Environment

“10 per cent more efficiency can be achieved”

Published

6 years ago

April 30, 2018

admin

– PK Ghosh, Group Managing Director, Ercom Engineers Pvt Ltd

What is the unit per tonne of energy consumption consumption in a cement plant in India?
The average electrical energy consumption in India is around 90-95 kWh/tonne cement (OPC) whereas the best achievement is around 80 kWh/tonne cement (OPC). Similarly, average thermal energy consumption is around 760 kcal/kg clinker, whereas the best figures achieved are around 680 kcal/ kg clinker. There is scope for reduction in both thermal and electrical energy consumption in many of the cement plants in India.
The contribution of the various departments to power and heat consumption is given in the Table-1 (refer this table in the page 31).
The best achievable figures are generally observed for the larger scale plants in India using the state of the art technology when operating at or higher than design levels.What are the factors affecting Energy efficiency? What steps/ operational measures you have initiated to achieve the target – for both thermal and electrical energy optimisation?
The energy performance of cement manufacturing units is dependent on the following factors:
a. The age and type of the manufacturing technology such as:
i. Number of preheater stages
ii. Presence and type of calciner
iii. Type of cooler
iv. Type of raw mill grinding system and the separator
v. Type of cement grinding system and presence of pregrinders
vi. Auxiliary material transport systems
b. Cement product type such as OPC, PSC or PPC
c. Capacity utilisation
The energy efficiency achieved is the result of optimization between capital expenditure and reducing operating expenses.
In case of specific heat consumption, approximately 20 per cent losses are through preheater exhaust gases, 12 per cent are through cooler exhaust gases and around 4-5 per cent are radiation losses (for 6 stage preheater – precalciner system with the state-of-the-art cooler). These losses may be reduced by:

Reduction of false air entry to reduce the amount of exhaust air
Installation of VFD in cooler fresh air fans to reduce the inlet air efficiently in case the operation is at lower than design levels. This will ensure that excess air is not exhausted from the system.
If PH gases exit at higher temperatures, it indicates that the heat exchange between raw meal and hot gas is not proper in the preheater cyclones. Root cause analysis will help indicate which of the cyclones are not functioning properly and the situation can then be rectified. Further temperature reduction of exhaust gas can be carried out by taking advantage of waste Heat recovery systems.
In case cooler exhaust temperature and clinker temperatures are high, optimisation of cooler operations by adjusting cooler speed, bed height and balancing of the cooling air may be necessary.
Radiation losses need to be taken care of by ensuring that refractory lining is intact in preheater, calciner, cooler and no hot zones are formed in the kiln shell.

The cement grinding department and the raw material grinding are the major consumers of electrical energy. The material transport systems have also to be looked in to ensure that the power consumption is lowered. Some of the factors to reduce specific energy consumption (SEC) are as follows:

The choice of grinding mills, the design of separators, and the layouts of these systems play a major role in determining have energy consumption.
The process air fans are big electrical energy guzzlers. Since power consumption is a product of pressure drop and gas volumes, solutions can be worked out on both fronts.
Installation of highly efficient screw compressors can help reduce the energy consumption.

Have you suggested any modifications/process improvement lately to help conserve energy?
Yes, once a detailed audit is carried out it becomes possible to carefully identify the improvement areas as well as classify them into:

Opportunities requiring minimum investment – short term measures
Opportunities requiring some investment – medium term measures
Opportunities requiring major investment and down time – long term measures which result in considerable increase in productivity and reduction in specific heat consumption.

The projects for energy efficiency improvement will have to be prioritised based on possible benefits, funds available and required downtime. Some corrective measures are described as follows:1. Short term measures
The short term measures are as follows:

Replacement of worn-out parts of crusher and grinding machines
Controlling the combustion air (10 per cent reduction in excess air can save 8-20 kcal/kg of clinker)
Ensuring uninterrupted operation of the kiln
Power factor improvement of electric motors and installation of VFDs / VSD.
Depending on the specific site conditions, reduction in energy consumption of 10-15 per cent can be achieved by adopting these measures.

