Environment

What after Petcoke?

Published

6 years ago

January 12, 2019

admin

India annually consumes around 27 MT of pet coke. It is nothing but a dark solid carbon material left out by petroleum refineries that emit 11 per cent more greenhouse gases than coal. In August 2018, the Supreme Court put restrictions on free import of pet coke. The authors look at the options for the cement industry.

Petcoke has been under scrutiny since October 2017 when the Supreme Court first put a ban on its usage in Delhi, which it later relaxed for the cement industry. However, a nationwide ban on petcoke, or at least restrictions on its import and usage, is still not off the table. In July 2018, the Union Ministry of Environment told the Supreme Court that it was undertaking a study on the petcoke ban before deciding on imposing a ban on its import.

Energy consumption is a fundamental indicator of a country’s social and economic development. Broadly, our industrial sector is one of the largest consumers of energy (> 270 million tonne of oil equivalent or MTOE). It includes energy intensive industries like iron and steel, chemical, textiles, aluminium, fertilisers, cement, and paper and pulp, which together account for more than half of the energy consumed. It is for such industries that petcoke, along with low-cost coal, and furnace oil, serves as primary fuel. These industries thus account for a large amount of carbon dioxide (CO2) and particulate matter emissions in India.

The cement industry
Over 70 per cent of the fuel requirement of cement manufacturers in India is met through petcoke. Cement manufacturing is an emission and energy intensive process and was responsible for 218 MT of CO2 emissions in 2013 with close to 40 per cent of the emissions resulting from combustion of fuel to operate the kilns. Historically, the cement industry used coal but in the past few decades it has moved to the cheaper and ubiquitous alternatives – petcoke and furnace oil. Petcoke usage in the cement industry increased at a compounded annual growth rate of 24 per cent from financial year (FY) 13-17. Petcoke has high calorific value (34.8 mega joules/kg), but also contains a high amount of sulphur (five to seven weight per cent) and vanadium (up to 500 parts per million) that cause corrosion and are responsible for toxic emissions, especially in their present application as fuel for boilers/furnaces. In fact, the global cement industry contributes to five per cent of the world’s CO2 emissions. Petcoke and other cheap, highly polluting fuel such as furnace oil are widely used by cement factories.

Options for the industry
There is a need to explore a low-emission pathway powered by innovative, smart and locally relevant solutions. Moving from carbon-intensive fuels to fuels with a high hydrogen-to-carbon (H/C) ratio can reduce CO2 emissions. While natural gas and electricity (preferably generated from renewable sources) exist as cleaner alternatives to coal or petcoke, the competitive uses and cost of generation respectively might lead to dearth in availability. Efficient fuel utilisation with reduced emissions and substitution of conventional fuels with alternative fuels is a viable two-pronged approach to reduce emissions in cement manufacturing.

Petcoke gasification, a proven thermo-chemical technology for conversion of solid fuel to gaseous fuel, can be employed for petcoke’s conversion to producer gas, which is a mixture of carbon monoxide, hydrogen and methane. This can be combusted in the furnace and would yield much less particulate matter without compromising on the energy content. In addition to this, the producer gas generated from the petcoke’s conversion can be converted to chemicals such as methanol and dimethyl ether (these are also alternative fuels) that emit less particulate matter on combustion. Conversion of petcoke to products such as methanol and dimethyl ether (DME) will also be point of interest for Indian refineries, where petcoke is generated as part of the crude oil refining process, as methanol and DME blending options are recommended in India’s biofuel policy.

Alternative fuels can be further employed as a long-term method to bring about emission reduction. Waste materials such as agro-residues (paddy straw) and agro-industrial residues (wood chips, waste wood, rice husk, sawdust), municipal solid waste, sewage sludge, refuse derived fuel from paper and pulp industry, etc. are examples of alternative fuels for application in the kiln. However, moving towards these resources is not free of qualitative and environmental challenges due to their heterogeneous nature and composition. Some examples are high silica content (78 to 90 per cent) of rice husk ash or chlorine from polyvinyl chloride (PVC) in municipal waste. In this case, gasification and pyrolysis can be used to produce gaseous and liquid fuels of uniform quality from the above-mentioned waste streams alone or along with petcoke, which can then be used more effectively in the cement kilns. Waste heat recovery for cogeneration of power, production of composite cement using slag and fly ash, and government push in terms of stricter emission norms will further create opportunities to establish a cleaner cement industry.

Actions required at all levels
Increasing awareness among the public and in the government about CO2 and particulate matter emissions from the cement industry is a positive development in terms of pressure to aggressively reduce the industry’s emissions, which would also help mitigate the rising smog in Delhi and other cement industry hubs in India. The use of alternative fuels is likely to raise production prices. Cement industries could also shift to imported coal. However, it is approximately 15 per cent more expensive than petcoke and would require a price hike of about Rs 10 per bag to sustain production. This burden would likely be shifted to the end user. At present though, there is not enough clarity as to whether the cement industry’s current growth rate would be able to meet the rise in price or will industries have to bear the brunt of the increased expenses to ensure that their inventories are cleared. There is a lacuna between the policy directives and scope of implementation, which can be addressed by a continuous dialogue between stakeholders, the government and the general public. Both, improved infrastructure and public health concerns due to rising pollution have to be considered if measures such as fuel replacement are to prove successful in the long run. It is high time that energy and emission intensive industries such as cement take initiatives to start exploring and adopting clean fuels and technologies apart from their energy efficiency efforts. Technologies such as gasification and pyrolysis will play a significant role in this pursuit.

ABOUT THE AUTHORS:

The authors – Anshu Yadav and Anubhuti Bhatnagar – are from TERI (The Energy and Resources Institute), New Delhi.

Concrete

India donates 225t of cement for Myanmar earthquake relief

Published

2 weeks ago

June 17, 2025

admin

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

Concrete

Reclamation of Used Oil for a Greener Future

Published

2 weeks ago

June 16, 2025

admin

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

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

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

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

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

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

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

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

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

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

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

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

Concrete

Charting the Green Path

Published

2 months ago

May 13, 2025

admin

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