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Switching to AFR using emerging & efficient technology

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KHD Humboldt Wedag has state-of-the-art solutions for wide range of fuels and the same are being updated from time to time as per the demands of industry.

KHD Humboldt Wedag has vast experience in the field of providing latest state-of-the-art technologies and keeping-up the solutions ahead of the market requirement. The consistent market share for last 160 years is the benchmark that we have set-in and this legacy is continued with much more thrust in last 10 years. Coming to Alternative Fuels and Raw material (AFR) applications, we have diversified solutions depending up on the type of alternative fuel the end Customer wants to use. Snapshot of the product portfolio is summarised below:

PYRO-JET? AFR Kiln Burner: KHD has specially designed PYRO-JET? AFR kiln burner for maximum utilisation of alternative fuels. The unique features of this burner enables perfect flame shaping and mixing of fuels with oxygen from primary air and secondary air, faster AFR burn-out in the entrained phase, stable ignition and maintaining hot sintering zone due to better flame characteristics. For higher alternative fuel substituiton rates, the specially designed AFR retractable swirl nozzle is also configured in the system to make surte that fracturing, mixing of the AF flow achieved shortly before entering the kiln with appropriate spraying angle and improving the mixture within the flame core and with oxygen.

Alternative fuels such as plastic, paper foil, rice husk, RDF, saw dust, wood ships etc. with acceptable feed size can be fired in the kiln with this burner. Also, liquid alternative fuels such as solvent, pharmaceutical waste, etc. can be used in this burner with additional guide tube and associated valve train system.

PYROCLON? Calciner: Over the years, KHD has continuously improved the calciner systems to accommodate firing options to use wide range of alternative fuels. The KHD trade mark tubular calciners are perfect choice for firing coarse solid AFR, due to well balanced velocity and retention time inside the calciner. Patented PYROTOP?, part of the calciner takes care of mixing of fuel with gas & meal and also increases the retention time.

PYROCLON? R Calciner: Suitable for solid fuels with 2D size of <40 mm which can be lifted in the gas and easy to ignite.

PYROCLON? R Extended Calciner: Suitable for solid fuels with 2D size of <50 mm which can be lifted in the gas and easy to ignite.

PYROCLON? R Calciner + Combustion Chamber: Suitable for solid fuels with 2D size of <100 mm which are coarse and difficult to ignite. High calciner volume and additional residence time will be achieved with Combustion chamber. Start of combustion in pure tertiary air, open flame and center of combustion chamber is nearly kept free from meal leads to faster ignition. Additional mixing will be achieved at transition point of combustion chamber to calciner tube.

What are the advantages of this equipment and where they are installed?
In greenfield cement plants, the solutions discussed above can be integrated in the system design with minimal Capex to achieve maximum benefits. Also, in existing plants, most of these solutions can be introduced looking in to the layout feasibility. Solutions such as Burner, calciner, etc. are anyway required for clinker manufacturing process. Adopting them for suitable AFR usage can lead to advantages in terms of higher AFR substitution. The process advantages of these solutions are already discussed above.

We have AFR feeding and dosing installation references with renowned cement houses like UltraTech, Lafarge (now Nuvoco), Jaypee Cement (now UltraTech), J K Cement, etc.

What are the changes that have to be made in the process for installing these equipment?
In existing systems suitable adoptions in layout to be accounted for and in some cases tailor-made solutions to be exercised due to compact layouts. Further, looking in to the chemical composition, physical properties such as moisture etc. of fuels and its heat value, one has to review the capacity of Preheater fan. More often than not, the exhaust gas volume tend to increase with AFR usage at base clinker production rate.

It is necessary to have certain design margin for trouble free operation. Further, with respect to the chemical composition and circulating elements viz. Cl and S, necessary precautions to be incorporated in the system to avoid heavy build-ups, jamming issues by installing air blasters, compressed air rings at appropriate locations and if necessary bypass arrangement of kiln gases to minimise the operational constraints. Also, raw mix to be reviewed and optimised with respect to type of AFR usage.

How do they impact operating and capital costs? What are the factors one has to look into while selection of AFR materials?
For any alternative fuel usage, a detailed study is mandatory before going ahead with the execution of project. Of course, the availability of alternative fuels is one of the main criterions to be taken in to consideration. The capital costs are one time investment and should be evaluated on case to case basis looking in to the technology, reliability, availability of the system.