2. Medium term measures
i. Separate grinding of petcoke and coal: In many plants it is observed that petcoke and coal are ground together. This caused coal to be ground finer than required to meet the petcoke fineness requirement of 2 per cent on 90 microns. The energy consumption can be reduced by separately grinding coal and petcoke to their respective fineness. Expenses will be incurred in installation of separate bins and blenders for the mix fuel.
ii. Change in clinker grinding system: Vertical roller mills (VRM) to replace tube and ball mills: The power consumption of VRM is approximately 35 per cent less than the ball mill. Up to 25 per cent electricity may be saved by replacing ball mills with roller mills. Pregrinders can be installed before existing ball mills to reduce the power consumption in the totals circuit by 10-15 per cent. In new plants, roller mills or roller press/ ball mill combinations are recommended to be used instead of ball mills.3. Long term measures
i. Replacement with LP cyclones: Depending on the efficiency of the fan, 0.66 to 0.77 kWh/t clinker can be saved for each 50 mm w.c. reduction in pressure drop. Installation/ modification of the inefficient cyclones often entail rebuilding or modification of preheater tower and implementation costs are site specific. An overall heat and mass balance would have to be carried out to ascertain the likely benefits which will be obtained after the modification.
ii. Addition for preheater cyclone stage: A 6-stage preheater calciner using coal shows exit gas temperatures of about 280?C, 5-stage preheater 310?C and 4-stage preheater, 350?C. Specific heat consumption would reduce by 20-25 kcal/kg clinker if a fifth stage is added. This may also result in higher pressure drop across the system and may warrant change of preheater i.d. fan. The implications on the cooler fans, the cooler i.d. fan and the preheater exhaust fan on addition of the Preheater stage will have to be evaluated in totality.
Addition of a cyclone stage is feasible if the original design was conservative. There may be efforts required for supporting of new cyclone if the original preheater building cannot bear the additional loads.What is the scope of using flyash and other cementitious materials in cement manufacturing for reducing energy consumption?
The manufacture of PPC and PSC have gained momentum over the last few years. PPC is obtained by mixing clinker and gypsum with suitable Pozzolans such as flyash (FA). Composed typically of 60 per cent clinker, 5 per cent gypsum + approximately 35 per cent fly ash. As it prevents cracks, it is useful in the casting work of huge volumes of concrete.
Portland slag cement has a composition of 55-35 per cent clinker, 5 per cent gypsum + 40-60 per cent GGBS of fineness 3,000 to 4,000 blaine. It is thus generally used in water retaining structures or where structure is vulnerable to any form of chemical attack.
Consider the same plant described earlier, manufacturing PPC or PSC with suitable substitution proportions.
The reduction of heat consumption in PPC production (as against OPC) is directly correlated to the substitution percentage. In case of power consumption, depending on the fineness of flyash (FA) obtained, there may be the necessity for inter-grinding FA with the OPC. If the flyash obtained is of acceptable fineness, then the electrical energy consumption will be limited to blending and transportation of FA and overall reduction can be achieved per tonne of cement as shown in Table 2.
For PSC, some heat may be required for drying of slag. However the savings are achieved in overall heat consumption. The slag will have to be ground, preferably separately, before blending with the OPC. In spite of power consumption to the tune of 40 -45 kWh/ton of slag material ,when ground at a fineness of 4000-4200 blaine, as per Table 2, substantial gains are seen in SPC per ton of cement produced.To what extent can IT be harnessed to save energy?
The use of IT and automation are essential to have in two major fronts.1. Improvement of overall equipment efficiency
This has a direct influence on reducing the SEC as described below:

Online monitoring of process and introducing Fuzzy Logic- and Neural Network-based control systems, helps in optimising operations and maintain product quality. Energy savings from process control systems may vary between 2.5 per cent and 10 per cent, and the typical savings are estimated at 2.5-5 per cent. The economics of advanced process control systems are very good and payback periods are quite attractive depending on the status of the plant operation.
The move from breakdown maintenance to reliability-centered maintenance is possible by having remote monitoring of equipment health using IoT and cloud-based data handling systems and reducing unplanned shutdown.
All these factors ensure that the availability of equipment is maximised and rejects are minimised and thereby increasing productivity.
The implementation of MIS (management Information systems) like SAP helps in keeping track of key performance indicators. Management is able to monitor both plant operations and the productivity in a continuous manner.

2. Production planning and inventory management

Plants having multiple cement products and optimise their production plans to meet the dispatch requirements with the implementation of relevant software.
Similarly, the use of the correct mix of fuels, coal, pet coke, alternate fuels can also be managed properly vis-?-vis availability, cost and related process adjustments.
The ordering of equipment spares, refractory and other consumables can be managed to ensure that there are no delays in plant start-up due to procurement related delays.
Automation can be used to run equipment with heavy power consumption during low power tariff durations. This is applicable to the operations of clinker grinding mills and at times the raw mills. The power costs can be tracked in real time and operational modes can be made to adapt to the energy costs.

