Technology

“Waste Heat Recovery” maximisation in clinker cooler systems

Published

8 years ago

April 30, 2018

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New technologies from FLSmidth are helping to maximise waste heat recovery for today’s cement producers – without compromising recuperation efficiency.
As cement producers are continually looking to improve the performance of their existing assets, many are seeing the upsides of bringing waste heat recovery into the production process. In particular, integrating a waste heat recovery system (WHRS) into the clinker cooler is highly attractive, providing compelling reasons for retrofitting and upgrading the clinker cooler.
But producers face several challenges if they are to get the full benefit, including the need to balance specific fuel consumption against waste heat recovery power generation. The key is to maximise waste heat recovery, while maintaining high recuperation efficiency. Seeking greater productivity
Coolers are often the cause of operational bottlenecks. Reduced recuperation efficiency, increased vent losses, high clinker temperature and insufficient heat input to the WHRS boiler are just a few. These bottlenecks add to the complexity of day-to-day operations and maintenance, creating inefficiencies in the pyro processing systems and ultimately undermining the plant’s commercial performance.
Fortunately, coolers that include waste heat recovery technology are providing cement producers with compelling opportunities to improve equipment efficiency and plant productivity. Cooler performance is to be optimised prior to WHRS integration.
The performance of clinker coolers is not just about recuperation efficiency and energy ; it is also necessary to consider maximum heat recovery for WHRS generation. A common assumption is that an efficient cooler can only support higher recuperation and, in turn, provide lower heat for the WHRS. But it is possible to improve cooler recuperation efficiency and WHRS performance via FLSmidth Cross-Bar? cooler – through supplying more heat to the WHRS boiler – by using innovative cooler concepts, such as hot air recirculation from the cooler stack. Solution for maximising WHRS
Applying innovative technologies to achieve energy-efficient pyro processing solutions is a key focus area for FLSmidth, which has supplied equipment and services to the cement industry for more than 135 years. FLSmidth has pioneered the development of WHRS to optimise heat recuperation and energy efficiency in clinker cooler systems. Integrating WHRS into the FLSmidth
Cross-bar? cooler is ideal for either new coolers or retrofits. This combined solution sets industry benchmarks in recuperation efficiency, power consumption, maintenance costs and overall reliability. It enables the recirculation of hot air, maximising heat recovery from mid-air for WHRS generation. Hot air recirculation concept
The cooler’s hydraulic cylinders can be relocated such that hot air recirculation is made available to most of the compartments as necessary to improve mid-air temperature and volume. All under-grate components, including support rollers, bearings, seals and lamps, are designed to operate at a hot air recirculation temperature of approximately 130?C.
The hot air is recirculated into selected cooling fans supplying air to the mid-air zone. There are no hazards associated with hot air recirculation into the cooler’s compartments, and this concept can be easily integrated into the cooler layout.
All essential safety aspects and operational parameters have been considered in the design. This includes hot air fans being placed on one side, careful duct routing to avoid unwanted pressure drop, and the shut off and bleed air dampers being positioned correctly at the hot air recovery duct. The recirculation of hot air provides approximately 15-20 percent more heat for mid-air.
FLSmidth has successfully delivered solutions for recirculating hot air to clinker coolers since the early 1980s.
Through the years, different solutions have been developed depending on the specific needs of the facility. Especially for coolers in the US and Canada, the driving force is to meet emission regulatory requirements, where emissions of cooler vent air – both partial and full – are highly undesirable. Essentially, solutions here involve reintroducing the vent air into the cooler compartments as well as modifying the ducting and cooler control scheme to allow hot air recirculation. For coolers in Korea, India and Nepal, the main objective is to maximise WHRS generation.
Crucially, any FLSmidth cooler can be upgraded to include hot air recirculation. The solution can either have partial or 100 percent recirculation, depending on the project’s specific needs and maximising waste heat recovery potential.Making the best even better
FLSmidth Cross-Bar? cooler design alongwith WHRS integration have made it possible to meet customer demands like reduce vent losses, improve recuperation efficiency, and maximise WHRS generation.
Cement producers choose to implement innovative technology, consider hot air recirculation from stack to cooler compartment’s so as to maximise waste heat recovery without compromising efficiency of clinker cooler.Author: G Renga Prasad, Product Line Manager-Pyro, FLSmidth.

Key benefits:

High reliability and availability
Minimum maintenance
Sustainable, optimised performance
Maximised WHRS power generation
Faster payback of investment
Low total cost of ownership

Technology

ARAPL Reports 175% EBITDA Growth, Expands Global Robotics Footprint

Affordable Robotic & Automation posts strong Q2 and H1 FY26 results driven by innovation and overseas orders

Published

2 months ago

October 15, 2025

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Affordable Robotic & Automation Limited (ARAPL), India’s first listed robotics firm and a pioneer in industrial automation and smart robotic solutions, has reported robust financial results for the second quarter and half year ended September 30, 2025.
The company achieved a 175 per cent year-on-year rise in standalone EBITDA and strong revenue growth across its automation and robotics segments. The Board of Directors approved the unaudited financial results on October 10, 2025.

