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Challenges while utilising hazardous industrial waste

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Cement industry in the existing scenario can play an important role in processing of hazardous waste in its kiln when no other cost effective option is available. Milind Murumkar takes a stock of the situation.

Waste management is a growing concern for India. The Government of India is attempting to tackle this challenge through a number of initiatives, including the Clean India Mission. Cement industry can certainly play a key role in promoting better waste management practices & create a win-win situation by working with urban local bodies on waste segregation and management of municipal solid waste. Substantial fractions of industrial, commercial, domestic and other wastes contain materials that have the potential for use as an alternative raw material or as a supplementary fuel for energy recovery in cement kilns.

Co-processing is a proven sustainable development concept that reduces dependency on natural resources, reduces pollution and landfill space, thus contributing to reducing the environmental footprint. Co-processing is also based on the principles of industrial ecology, which considers the best features of the flow of information, materials, and energy of biological ecosystems, with the aim of improving the exchange of these essential resources in the industrial world.

This will be possible only when there will be appropriate will and proper facility in cement plants to process the non-homogeneous waste material into uniform quality AFR whether it is segregated municipal solid waste, waste from industrial sectors like-machinery parts making industry, forging industry, paint industry, FMCG, petrochemical, pharma industries, etc.

Cement industry in view of high temperature profiles that are available in their kiln system offers an excellent co-processing facility that can be utilised for management of any kind of waste. The best benefit of co-processing of different type of waste in the kiln system is a preferred option that helps in utilisation many waste materials without leaving any foot print on the environment and also on the product quality. There have been dramatic improvements in regulatory frame work and Pollution Control Authorities are also mandating for higher utilisation of waste in cement kilns. The waste generator are also satisfied with the facilities created by cement Plants for disposal of their waste in scientific and sustainable manner.

The concept of hand holding by the manufactures, waste generators and the authorities have greatly improved the waste utilisation in cement plants. Movement of waste from one state to other state, giving long term consents, authorising the transporters, etc. are some of the positive steps taken in this direction.On the other hand, the waste generators as well as the plant users are also gearing up by upgrading their facilities for improving the usage. All these steps will certainly help in avoiding land filling and shift to resource recovery in next two to three years through co-processing route.

The dream of the cement manufacturers is to raise their thermal substitution rate from present level of around 4 per cent to a level of 20 per cent in 2025, which is a very ambitious and the above initiatives can certainly help the industry. In order to have a step jump in utilisation the support of bodies like CII, CMA, etc. can boost the awareness and understanding in the waste generators and the community.In co-processing, the cement kiln in the cement manufacturing process has features that are suited for co-processing. These include:

Different feed points for AFR introduction in the cement process. Feed points can be via the main burner, secondary burners, pre-calciner burners, kiln inlet.

Alkaline conditions and intensive mixing in the kiln favours the absorption of volatile components from the gas phase. This results in low emissions of sulphur dioxide, hydrochloric acid (HCl) and most heavy metals.

The clinker reaction temperature at 1,450 degree Centigrade allows incorporation of ashes, in particular, the chemical binding of metals to the clinker

Cement kiln operates under negative pressure or draught, thus preventing the generation of fugitive emission.

With the large mass of clinker processed inside the cement kiln, there is a presence of a huge thermal inertia thereby eliminating the possibility of rapid swings in temperature

Carbon dioxide (CO2) emissions from cement manufacturing are generated by two mechanisms.

1.Combustion of fuels to generate process energy which releases good quantities of CO2.

2.Substantial quantities of CO2 are also generated through calcining of limestone or other calcareous material. This calcining process thermally decomposes CaCO3 to CaO and CO2

Emissions of metal compounds from cement grouped into three general classes: volatile metals, including mercury (Hg) and thallium (Tl); semi-volatile metals, including antimony (Sb), cadmium (Cd), lead (Pb), selenium (Se), zinc (Zn), potassium (K), and sodium (Na); and refractory or non-volatile metals, including barium (Ba),chromium (Cr), arsenic (As), nickel (Ni), vanadium (V), manganese (Mn), copper (Cu), and silver (Ag).

Although the partitioning of these metal groups is affected by kiln operating conditions, the refractory metals tend to concentrate in the clinker, while the volatile and semi-volatile metals tend to be discharged through the primary exhaust stack and the bypass stack, respectively.

Requirements for undertaking co-processing are: Best available technology for air pollution prevention and control with continuous emission monitoring

Exit gas conditioning/cooling and temperature less than 200 degree Celsius, in control devices to prevent dioxin formation.
Adequate emergency and safety equipment and Procedure and regular training.
Safe and sound receiving, storage, processing and feeding of hazardous wastes.

The operator of the co-processing plant should develop a waste evaluation procedure to assess health and safety of workers and public, plant emissions, operations and market dynamics.