How cement plants can take advantage of the PAT initiative and RECS?
As per the last report BEE, in the first PAT cycle, the cement sector has saved 1.48 MTOE against a target of 0.815 million MTOE. This indicates that the cement sector has had the best performance amongst the designated consumers.
While measures are taken for reduction of energy consumption by improving operations and upgrading equipment, the use of renewable energy can also help in reducing the gate to gate energy consumption. This has been brought about in the following ways:
1. Increased use of alternate fuels – Currently best Indian plants score between 8-10% substitution whereas Europe has crossed more than 80 per cent, hence there is scope for more utilisation of renewables.
2. Harnessing solar energy – With around 25-30 MW total installations in the Cement Industry, scope exists to increase it considerably in the next 3-4 years. This should go up further since the Government of India’s push for 100 GW of solar capacity by 2022.
3. Installation of Waste Heat Recovery systems – For the 420 MTPA installed capacity, WHR systems have been ordered/ installed of 350 MW capacity with a potential for going up to a total of 1000 MW.
ERCOM has carried out engineering for a 35.5 MW WHR at Gulf cement company Ras Al Khaimah, UAE, which is the largest WHR for a cement plant. Besides carrying out the feasibility and execution of solar power plants, ERCOM assists their clients in the designing of AFR handling and dosing/ firing systems in their existing facilities.BS SRINIVASALU REDDY

Concrete

Grinding aids help in reducing the agglomeration of particles

Published

4 weeks ago

August 23, 2024

Roshna

Lokesh Chandra Lohar, General Manager – Technical and Executive Cell, Wonder Cement, shares insights on overcoming challenges, leveraging innovations and the crucial role of R&D in maintaining high standards in cement production.

Can you provide an overview of the grinding process in your cement manufacturing plant and its significance in the overall production process?
Cement grinding unit is used to grind clinker and gypsum into a fine powder, known as cement. The process of grinding involves grinding of the clinker to a fine powder, which is then mixed with gypsum, fly ash and other additives to produce cement.
At Wonder Cement, our grinding processes are pivotal in ensuring high-quality cement production by utilising state of art technologies ex. Vertical Roller Mill (VRM), roller press with ball mill in combi circuit and finish mode grinding and high-efficiency classifier, have achieved optimal particle size distribution and energy efficiency.
Our commitment to sustainability is evident with usage of energy-efficient equipment, eco-friendly grinding aids and renewable energy sources. Continuous research and development efforts ensure we stay at the forefront of innovations, optimising our grinding operations and minimising impact on the environment.

The main processes involved in a cement grinding unit are:

Clinker grinding: This is the main process in a cement grinding unit, where the clinker is ground into a fine powder using a ball mill or combi mills (RP+ Ball Mill) or vertical roller mill circuit. The grinding process is controlled to achieve the desired fineness of the cement.
Gypsum and other additives: Gypsum is added to the clinker during the grinding process to regulate the setting time of the cement. Other additives such as fly ash, BF slag and pozzolana may also be added to improve the performance of the cement.
Packaging: Once the grinding process is complete, the cement is stored in silos before being packed in bags or loaded into bulk trucks for transportation.
Quality control: Quality control measures are in place throughout the grinding process to ensure that the final product meets the required specifications, including strength, setting time, and consistency.What are the main challenges you face in the grinding process, and how do you address these challenges to maintain efficiency and product quality?
The main challenges in the grinding process include high energy consumption, frequent wear and maintenance, variability in clinker properties, environment impact and ensuring consistent product quality. To address these challenges, we have implemented several strategies:
High energy consumption: Clinker grinding is energy-intensive, and high energy costs can significantly impact the overall production costs of cement.
This is one of the primary challenges in the grinding process.
Use of high-efficiency equipment: We have state-of-the-art energy-efficient grinding equipment, such as vertical roller mills (VRM), Combi Circuit (roller press with ball mill), which consume significantly less energy consumption.
Process optimisation: Real time monitoring and optimisation of the grinding process to minimise energy consumption.
Frequent wear and maintenance: The grinding equipment, such as mills and crushers, is subjected to wear over time. Frequent maintenance and downtime can affect production efficiency.
Regular maintenance: Implement a proactive maintenance schedule to address wear and tear promptly, ensuring the equipment remains in optimal condition.
Proper lubrication: Adequate lubrication of moving parts can extend the lifespan of grinding equipment.
Use of wear-resistant materials for components, which are prone to wear and abrasion.
Variability in clinker properties: Clinker properties can vary from one batch to another, leading to inconsistencies in the grinding process and the quality of the final cement product.
Clinker sources: At Wonder we have one clinker source, which is our mother plant at Nimbahera, Rajasthan and we distribute clinker to various split GU’s from Nimbahera. This helps us to maintain uniform clinker quality across each location.
Quality control: Rigorous quality control measures help us identify and address variations in clinker properties. Adjust grinding parameters as needed to compensate for these variations. (ex. use of cross belt analyser and on-line particle size distribution)
Environmental impact: Energy-intensive grinding processes can have environmental repercussions due to high dust emissions and energy consumption.
Use of high efficiency dust collection and suppression system to keep emissions below statutory norms
Sustainable grinding aids: Consider using eco-friendly grinding aids that enhance grinding efficiency without compromising cement quality and environmental standards.
Alternative fuels: Use alternative and more sustainable fuels in the cement kiln and hot gas generated to reduce carbon emissions.
Use of clean energy in logistics:
To reduce carbon emissions, sustainable alternatives are also sought for inland transport. We have involved neutral internal transports (electric powered trucks).
Automation and digitalisation of production:
Wonder Cement has already initiated the process to implement Smart Cement Industry 4.0.
With Industry 4.0, the automation and digitalisation of operations, including the use of sensors, remote diagnosis, analysis of big data (including the artificial intelligence analysis of unstructured data such as images and video), equipment, virtual facilities, and intelligent control systems will be done automatically (based first on ‘knowledge capture’ and then on machine learning). For Process optimisation we are using the FLS Process expert system (PXP) system. This allows for system optimisation and increased efficiency gains in production.

How do grinding aids contribute to the efficiency of the grinding process in your plant? What types of grinding aids do you use?
Grinding aids help in reducing the agglomeration of particles, thus improving the overall grinding efficiency and ensuring a smoother and more efficient grinding process without having adverse effect on any of the properties of the resulting cement. In cement manufacturing, various types of grinding aids are used to improve the efficiency of the grinding process. These include:

Glycol-based grinding aids

Composition: Ethylene glycol and diethylene glycol.
Usage: Commonly used in to improve the grinding efficiency and reduce energy consumption.

Amine-based grinding aids

Composition: Triethanolamine (TEA) and Triisopropanolamine (TIPA).
Usage: Effective in improving the grindability of clinker and other raw materials, enhancing cement strength and performance.

Polyol-based grinding aids
Composition: Polyethylene glycol and other polyol compounds.
Usage: Used to improve the flowability of the material and reduce the tendency of particles
to agglomerate.

Acid-based grinding aids
Composition: Various organic acids.
Usage: Used to modify the surface properties of the particles, improving the grinding efficiency and final product quality.

Specialty grinding aids

Composition: Proprietary blends of various chemicals tailored for specific materials and grinding conditions.
Usage: Customised to address challenges in the grinding process, such as the use of alternative raw materials or specific performance requirements.

Can you discuss any recent innovations or improvements in grinding technology that have been implemented in your plant?
Recent innovations and improvements in grinding technology:

Selection of state-of-the-art vertical roller mills along with high efficiency classifier (VRMs): VRMs are more energy-efficient and have lower power consumption, leading to significant energy savings. They also provide a more consistent product quality and require less maintenance. For raw meal grinding, we have both VRM and roller press.
Wear-resistant materials and components: Upgrading grinding media, liners and other components with wear-resistant materials. These materials extend the lifespan of the equipment, reduce downtime, and lower maintenance costs. Examples include ceramic liners and high chrome grinding media.
Intelligent monitoring and predictive maintenance: Utilising IoT sensors and predictive analytics to monitor equipment health. Predictive maintenance helps identify potential issues before they lead to equipment failure, reducing unplanned downtime and maintenance costs. It ensures optimal performance and prolongs equipment life.
Optimisation software and simulation tools: Using simulation software to model and optimise the grinding process. These tools help in understanding the process dynamics, identifying bottlenecks, and testing different scenarios for process improvement. This leads to better process control and efficiency.