The overall operating cost is combination of lot of factors such as impact of AFR on specific power consumption, specific fuel consumption due to increased moisture and excess air requirement. Further detailed analysis to be exercised on the critical chemical components, which will influence the clinkerisation process such as sulphur, chlorine etc. High amount of such components can lead to continuous operational disturbances with clogging, coating, etc. which in turn influences the production rate. Such parameters to be critically analysed during the project inception stage itself. The following factors has influence on operating costs which needs to be reviewed thoroughly.

Influence on energy balance thus specific heat consumption

  • Increased waste gas volumes (higher fuel moisture, fuel chemical composition, higher excess air demand, more fuel to maintain hot sintering zone).
  • Higher amount of primary air (transport air) and leakage air, decrease of recuperation air from clinker cooler.
  • In case of bypass system losses due to bypass gas extraction.

Influence on plant operation stability thus production rate

  • High demands on fuel dosing equipment, continuous fuel feed.
  • Formation of build-ups in case of Cl- and S- rich alternative fuels in the area at kiln inlet, riser duct, bottom most cyclone etc. This requires more manual cleaning efforts or else Bypass System is necessary.

Influence on clinker quality and market demand

  • "Raining" of unburnt fuel out of the kiln flame to the clinker bed => reduced burning conditions.
  • Cooling down of the sintering zone.
  • Possible enrichment of harmful elements in clinker, e.g. MgO, P2O5 (depending on Alternative Fuel ash composition).
  • Adaption of raw mix, e.g. high Fe- content in Alternative Fuel.

Influence on emissions / fossil fuel availability

  • Positive influence on avoiding NOx formation and / or NOx reduction.
  • CO formation in case of inadequate calciner technology or unsuitable secondary fuels.
  • Saving of primary fossil fuel.

What are the advanced technologies available for AFR? How receptive have Indian cement manufacturers to these innovations?
As already explained above, we have state-of-the-art solutions for wide range of fuels and the same are being updated from time to time as per the demands of industry. Looking in to the difficulties in preparing the alternative fuels to the required size to be fed in already known solutions such as kiln burner, Calciner, Combustion chamber etc., we have recently come up with more robust latest generation solution i.e, PYROROTOR, suitable for firing coarse alternative fuels. Two such installations are under execution stage Globally and after reviewing the results we would like to introduce the same in Indian market. We are sure that this latest technology will change the course of AFR utilisation process in cement industry.

Features of PYROROTOR?: PYROROTOR, unique combustion reactor for cement plant applications for the thermal treatment of alternative fuels and raw materials. Due to high temperature process and longer residence time it is suitable for nearly all types of alternative fuels. Tertiary air is used as combustion air in PYROROTOR. Mechanical fuel transport through the reactor provides sufficient residence time. PYROROTOR is generally located above rotary kiln, between tertiary air duct and kiln riser duct. Indian cement manufacturers have always welcomed such new innovations. The cement market in India is competitive and manufacturers always strive for achieving price advantage by implementing new technologies. Higher AFR substitution rates can reduce the overall fuel cost which is one of the major cost input factor in clinker/ cement manufacturing. Solutions like PYROROTOR should become instant hit due to its unique advantages of suitability for using wide range of alternative fuels with minimum processing which reduces the preparation cost significantly.

What are the challenges companies face in sourcing AFR materials and what are the strategies they follow?
The majority of cement plants in India are using alternative fuels as an alternative energy source to minimise the operating cost by substituting usage of expensive fossil fuels. This gives competitive edge in terms of reduced manufacturing cost of clinker/cement. Also, there are few cement groups who has taken alternative fuels usage as a corporate social responsibility to minimise waste. However, in future, alternative fuels usage in cement industry works on sustainable basis if there is reasonable advantage to manufacturers in terms of cost reduction. As of now, the main challenge lies in availability of waste alternative fuels of consistent quality throughout the year.

