFE membrane manufacturing and lamination technologies have become more commercially viable.
This has resulted in industry adopting fabrics with PTFE lamination which helps in better permeability, dust dislodging, less pressure drop, lower energy consumption and improved productivity. Industry is looking at this technology wherein reduction in pressure drop and increased productivity up to 10-15 per cent can be tapped from the existing filter.Low pressure filtration: One of the latest technological advancements in bag filters/bag house are low pressure filtration which uses filter bags cleaning pressure of 0.8 bar as against 4 to 6 bar pressure used in traditional Pulse jet bag houses / bag filters. This low pressure filtration is achieved by using physical flow model study / Computational Flow Distribution studies to achieve optimum gas flow distribution, energy efficient roots blowers, specially designed cages and filter bags, advanced pulse valves etc., This helps bag houses in achieving low energy consumption, lower outlet emissions, extended bag life & overall reduced operational cost.Technological advancement in pulse valves: Greater Technological advancements took place in pulse valves, which resulted in enhancing pulse valves performance wrt, its ability to take higher flow / valve, Longer life, ability to have consistent performance due to pressure variations and contamination, very fast and repeatable response time for quick and accurate purges, reliable performance in harsh environment conditions, self-cleaning ability, less consumption of air, faster response time for more efficient duty cycles and higher impact force when blowing. This has resulted in improving operational efficiency and lower energy consumption both in existing and new filters.
Pulse valve failure detection system: These systems will identify the operational failures with Solenoid valves and convey the same to the plant personnel to enable them to replace/repair the solenoid valves immediately. This protect the filter bags from negative impacts like dust build up, blinding etc., due to non-pulsing which in turn increases the Pressure drop and higher power consumption.
Automation in back leak detection through Invention of bag leak detection systems along with latest controls: The integrated Bag cleaning mechanism monitors the dust emission on continuous basis. In case of spike in dust emission due to broken bags, the associated solenoid is automatically disabled to avoid flexing of damaged bag, thereby avoiding the enlargement of hole. The controls have features to continuously adjust pulse off time to maintain differential pressure at single set point within a narrow band ? 2.5mmW.C. The solenoid activation pulse output can sense the short or open solenoid with instant failure detection and row identification. The system can also identify leaking or ruptured, stuck open or closed diaphragm with instant failure detection and row identificationRemote diagnostics: Latest automation provides an opportunity for us to have all the bag house operational data like Differential Pressure, Temperature, Pulsing cycle, Dampers position, dust build-up in hoppers, healthiness of dust handling systems, filter bags, solenoid valves, outlet emissions, etc., and fine tune various parameters from the plant control room / local control panel. This helps us in ensuring the operation of bag house at the optimum level to enhance its performance with respect to bag life, differential pressure, energy consumption, etc. and maintaining consistent outlet emissions.
Computational Flow Dynamics (CFD) studies of the baghouse to correct the flow distribution and prevent the bag failure: CFD is a branch of Fluid Dynamics that uses numerical analysis and data analysis and data structures to solve and analyse the problems that involve fluid flows. CFD helps in designing the Air Pollution control systems with better efficiency, minimise cost of product development and design the systems in much smarter method. Modern CFD programs permit the simulation and analysis of flows on the computer. The computer-supported analysis enables examination of the dynamics of flowing media and provides a computer model which represents the examined conditions of an installation. The special strength of CFD simulations lies in the fact that ‘trial and error’ experiments, which are practicable in reality only with great effort, can be limited by CFD to the most likely solutions of the problem and with a minimum of effort.