How do you ensure that your grinding equipment is energy-efficient and environmentally sustainable?

Energy-efficient grinding technologies such as VRMs: VRMs are more energy-efficient than traditional ball mills due to their ability to grind materials using less energy.
Benefits: Up to 30 per cent to 40 per cent reduction in energy consumption.
Use of renewable energy sources (solar power integration): Utilising solar power for grinding operations
Implementation: Signing of long-term open access power purchase agreements (PPA) with renewable energy developers
Benefits: Reduces reliance on fossil fuels, decreases greenhouse gas emissions.

Environmental sustainability practices

a. Dust collection and emission control
Description: Using bag filters, and covered material handling system
Implementation: Installing and maintaining high-efficiency dust control equipment.
Benefits: Reduces particulate emissions, improves air quality, complies with environmental regulations.
b. Water conservation
Description: Recycle and reuse water in the grinding process.
Implementation: Installing sewage treatment plant (STP)
Benefits: Reduces water consumption, minimises environmental impact.
c. Use of alternative raw materials
Description: Incorporating industrial by-products like fly ash, BF slag and chemical gypsum in the grinding process.
Implementation: Sourcing and blending alternative materials.
Benefits: Reduces the need for natural resources, lowers carbon footprint, enhances sustainability.
By implementing these practices, the plant ensures that its grinding operations are both energy-efficient and environmentally sustainable, aligning with industry best practices and regulatory requirements.

What role does research and development play in optimising your grinding processes and the selection of grinding aids?
Following is the role of research and development in optimising grinding processes and selecting
grinding aids:

Testing and usage of new low-cost cementitious material: Dedicated R&D teams work on developing and new low-cost cementitious material to reduce clinker factor in cement and
improve efficiency.
Process simulation and modelling: Uses simulation and modelling tools to understand the dynamics of the grinding process and identify areas for improvement.
Formulation of new grinding aids with reverse engineering: Formulate new grinding aids to enhance the efficiency of the grinding process.
Testing and evaluation: Conducting laboratory and plant-scale tests to evaluate the effectiveness of different grinding aids.
Collaboration with industry partners: Collaborating with suppliers, universities and research institutions to stay at the forefront of grinding technology advancements.

Research and development play a crucial role in optimising grinding processes and selecting the appropriate grinding aids. By focusing on innovation, process optimisation, sustainability and continuous improvement, R&D ensures that the plant remains competitive, efficient, and environmentally responsible. This commitment to research and development enables the plant to achieve higher productivity, lower costs and produce superior quality cement.

What trends or advancements in grinding processes and grinding aids do you foresee impacting the cement manufacturing industry in the near future?
The trends and advancements in grinding processes and grinding aids that we see coming up in the near future are:

1. Digitalisation and Industry 4.0

Advanced process control (APC) and automation
Internet of things (IoT) and predictive maintenance
Artificial intelligence (AI) and machine learning (ML)

2. Energy efficiency and sustainability

Energy-efficient grinding technologies
Use of renewable energy

3. Innovations in grinding aids

Eco-friendly grinding aids
Tailored grinding aids
Multifunctional grinding aids

4. Advanced materials and components

Wear-resistant materials for liners
High-density grinding media

5. Process optimisation and integration

Holistic process optimisation

6. Sustainability and circular economy

Circular economy practices
Carbon capture and utilisation (CCU)

– Kanika Mathur

Concrete

Shaping the Future

Published

2 months ago

July 16, 2024

admin

Jigyasa Kishore, Vice President Enterprise Sales and Solutions, Moglix discusses the critical role of cement capacity expansion in India’s infrastructure development, highlighting the importance of technological advancements, sustainability and strategic investments amid market challenges.

With an installed cement capacity of 600 million tonnes, India is the second-largest cement producer in the world. Cement consumption in India is expected to reach 450.78 million tonnes by the end of FY27, owing to rapid urbanisation and smart city development plans. Infrastructure, typically, receives the most funding from the government which bodes well for the cement industry. At a time when India is urbanising and building infrastructure at breakneck speed, the role of cement capacity expansion is becoming critical. This expansion, today, supports the market demands as well as contribute towards the nation’s economic ambitions.

