Connect with us

Environment

“We will focus on utilising sustainable biomass”

Published

on

Shares

Berthold KRen, Business Head, Geocycle India

What are the main AFR materials you are using in your plants in India?
Geocycle India is co-processing materials ranging from industrial hazardous and non-hazardous waste such as sludges, waste solvents, packaging waste, date expired medicines, trade rejects etc. to agricultural residues and sorted combustible fraction of municipal waste. In general, Geocycle is targeting to use only non recyclable wastes for the thermal use, and indeed mineral waste, that is recycled in the kilns and used for its mineral content. By doing so Geocycle is not only reducing the exploitation of natural resources for fossil fuels, limestone, iron, alumina and silica but also contributing significantly to reduce the volume of waste that is landfilled in India.What is the level of energy efficiency you have achieved?
Geocycle India has set up state-of-the-art infrastructure and facilities for sustainably managing a large volume of waste. These seven dedicated state-of-the-art pre-processing facilities with installations for blending liquids, shredding solids and sludges and homogenising waste prior to its co-processing have allowed Geocycle to handle large volumes of waste safely and sustainably. Through co-processing these wastes with proper OH&S arrangements, Geocycle has ensured that any energy and material value inherent in them can be utilised and has reached up to 5 per cent TSR in its kilns. The energy efficiency of our cement kilns is more than 80 per cent. This is much higher than any other thermal waste to energy process and on top of it does not provide any residues for landfilling.To what extent Indian cement companies are exploiting AFR compared to global benchmarks?
The level of co-processing of wastes being implemented in the cement plants depends upon the location of the plant and the available waste and agricultural residues around it.
All developed nations globally have utilised cement kilns in their countries as an important part for an effective waste management plan for the country and a viable outlet for industrial, municipal and hazardous waste disposal. The cement industry has become an important part in the national and local waste management plans in many industrial countries, especially where landfilling is reduced to a bare minimum to reduce the landfilling footprint, water and air pollution.
Some cement players in India have taken the lead in AFR utilisation but, the current thermal substitution rate (TSR) in Indian cement industry, on an average, is less than 2% as compared to some European countries that have a thermal substitution rate as high as 40%. What are the challenges companies faces in sourcing AFR materials, and what are the strategies you follow?
The cement companies are offering a service of waste disposal. We utilise the waste, and convert it safely to fuel and raw material, which demands a significant amount of investment and cost. Dealing with waste can be challenging and requires specialised capabilities. While the heterogeneous nature and varying chemical composition of various waste streams poses a challenge in itself, an additional challenge stems from the fact that obtaining the necessary permits for disposal and co-processing waste in cement kilns may be difficult and can require long time in some cases in spite of the recent positive updates in the policy landscape.
Geocycle ensures regulatory compliance, highest health and safety standards as well as traceability, and offers complete destruction of waste material while ensuring its inherent energy and material value is utilised. Our innovative and tailored solutions provide an answer to the challenges faced by waste generator and also help cement industry contribute to saving natural resources.
Geocycle’s pre-processing facilities have adequate safety arrangements ranging from avant- garde fire detection and suppression systems, full-fledged waste testing laboratories and adequate infrastructure ensuring environmental protection. All of Geocycle’s pre-processing facilities are ISO certified and are subject to regular internal and external audits and are staffed with a team of well-trained, highly experienced and professional waste management experts ensuring highest standards of safety, control and quality.
Geocycle is now also focussing on partnering with municipalities across the country for providing solutions for management of sorted, non-recyclable municipal waste. In terms of earnings, how beneficial is this for your company?
As mentioned earlier for safe co-processing, special pre-processing infrastructure needs to be set up so that large waste quantum can be managed. Geocycle has already invested around Rs 6 billion in setting up seven dedicated pre-processing facilities for the purpose and both ACC and ACL are determined to continue that path as we see this also as a contribution to a sustainable business and as a more viable business opportunity for the future. Indeed there is a significant cost to run and enable the kilns to utilise waste, but with a proper quantum of waste in the future this will as well become a beneficial business.
The pre-processing of waste and other material such as agricultural residues ensures that a compatible fuel mix is prepared such that the energy and material value inherent in the waste can replace a part of natural resources utilised in the cement kilns. This basically means cement kilns get substitution benefit to a certain extent if proper processes and systems for waste / AFR utilisation are adopted.What are the long-term plans for improving energy efficiency in your plants?
In the long term while partnering with Industries to provide sustainable solutions for industrial waste, Geocycle will continue to focus on utilising sustainable biomass as well as sorted, non-recyclable, combustible fraction of municipal waste (the
RDF /SCF), ensuring that while these streams are sustainably managed, the energy efficiency of the plants is also improved in parallel and CO2 emissions can be reduced.
Geocycle India together with ACC and ACL are determined to reach international standards with AF rates over 40 per cent and even compete with the global top performers within the LH Group where sustainably AF rates of more than 90 per cent are achieved.

Continue Reading
Click to comment

Leave a Reply

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

Concrete

India donates 225t of cement for Myanmar earthquake relief

Published

on

By

Shares

On 23 May 2025, the Indian Navy ship UMS Myitkyina arrived at Thilawa (MITT) port carrying 225 tonnes of cement provided by the Indian government to aid post-earthquake rebuilding efforts in Myanmar. As reported by the Global Light of Myanmar, a formal handover of 4500 50kg cement bags took place that afternoon. The Yangon Region authorities managed the loading of the cement onto trucks for distribution to the earthquake-affected zones.

Continue Reading

Concrete

Reclamation of Used Oil for a Greener Future

Published

on

By

Shares

In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.

The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.

The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.

Circular economy in lubricants
In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt, and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.

Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.

Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)

The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.

On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:

  • Kinematic Viscosity
  • Flash Point
  • Total Acid Number
  • Moisture / Water Content
  • Oil Cleanliness
  • Elemental Analysis (Particulates, Additives and Contaminants)
  • Insoluble

The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.

Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.

About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

Continue Reading

Concrete

Charting the Green Path

Published

on

By

Shares

The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

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

 


    This will close in 0 seconds