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CFD: A cross-sectoral tech for performance optimisation

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Computational fluid dynamics (CFD) is the science of predicting fluid flow, heat transfer, chemical reactions, and related phenomena by solving mathematical equations, which govern these processes using a numerical process. CFD is sometimes referred to as flow simulation, and is a computer simulation technique that permits the fluid flowing around, or through any product, reactions, processes to be analysed in great detail.

CFD technique can be applied across the sectors for performance optimisation in different kinds of equipment; general applications are found in the following industries: aerospace, power, cement, oil and gas, automotive, paper and pulp, steel, etc. Using this technique, designers can verify that their products will conform to a client’s needs early in the design cycle, accelerating the product development process. CFD can be used to calculate design mass flow rates, pressure drops, heat transfer rates, erosion rate, chemical reaction and fluid dynamic forces such as lift, drag and pitching moments. It creates virtual prototyping which is faster, and cost-effective.

Key features:
Good, detailed insight into systems for which prototype development or experimentation is difficult. The level of detail is practically unlimited
Ability to foresee design changes and optimise accordingly, reducing time and cost involved in evolving new designs
Ability to predict mass flow rates, pressure drops, mixing rates, heat transfer rates and fluid dynamic forces accurately. CFD techniques offer the capacity of studying system under conditions over its limits
Can be used for brown field and greenfield applications

Methodology:
Modeling:
Based on drawings and data provided a 3D model is developed on computers.
Pre-processing: A model is discretised into small elements known as mesh and boundary conditions (real time operating/design data) are applied to the model.
Simulation: Simulations are started and the equations are solved iteratively as steady-state or transient. Finally, post processors are used for analysis and visualisation.
Once problems are identified the model is modified and simulations help solve the problem.

Applications:
Aerodynamics
Industrial fluid dynamics
Fluid structure interaction
Heat transfer
Hydrodynamics
Multi-phase flows

Benefits of CFD:
Low cost:
Generating essential engineering data via physical experiments could be expensive.
CFD simulations are relatively cheap, and costs are likely to go down as computers become more powerful
Completely offline application

Speed:
CFD simulations are quick which could be executed in a short period of time
Quick turnaround means engineering data could be introduced early in the design process

Able to simulate real conditions:
This provides the ability to theoretically simulate most physical conditions (except hypersonic flows, for example)

Able to simulate ideal conditions:
CFD permits great control over the physical processes, and offers the ability to isolate specific phenomena for study e.g. heat transfer processes can be idealised with adiabatic, constant heat flux, or constant temperature boundaries
Experiments permit data to be extracted at a limited number of locations in the system
CFD permits the analyst to examine a large number of locations in the area of interest, and yields a comprehensive set of flow parameters for examination

Case studies in different industries Power plants
Boiler:
A problem with frequent boiler leaks was causing unplanned shutdowns, generation losses and necessitating replacement of boiler tubes. A physical identification of such failures would not have been possible, but CFD analysis showed how erosion would occur over time. Boiler tube failures were reduced to 1 per year from 5 to 7 per year. The total cost for CFD and modifications was Rs 1 crore and benefits were no generation loss, very less consumption of LDO as shutdowns are reduced.

Flue gas ducting: Areas often neglected by power plant manufacturers is flue gas ducting leading to generic problems such as high pressure drops, erosion of flue gas ducts, non-uniform flow in branching ducts, unequal mass flow distribution, turbulent flow, no/low ID fan margins. CFD applications in this area have proven very successful in several power plants. Simple modifications requiring short shutdown periods led to large benefits, especially reduction in specific power consumption under the PAT scheme, improving the power plant’s performance.

In power plants, CFD is used in the following areas: coal mill, boiler first pass, alternate fuel, air ducting, electrostatic precipitators (ESPs), feed water pumps, condensing water pumps, etc.

Cement plants
Pre heater system: CFD has been used in the cement industry to address problems in the pre-heater systems such as: high exit temperatures, high pressure drops, improper material distribution, material accumulation, low cyclone efficiency, high PH fan power consumption. With MWI’s expertise using CFD, cost-effective solutions were provided to cement plants with benefits in line with CFD results.

Raw mill system: Another major CFD application area in the cement industry is in the raw mill system. Major problems with material accumulation were solved at various plants.

Other areas where CFD can be used in cement plants are: cement mill, gas cooling tower, cyclones for improving collection efficiency, ESP flow as per ICAC norms, improving fan performance, improving blade profile of fans, improving combustion inside calciner, reducing castables erosion in kiln, prediction of flame propagation length in kiln, improving combustion. The CFD tool has been used in various industries with our expertise to solve problems.

A few other industrial applications of CFD-based technology are:

Oil and gas
CFD-based applications have been beneficial in design validation of burners, avoiding starvation of burners, uniform flow distribution throughout the combustion air ducts.

HVAC
To analyse flows through industrial sheds, to make work environment comfortable.
To maintain temperatures in operation theaters, to analyse smoke extraction through basement parking, etc.

Steel sector
In the cast house, stack house analysis, fume treatment plants. They use CFD analysis to carry out studies pertaining to:
Single phase flow/multiphase flow
Combustion
Heat transfer
FSI analysis

As part of the company’s FEA service, they carry out studies pertaining to:

Thermal studies
Vibration analysis
Stress analysis (static, dynamic, non-linear, impact)
Fatigue analysis

ABOUT THE AUTHORS:
Mehul Shah, General Manager – Marketing, and Akshay Shah, Sr Engineer- Marketing, Mechwell Industries. Mechwell is capable of providing CFD and FEA (finite element analysis) based analysis and solutions to optimise and enhance the design and manufacturing of existing or newly developed products and a leading supplier of flue gas desulphurisation dampers.

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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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Economy & Market

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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Economy & Market

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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