Setting a firm foundation
Cement is an essential component in the construction of any nation. Roads and bridges, airports and public buildings all indicate cement’s critical importance in infrastructure development. Urbanisation is fuelled by it through the creation of housing projects aimed at achieving economic growth and development. Here’s why capacity expansion of cement production is critical:
Urbanisation: The demand for cement increases as urbanisation intensifies. This is further evidenced by the budget estimate for the Pradhan Mantri Awas Yojana for affordable housing, which has been pegged at US$ 9.63 billion (Rs.79,590 crore) for the first time, registering an increase of 66 per cent over the previous year’s budget.
Major infrastructure projects: Large infrastructure projects like highways, bridges, and city-development require considerable quantities of cement. Capacity expansion can ensure steady supplies of good-quality cement to these large-scale projects and see their timely and expeditious completion. The National Infrastructure Pipeline (NIP) has been widened to 9,735 projects worth $1,828.48 billion. Many of the upcoming projects will be heavily dependent on the cement industry. In addition, the PM Gati Shakti National Master Plan for infrastructure is further driving up the
cement demand.
Employment Generation: Increased production capacity directly results in job creation in the cement industry. Additionally, a corresponding demand for further employment in complementary sectors such as construction, logistics, and retail is also generated. This bolsters holistic economic development and prosperity.
Regional Economic Growth: New cement plants are often set up in regions with abundant raw materials but stunted industrial development. By setting up new plants in these regions, local resources can be leveraged and the overall growth story of the region can be improved. For instance, Dalmia Bharat recently announced a $10.9 million investment for further expansion of its already existing cement plant in the small town of Banjari in Bihar. The increasing presence of small and mid-size cement players across various regions helps dilute market concentration of industry leaders, leading to a more competitive and diverse market landscape.

Reinforcing the Structure
India’s cement industry is currently experiencing a tough fiscal year and there has been a downturn in pricing. Moderate demand is expected for H1FY25. Temporary setbacks such as labour shortage and heavy monsoons have also caused the demand for cement to take a dip in the past couple of months.
Needless to say, expanding capacity during periods of subdued demand involves risk. Cost implications of such investments can be significant. And firms could fail to recoup their investments if market conditions don’t improve as planned. Over-expansion could also result in an oversupplied market and further impact the prices as well as profit margins. Cement producers are currently under pressure due to reduced prices and slow demand. While this price dip might adversely affect profits in the short term, it could be seen as market adjustment ahead of a surge in anticipated demand during the second half of the fiscal year
Periods of uncertainty can be looked at as opportunities for companies to diversify risks and invest in innovation. Developing and launching new cement products for specific use-cases would contribute to the top line. Targeting export markets for better demand can also ensure the optimal use of additional capacities. At the same time, focusing on operational efficiencies would help the companies keep the cost of production in check.
New investments made in cement production facilities automatically come with the latest technological advancements that can enhance efficiency, minimise environmental impacts, and improve the quality of cement. This leads to construction practices that are more durable and sustainable. JSW, for instance, has initiated research on the integration of supplementary cementitious materials (SCMs) like fly ash, slag, calcined clay, and more. These materials not only improve the durability and strength of cement but also contribute towards reduction of carbon footprint of the cement industry. In order to meet energy demands sustainably, we must look at better industry practices such as usage of waste heat recovery systems, high-efficiency coolers and preheaters, and transition towards clean energy sources like solar or wind power.
There is also a growing need for cement companies to become environmentally conscious. Modern cement plants are increasingly adopting greener technologies owing to the decarbonisation pressure. Capacity expansion while keeping sustainability at its core will help check environmental impact of cement production while also aligning with the challenging global environment-conservation goals. Recently, UltraTech announced that it had received Environmental Product Declaration (EPD) certificates for four of its cement products. Similarly, Dalmia Bharat (Cement) has announced plans to produce 100 per cent low-carbon cement by 2031 and has a US$ 405 million carbon capture and utilisation (CCU) investment plan to achieve this goal. Such efforts are laudable and set a fine example for all industry players.

Shaping a Stronger Nation
Cement capacity expansion is a strategic move for the Indian cement industry. While short-term market fluctuations present challenges, continued investment in capacity expansion reflects a long-term vision for shaping India’s future infrastructure landscape. The current economic climate demands agility and innovation from Indian cement players. The leaders need to lead by example. By adopting industry best-practices, aiming for sustainable development, and working towards continuous growth and advancement, the cement industry is sure to rise like a phoenix from the ashes.