Market information on waste availability is key for our service selling business. If parameters are not clearly defined, market surveys can be too vague.

The objective of a market survey is to:

  • Gather, collect, and document information from an identified waste stream
  • Compile knowledge of a waste stream
  • Quantify opportunities of a selected waste stream
  • Help in the AFR Marketing and Business Planning process
  • Assess current disposal routes and disposal practices of wastes, including perception of present customers. An effective AFR market survey requires resources for implementation. For a focused market survey, a general knowledge of the waste market is needed. survey. The process needs to be clearly defined by the AFR manager before the start of the market research.Waste market survey (Rough qualification)

For cement kiln usage the following industrial segments have high-priority:

  • Automotive industry
  • Chemical industry
  • Electronic and photographic industry
  • Food industry
  • Paints and related industries
  • Petroleum industry
  • Pharmaceuticals and cosmetics industry
  • Plastics industry
  • Tires industry

The following industries may be important, depending on their area of activity

  • Agricultural industry
  • Leather products
  • Mining, construction, quarrying
  • Wood and related industry

Moreover the following issues are looked at before selecting a waste stream,

  • Material profile and availability
  • Generating process
  • The regulatory situation
  • The competition and treatment alternatives
  • The issues the cement plant could have with the stream

Waste generators should provide information on characteristics, generating process, geographic availability, regulatory/legislative disposition, specific producers, volumes, prices, disposal alternative method and impacts/fits with the cement process per each waste type. Furthermore it should capture competitive information, the basic industry economics and the trends and events impacting the waste industry.

The waste generators requires a cement plant that can offer a Total service strategy (TSS) which means understanding the waste customer’s problem and offering all required services to solve this problem, either through internal activities or in coordination with third-party-services (e.g. transport, chemical analysis, cleaning, etc.).

AFR quality control in a cement plant plays a vital role. The cement plant needs to address if it…

  • Is aligned with the local legal framework.
  • Is suitable for the Health and Safety of all personnel (including employees, contractors,Sub-contractors and visitors)
  • Fits the process requirements of the cement production process.
  • Fits the commercial agreements.

India is primarily a cement producer. Manufacturing of cement requires stable inputs of raw material of a certain composition to reach stable output qualities.Only certain waste types can be accepted and the timing of inputs must be aligned. An AFR Quality Control Scheme is absolutely necessary to minimise and control all possible risks associated with AFRs. The AFR Quality Control Scheme applies to waste materials prior to delivery, at time of delivery, during handling & storage phases and even through to feeding into the kiln.

As cement and AFR are very different, very different key success factors are present, too.These factors are industry specific, i.e. the cement industry as newcomer in the waste business needs to adapt to these key success factors.

The main success factors are:

  • Customer orientation
  • Specialised service portfolio
  • Constantly adapted product / service portfolio
  • Brand image and recognised corporate image
  • Lobbying and relationship management

It is necessary to recognise that a waste generator is a customer (we are selling a service to the waste generator) and not a supplier is sometimes a hard learned lesson for a cement plant. But experience has shown that not paying attention to the above, business success factors will slow down or stop the AFR progress.

ABOUT THE AUTHOR:
Milind Murumkar is an Advisor & Consultant for AFR. He has been associated with Dalmia Group, Vicat Group, Orient Cement, Shree Digvijay Cement, Toshaly Cement Companies as an advisor and consultant. He can be contacted at: +919100960039 | +919004476333 or Email: milind.murumkar@gmail.com.

One needs to describe the waste, its form, characteristics, contaminants, legal status, additional storing and handling equipment, etc…. like

  • Is this material available in different forms from different generators?
  • Is this material susceptible to self-ignition?
  • Is this material explosive and if so then in what conditions?
  • At what temperature does this material melt/freeze?
  • Does this waste agglomerate?
  • What is the general character of the material i.e. is it wet, dry, sticky, dusty, lumpy, etc?
  • What is the viscosity of the material? Is it solid, semi solid or liquid?
  • What is the flash point?
  • What is the pH of the material?
  • What is the angle of repose?
  • What is the granulometry or particle size?
  • What is the approximate percentage of the major oxides for cement manufacture?
  • What is the heavy metal content?
  • What is the content of titanium, zinc and manganese?
  • What is the chlorine/halogen content of this material?
  • What is the sulfur content of this material?
  • What is the moisture content?
  • What is the loss on ignition?
  • What is the heat content in BTUs per pound?
  • What is the ash content?
  • Is this material a solid waste?
  • Is the material a hazardous waste? If so, how did it become so classified?
  • Is the material considered a municipal waste?
  • Is the material a regulated biohazard?
  • Are there other regulations covering the management of this waste?
  • Does it require a placard for transportation?
  • Is MSDS available?
  • What PPE would be required?

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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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Concrete

Human Factor in Grinding Optimisation

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Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.

The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.

Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.

Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.

Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.

Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.


A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.

Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.

About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.

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