CFD speeds up project work in conceiving and realising industrial dust removal installation, but it also serves as a tool for basic advancements. With a suitable choice of the simulation model, optimisation possibilities close to the installation can be found. The key to efficiently solving tasks is the networking of the CFD program with the CAD system. Nevertheless a simulation program is only as good as the user who serves it. The model construction, the simulation realisation and evaluation need
a lot of experience. Typical CFD outcomes are as given below:
Constant pressure drop based bag cleaning system: Current bag cleaning systems are automated to maintain constant pressure drop across the bag house. This helps in operating the bag house with consistent performance with respect to pressure drop, energy consumption.Usage of taller bags of 10-15 m long: Advanced pulse valves along with latest ventures are facilitating in effective cleaning of longer bags up to 10 – 15 meters long. This helps in having new bag houses with lesser foot print, converting ESPs to bag houses / hybrid filters.Mandatory pre-coating of bags: Dust with finer particles of 0.5 microns or smaller can leak right through pores of a new bag working their way deep into the media to the point of blinding, or clogging, the filter and slowing or stopping airflow through the bag house / bag filter, which in turn affect the performance of bag house and lead to higher power consumption. Pre-coating can reduce or prevent the permanent failure of new filter bags. Built up of pre-coating material as initial dust cake on the media, prevents dust particles from flowing into and blinding the media. Pre-coating ensures that air flows freely through the dust collector, improving filtering performance while extending the bag life. Pre-coating of new filters provides other benefits like improving the dust collector’s initial filtration efficiency at start-up, ease of cleaning, better dust cake release etc.
Operating bag house at least 20 deg C above water / acid dew point temperature: It is mandatory to operate the bag house at least 20 degree C above water / acid dew point temperature to avoid condensation of water / acids on the filter fabric which in turn will damage the filter bags and leading to higher pressure drop, higher energy consumption and higher emissions (if the bags are damaged due to acid attach). Residual bag life analysis: To ensure consistent performance of the bag house, it is essential to periodically check the filter bags for residual life and to replace the bags before the failure happens. This will help in preventing the higher emissions from the bags and to ensure consistent performance of the bag house.Mandatorily adopting all seasons weather enclosure: Bag houses / Bag filters are prone to water seepage through the top doors, top roof during the rainy season which will impact the performance of bag house by blinding the bags due to water condensation. Hence it mandatory to provide weather enclosure on all the existing/new baghouses to prevent moisture ingress and to ensure consistent performance of the bag house.Conversion of RABH to PJBH/additional module: When the plant capacity is enhanced, few of the options available for accommodating the higher gas volume is either converting reverse air baghouse to pulse jet baghouse or addition of module which will facilitate in creating more filtration area and thus accommodating the additional gas volume.
Current constraints and design challenges for bag filter suppliers
In spite of technological advancements in fabrics and bag house technology, still the bag filter / bag house suppliers continue to face few challenges as given below:

Online maintenance of the filter
Emissions exceeding beyond the permissible limits
Ability to install new filter with least shutdown time
Minimising the ID fan energy consumption and compressed air consumption
Consistent longer bag life
Ability to install fabric filter in ESP Casing
Ease of bag house maintenance / bags replacement
Fabrics which can withstand consistent operating temperatures > 260-280 deg C
Catalytic filter media
Expenses Cages

Advancements in ESPs
In spite of the advancements in Fabric Filters, Electrostatic Precipitators are still preferred over Fabric Filters especially for high temperature applications like Clinker Cooler and treatment of flue gas in Power Plant. One of the main drawbacks of ESP is that it is highly influenced by the process parameters. Small changes in the operation conditions – flue gas temperature, dust/flue gas characteristics have enormous impact on the ESP efficiencies.
Majority of recent advancements in ESPs are as given below:

Smart Controllers for conventional transformer rectifier (TR sets)
Three Phase transformers
High frequency transformers

Smart Controllers for conventional TR sets: Optimum power to the ESP is a key in achieving the maximum dust collection in the different fields of the ESP. Adapting smartly to changing process conditions, reducing the impact of sparking in the field as well as back corona occurrence thereby improving the energising level helps in reducing emissions to desired levels. Fast response to sparking condition thereby always maintaining peak power levels is an inherent feature of these controllers.
Manufacturers are developing better products and software for combating back corona especially in Indian coal scenario. Advanced Algorithms for automatic detection / control of back corona with very high pulse blocking ratios has been effective in mitigating impact of back corona. Reliability has been another issue which has been addressed with the selection of superior components. With ESPs designed with 3-4 electrical fields, failure of one controller can impact collection area of around 25 to 33 per cent. Sectionalisation of mechanical field by splitting into two fields (either across gas flow or in direction of gas flow) to increase number of electrical fields, can result in substantial improvement in the ESP performance.Three Phase Transformer: Recent trends for improvement in power levels have been the increasing up-gradation of existing transformers (single phase 415 V) with Three Phase transformers. Sparking in the field is predominantly due to the peak KV reaching spark over level across the collecting and discharge electrodes. With conventional TR sets, the average KV is 60 to 90 per cent of the peak KV. With conversion to Three Phase transformers, the average KV can be more than 90 per cent of the peak voltage thereby drastically increasing the energisation levels of the ESP, thereby reducing emission levels. Equipment suppliers are willing to offer 20 to 30 per cent reduction in emission for up-gradation with three phase transformersHigh Frequency Transformers (HFTR): In conventional TR sets, the power level to the TR set and thereby to the ESP is controlled by the firing angle of the Thyristor (SCR) – point in the AC power cycle where the voltage is applied to TR set. Once the Thyristor start conducting, it can be stopped only during cross over to the reverse cycle. This limits the point at which the conduction of the SCRs can be stopped, rather there is no control. With the advent of IGBT’s the start / stop of the conduction of the device can be controlled. It is possible to provide more precise control of the ESP parameters such as the output voltages and currents. It is also possible to make a rapid increase or decrease in voltage and to provide a very fast response to load changes.
The HFTR supply uses an IGBT converter which supplies the primary of transformer with 5 kHz – 20 kHz AC. (Conventional TR set are controlled at mains frequency i.e 50 Hz). Due to these advantages it is possible to suppress the supply quickly in the case of sparking, reducing the spark energy and the quantity of ionised gasses produced by the electric arc. Similarly the recharging is also faster. Reduction in the spark energy is many times compared to conventional SCR solution.Thus HFTR can comfortably operate with 50 to 100 sparks per minute without significant loss of corona power and very close to flash over levels unlike traditional Sets.
The lower quantity of ionised gasses produced by the spark contribute to much shorter de-ionisation intervals, required to quench sparking and evacuate charged particles in order to reinstate the voltage and proceed with the operation.
Since the average and peak KV being very close, they can operate at significantly below flash over levels in case of combustible and explosive applications thereby reducing chances of fire and maintaining the desired efficiency.
As a result, the collection efficiency and energy efficiency of the electrostatic precipitator can be increased many fold by applying high frequency high voltage power supply. Hybrid Dust Collectors: ESP-Bag filter
Another approach quickly gaining widespread usage especially for CPP Boiler is Hybrid Dust Collectors. For a typical four field ESP, the outlet two fields can easily be converted to bag filter by simple modification of the ESP internals. The Coarse particles are easily collected in the inlet fiels and the fine particles which are comparatively difficult to collect in ESP are collected by the filter bags. The cost for new bag house is reduced as in most cases the existing ESP casing / ducting & hopper / dust conveying system is used. Also the operating cost is reduced as the DP is on lower side as dust loading is quite low.
HFTRs and Three Phase work the best in inlet fields. So in Hybrid filters providing HFTR / 3 Phase in the field-1 is a great idea! Benefits a) In case of minor bag failures emissions will not rise alarmingly. b) The requirement of cleaning bag is less since it is exposed to less dust, meaning longer bag life and less compressed air usage.Closed Loop Energy Management System
The importance of closed loop energy management systems with opacity monitors is being looked at seriously. Although the limited electrical fields do not give enough room for energy management, this will slowly become the norm rather than exception.
Another off shoot of new emission norms is that a lot more care is taken in dust and ash conveying, especially false air leakages through them. This not only reduces emissions, but saves power also. Care is also taken to avoid dust build-up in hopper so as to avoid tripping of the fields due to ‘hopper
level high’Conclusion
Environmental Protection and continuous adoption of environment abatement technologies continue to be the primary focused area of Cement Industry to comply with environment regulations and to beyond the regulatory regime. Various technical advancements in filtration technology indicated above are clearly demonstrating their significance for new emission regulations by overcoming constraints like layout constraints, longer shutdown timelines, reduced financial resources requirements, etc. Acknowledgement
We thank Dilip Sakphara – Managing Director and Rushabh Sakhpara – Business Development -MaxTech Industries and Dr VS Rajan – Chief Technical Advisor – Supreme NonWoven Industries Pvt Ltd for providing technical inputs in drafting this article.
The article is authored by: KN Rao, Director – Energy, Environment & Sustainability, ACC Limited

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

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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

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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.