About the author
Jigyasa Kishore comes with 15+ years of experience at building brands, enabling enterprise growth, and transforming organisational performance with a technology-first approach. At Moglix, she leads brand growth as a digital supply chain solutions architect for large manufacturing enterprises.

She is an alumnus of the Indian

School of Business, Hyderabad, and Bangalore University.

Concrete

Filtration can help to control climate change

Published

5 months ago

April 16, 2024

admin

Niranjan Kirloskar, Managing Director, Fleetguard Filters, elaborates on the importance of filtration and its profound impact on efficiency, longevity and environmental sustainability.

Tell us about the core principle of filtration.
Filtration is segregation/separation of matter by density, colour, particle size, material property etc. Filtration is of four basic types:

Separation of solids from gas
Separation of solids from liquids
Separation of liquids from liquids
Separation of Solids from solids.

As applied to engines/equipment, the main objective of filtration is to purify the impurities and provide the desired fluid or air for enhanced engine/equipment performance in turn optimising their performance and life.

Can better filtration bring productivity to the work process? How?
Better filtration can improve the quality of application performance in multiple ways. Filtration improves engine performance as it filters and prevents dirt, dust, and debris from entering into the engine. This ensures that the quality of air or fluid that reaches the combustion chamber is as per the specific requirements of optimal performance of the engine. It also extends engine life by filtering out contaminants. Efficient filtration ensures optimal performance of the engine/equipment over its entire operating life. Filtration also improves fuel efficiency as a clean filter allows for a better air-fuel mixture in the engine, thus improving combustion efficiency, which in turn results in better fuel economy. It keeps emissions under control as fuels burn more efficiently leading to lesser harmful residue in the environment. Thus, to sum up, an optimal filtration solution ensures better performance, prolonged engine life and less hazardous waste in the environment.

What is the role of technology in the process of filtration?
Innovation, research and development as well as technology play a pivotal role in catering to the ever-evolving environmental norms and growing market demands. At FFPL we have NABL Accredited labs for testing, we have ALD Labs for design, and a team of R&D experts constantly working on providing advanced solutions to cater to the evolving market needs. We have robust systems and advanced technologies that make high-quality, high-precision products. Our state-of-the-art manufacturing facilities use advanced technologies, automation, robotics and also Industry 4.0 as applicable to provide the best products to our customers. To ensure each product delivered to market is of utmost precision, advanced quality equipment such as CMM, scanning systems and automated inspection technologies for real-time monitoring and quality control during the manufacturing of filtration systems and to comply with standard quality requirements are used.

Tell us about the impact of good filtration on health and the environment.
Good filtration of equipment is to the environment what a good respiratory system is to the body. There are various benefits of an efficient air filtration system as it improves the air quality by ensuring optimum combustion of fuel thereby reducing/controlling emissions to the environment. Efficient lube filtration ensures low wear and tear of the engine thereby extending life of the engines and maintaining optimal performance over the entire operating life of the engine. Efficient fuel filtration ensures low wear and tear of expensive and sensitive fuel injection thereby ensuring perfect fuel metering resulting in best fuel efficiency and saving of precious natural resources. This efficient filtration can help to control climate change as it reduces the carbon footprint due to combustion in the environment.

Can your products be customised and integrated with other machinery?
Fleetguard Filters have been known as a leading solutions provider for decades. With relevant experience and close customer relations, we understand the market/applications requirements and develop solutions to address the pressing technical challenges our customers face concerning filtration solutions. Filters can be customised in terms of size, shape and configuration to fit specific requirements. Customised filters can be designed to meet critical performance requirements. Filtration systems can be designed to integrate seamlessly with any auto and non-auto application requirements.

What are the major challenges in filtration solutions?
Major challenges faced in filtration solutions are:

With every emission regulation change, filtration requirements also keep changing.
Engines are being upgraded for higher power ratings.
Space for mounting filtration solutions on vehicles/equipment is shrinking.
For fuel injection systems, the water separation efficiencies are becoming more and more stringent, so are particle separation efficiencies.
Due to next level filtration technologies,filtration systems and filter elements are becoming expensive, thereby increasing TCO for customers.
Customers prefer higher uptimes and longer service intervals to ensure lower maintenance and operating costs.

We, at Fleetguard, strive continuously to ensure that all the pains experienced by our customers are addressed with the fit to market solutions. Balancing the cost of filtration solutions with their performance and durability can be challenging, especially where the requirements of high filtration standards are required. Also, wrong disposal methods for used filters can have environmental impact.