Depending upon their geological locations and availability, the plants which are closer to the waste generation locations like pharmaceutical waste, treated RDF municipal solid waste, plastics, agriculture waste etc., are using AFR. The negative fuel cost in comparison to fossil fuels is working in cement plants favor as of now as these wastes are available at negative cost or at very marginal cost. The per kcal cost of prepared alternative fuel inclusive of sourcing, transportation, preparation, feeding etc. is lower than fossil fuel specific rate which keeps the balance to use AFR in cement plants. Looking in to this derivative, plants are sourcing and using alternative fuels on case to case basis. The evergreen economics rule of demand vs supply vs price will prevail and such situation may arise in future as the case is now for flyash, petcoke, etc. However, there should be some strict legislation from Government with well-modulated incentives to increase total substitution rate.

At what level is AFR used in Indian cement plants when compared to global benchmarks, and how long the industry may take to reach that level of efficiency?
The AFR substitution rate in Indian cement industry is less than 5 per cent TSR, which is remarkably low when compared to the standards of Europe where the AFR substitution rate is more than 40 per cent. There is huge scope for improving the figures that we are clocking today. It needs continuous support from Government and associated bodies. A critically reviewed vision plan to be laid out involving all the stakeholders to target the TSR levels of developed nations. Actions by all stakeholders are critical for realisation of the vision to become reality. Government and industry must take collaborative action to create a favorable framework for accelerating and implementation of AFR usage in cement plants.

Government should create and enable level playing field for the AFR users by providing interim financial stimulus packages that compensate and provide an edge in pricing pressures. Also, Government should take initiatives to establish latest state-of-art waste treatment plants, crop waste processing units, etc. in collaboration with cement plants in that particular cluster to supply segregated and treated alternative fuels.

Putting latest and innovative technological change into action is another aspect to improve the AFR usage. All stakeholders should intensify collaborative action to increase the implementation of state-of-the-art technologies and share best operating practices. Governments and industry should ensure sustained funding and supportive risk-mitigating mechanisms to promote the development and demonstration of new technologies and processes that offer increase in AFR utilisation. Such measures will act as springboard to improve the AFR utilisation and TSR in Indian cement industry.

About the authors: Authored by: Ashok Kumar Dembla, Managing Director & President, Humboldt Wedag India Pvt Ltd

Co-authored by: Sita Ram Sharma, Head – Parts & Services, Humboldt Wedag India Pvt Ltd.

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Economy & Market

SEW-EURODRIVE India Opens Drive Technology Centre in Chennai

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The new facility strengthens SEW-EURODRIVE India’s manufacturing, assembly and service capabilities

SEW-EURODRIVE India has inaugurated a new Drive Technology Centre (DTC) in Chennai, marking a significant expansion of its manufacturing and service infrastructure in South India. The facility is positioned to enhance the company’s responsiveness and long-term support capabilities for customers across southern and eastern regions of the country.

Built across 12.27 acres, the facility includes a 21,350-square-metre assembly and service setup designed to support future industrial growth, evolving application requirements and capacity expansion. The centre reflects the company’s long-term strategy in India, combining global engineering practices with local manufacturing and service capabilities.

The new facility has been developed in line with green building standards and incorporates sustainable features such as natural daylight utilisation, solar power generation and rainwater harvesting systems. The company has also implemented energy-efficient construction and advanced climate control systems that help reduce shopfloor temperatures by up to 3°C, improving production stability, product quality and working conditions.

A key highlight of the centre is the 15,000-square-metre assembly shop, which features digitisation-ready assembly cells based on a single-piece flow manufacturing concept. The facility also houses SEW-EURODRIVE India’s first semi-automated painting booth, aimed at ensuring uniform surface finish and improving production throughput.

With the commissioning of the Chennai Drive Technology Centre, SEW-EURODRIVE India continues to strengthen its manufacturing footprint and reinforces its long-term commitment to supporting industrial growth and automation development in India.

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RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways

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Roundtable discussions focus on innovation for safer highways.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.

Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.

Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.

RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.

Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.

Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.

The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.

From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.

Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.

Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.

Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.

The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.

Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.

The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.

Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.

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CTS Roundtable Charts Tech-Led Roadmap for Construction

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CTS Roundtable Maps Technology Roadmap for Construction

Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.

A platform to move from discussion to deployment

Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.

Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.

Industry at a turning point

Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.

Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.

His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.

From BIM to AI, data to governance

A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.

Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.

Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.

The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.

Industrialised construction gains ground

The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.

Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.

Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.

Adoption remains the biggest hurdle

While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.

Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.

Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.

That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.

Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.

Beyond buzzwords

A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.

The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.

Setting the agenda for CTS 2026

By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.

More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.

As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.

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