Key Highlights – Q2 FY2026
• Strong momentum across core automation and robotics divisions
• Secured the first order for the Atlas AC2000, an autonomous truck loading and unloading forklift, from a leading US logistics player
• Rebranded its RaaS product line as Humro (Human + Robot), symbolising collaborative automation between people and machines
• Expanded its Humro range in global warehouse automation markets
• Continued investment in deep-tech innovations, including AI-based route optimisation, autonomy kits, vehicle controllers, and digital twins
Global Milestone: First Atlas AC2000 Order in the US

ARAPL’s US-based subsidiary, ARAPL RaaS (Humro), received its first order for the next-generation Atlas AC2000 autonomous forklift from a leading logistics company. Following successful prototype trials, the client placed an order for two robots valued at Rs 36 million under a three-year lease. The project opens opportunities for scaling up to 15–16 robots per site across 15 US warehouses within two years.
The product addresses an untapped market of 10 million loading docks across 21,000 warehouses in the US, positioning ARAPL for exponential growth.

Financial Performance – Q2 FY2026 (Standalone)
Net Revenue: Rs 25.7587 million, up 37 per cent quarter-on-quarter
EBITDA: Rs 5.9632 million, up 396 per cent QoQ
Profit Before Tax: Rs 4.3808 million, compared to a Rs 360.46 lakh loss in Q1
Profit After Tax: Rs 4.1854 lakh, representing 216 per cent QoQ growth
On a half-year basis, ARAPL reported a 175 per cent rise in EBITDA and returned to profitability with Rs 58.08 lakh PAT, highlighting strong operational efficiency and improved contribution from core businesses.
Consolidated Performance – Q2 FY2026
Net Revenue: Rs 29.566 million, up 57% QoQ
EBITDA: Rs 6.2608 million, up 418 per cent QoQ
Profit After Tax: Rs 4.5672 million, marking a 224 per cent QoQ improvement

Milind Padole, Managing Director, ARAPL said, “Our Q2 results reflect the success of our innovation-led growth strategy and the growing global confidence in ARAPL’s technology. The Atlas AC2000 order marks a defining milestone that validates our engineering strength and accelerates our global expansion. With a healthy order book and continued investment in AI and autonomous systems, ARAPL is positioned to lead the next phase of intelligent industrial transformation.”
Founded in 2005 and headquartered in Pune, Affordable Robotic & Automation Ltd (ARAPL) delivers turnkey robotic and automation solutions across automotive, general manufacturing, and government sectors. Its offerings include robotic welding, automated inspection, assembly automation, automated parking systems, and autonomous driverless forklifts.
ARAPL operates five advanced plants in Pune spanning 350,000 sq ft, supported by over 400 engineers in India and seven team members in the US. The company also maintains facilities in North Carolina and California, and service centres in Faridabad, Mumbai, and San Francisco.

Technology

M.E. Energy Bags Rs 490 Mn Order for Waste Heat Recovery Project

Second major EPC contract from Ferro Alloys sector strengthens company’s growth

Published

2 months ago

October 15, 2025

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M.E. Energy Pvt Ltd, a wholly owned subsidiary of Kilburn Engineering Ltd and a leading Indian engineering company specialising in energy recovery and cost reduction, has secured its second consecutive major order worth Rs 490 million in the Ferro Alloys sector. The order covers the Engineering, Procurement and Construction (EPC) of a 12 MW Waste Heat Recovery Based Power Plant (WHRPP).

This repeat order underscores the Ferro Alloys industry’s confidence in M.E. Energy’s expertise in delivering efficient and sustainable energy solutions for high-temperature process industries. The project aims to enhance energy efficiency and reduce carbon emissions by converting waste heat into clean power.

“Securing another project in the Ferro Alloys segment reinforces our strong technical credibility. It’s a proud moment as we continue helping our clients achieve sustainability and cost efficiency through innovative waste heat recovery systems,” said K. Vijaysanker Kartha, Managing Director, M.E. Energy Pvt Ltd.

“M.E. Energy’s expansion into sectors such as cement and ferro alloys is yielding solid results. We remain confident of sustained success as we deepen our presence in steel and carbon black industries. These achievements reaffirm our focus on innovation, technology, and energy efficiency,” added Amritanshu Khaitan, Director, Kilburn Engineering Ltd

With this latest order, M.E. Energy has already surpassed its total external order bookings from the previous financial year, recording Rs 138 crore so far in FY26. The company anticipates further growth in the second half, supported by a robust project pipeline and the rising adoption of waste heat recovery technologies across industries.

The development marks continued momentum towards FY27, strengthening M.E. Energy’s position as a leading player in industrial energy optimisation.

Technology

NTPC Green Energy Partners with Japan’s ENEOS for Green Fuel Exports

NGEL signs MoU with ENEOS to supply green methanol and hydrogen derivatives

Published

2 months ago

October 15, 2025

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NTPC Green Energy Limited (NGEL), a subsidiary of NTPC Limited, has signed a Memorandum of Understanding (MoU) with Japan’s ENEOS Corporation to explore a potential agreement for the supply of green methanol and hydrogen derivative products.

The MoU was exchanged on 10 October 2025 during the World Expo 2025 in Osaka, Japan. It marks a major step towards global collaboration in clean energy and decarbonisation.
The partnership centres on NGEL’s upcoming Green Hydrogen Hub at Pudimadaka in Andhra Pradesh. Spread across 1,200 acres, the integrated facility is being developed for large-scale green chemical production and exports.

By aligning ENEOS’s demand for hydrogen derivatives with NGEL’s renewable energy initiatives, the collaboration aims to accelerate low-carbon energy transitions. It also supports NGEL’s target of achieving a 60 GW renewable energy portfolio by 2032, reinforcing its commitment to India’s green energy ambitions and the global net-zero agenda.