Economy & Market
Is Germany Making Too Much Renewable Energy?
Published
5 years agoon
By
admin
Wind turbines are seen on a plain near Bremerhaven, Germany on Dec. 26, 2017. PATRIK STOLLARZ/AFP VIA GETTY IMAGES
For Germany, 2020 was a banner year in the production of renewable energy. Clean energy sources??ind farms and solar arrays as well as hydroelectric and biogas plants??atcheted their share of power consumption up to 46 percent, nearly equaling that of coal, gas, oil, and nuclear power combined. And after a period of stagnation in the 2010s, the greenhouse emissions of the world?? fourth-largest economy have been dropping again, last year by around 80 million tons of carbon dioxide. That puts Germany 42 percent down from its 1990 emissions level, thus surpassing its decade target by 2 percentage points. This trajectory is good news for Germany??nd for the EU, which wants to turn the continent carbon-neutral by 2050.
Yet Germany?? move to a power system largely reliant on weather-dependent renewables is quickly running up against limits??ssues that all countries exchanging conventional fuels for wind and solar will eventually face. What happens when the sun doesn?? shine and the wind doesn?? blow for hours or even days at a time? And what about the short, dark, cold days of midwinter when renewables of Germany?? power demand?
And it?? not only shortages that are problematic but also surpluses: Stormy days can be so windy that the power flows from wind parks on- and offshore overwhelm the power grid, even triggering its collapse.
These electricity tsunamis can threaten the stability of neighboring countries??energy systems, a brickbat the Poles and Czechs wield. Moreover, when there?? excess power in the grid, prices can go negative, forcing grid operators to pay customers to take the electricity,
The transition from a conventional energy system with 24/7 production to one based on intermittent renewables entails more than just swapping one set of energy sources for another; it demands rethinking and restructuring the entire energy system.
Georg Stamatelopoulos, an energy expert at the utilities company EnBW, sums up the conundrum: ??enewables now cover around half of the demand, and there is still sufficient available power in the system and there is still the possibility of obtaining electricity from our neighbors. What is certain, however, is that further expansion of renewables will increase the volatility in the system. That is why we will always need available service, i.e., service that is available to us when we have the corresponding need.??/p>
Energy blackouts are the bugbear that industrialists and the conventional energy sector have long warned about in ominous tones. Too much or too little power in the grid can indeed prompt energy shortfalls, causing whole regions to go dark and assembly lines to halt. But thus far, in highly industrialized Germany, blackouts have not??et??ome to pass. There?? been no countrywide blackout for years, and last year, the average German experienced just 12 minutes of outage: the lowest in Europe and infinitesimal compared the U.S. citizen?? 2019 average of 4.7 hours.
The Germans??feat was possible, however, only because the country has mostly just added clean energy capacity to the supply over the last two decades, investment encouraged through price supports that make its energy among the most costly in Europe. At the same time, the country maintained much of its fossil fuel generation and a handful of nuclear plants. The surplus power is exported??t a handsome profit for coal-plant-owning utilities.
This whole calculation is changing dramatically, however, as Germany moves to shutter its coal-fired plants (the country?? last will close, at the latest, in 2038) and nuclear power stations (which will be disconnected from the grid in 2022). On Jan. 1, 11 coal-fired plants??ine in North Rhine-Westphalia and two near Hamburg??ent dark, and others will soon follow. Of the six remaining nuclear plants, three will terminate at the year?? end and the final three a year later.
Moreover, while utility power storage options, such as batteries, are quickly improving, batteries still don?? have the capacity to bottle up enough clean power for Germany to hold out even for a couple of fossil-free hours, much less days. Another factor: Even if energy efficiency improves dramatically??hrough the mass insulation of buildings and modernization of their energy systems, for example??ermany will in the future still need more power than it uses today for its fleets of electric cars and trucks, for public transportation, for electrified heating, and for producing the hydrogen and e-fuels that will fly planes and produce cement.
This drop-off is steep and fast, and it throws the Germany energy system into unknown territory??here the interests of energy providers, environmentalists, politicians, and grid operators clash fiercely. There?? more than one way to balance the grid, and it will have wide-ranging implications for Germany?? march to carbon neutrality.
The German gas sector and most German industry underscore that flexible, gas-fired electricity generation is the perfect partner for fluctuating renewables. Indeed, the most modern gas-fired power plants emit significantly less carbon than coal and oil. (Damning reports about gas methane emissions, another greenhouse gas, have tarnished its brand but not enough to disqualify it.) The gas lobby and many experts want more state-of-the-art gas-fired plants constructed, which they say will operate to 2050 and beyond. The gas companies, which now advertise their product as ??reen energy,??are naturally all in favor of replacing nuclear, coal, and oil with their product as fast as possible. Gas-fired electricity, they argue, will also be essential to producing hydrogen, which will power fuel-celled vehicles and produce synthetic fuels as well as store electricity.
Economists, however, point out that as higher carbon pricing boosts the surcharge on carbon dioxide to new highs, natural gas will price itself out of the market. ??as looks like the easiest answer,??said Toby Couture, director of E3 Analytics, an independent renewable energy consultancy in Berlin. ??ut in the near future, gas is increasingly likely to be outpriced. The question is: Can other technologies and approaches balance more cheaply? And the answer is yes.??/p>
Experts like Couture say demand management has enormous, thus far mostly untapped, potential. Through price incentives, massive quantities of power demand can be shifted from, for example, daytime peaks to night hours when demand is almost none. The state-financed German Energy Agency argues that management of electricity demand can be accomplished through ??he targeted switching off and on of loads according to market signals. This can be done ??in mills, furnaces, or pumps.??/p>
??n short,??Couture said, ??hat we need to do is flip the previous paradigm on its head used to build power plants to meet demand. Now we need to intentionally shape our electricity demand so that it is better adapted to our supply: variable, renewable, and abundant.??/p>
Storage is the obvious go-to option. Utility-size batteries can give back in the dark the surplus they collect during the day??nd tank up on super blustery days so upsurges don?? crash the system or cost grid operators. Other, non-battery means of storage, such as hydrogen, seawater, and aluminum storage, are currently advanced enough to pitch in. ??ven when the excess electrons aren?? enough to crash the system, they have to go somewhere. Now, absurdly, power stations are shut down or other countries actually paid to take this electricity off Germany?? hands,??said Gretchen Bakke, author of The Grid: The Fraying Wires Between Americans and Our Energy Future.
Battery technology has advanced vastly in recent years and already contributes to the short-term reliability of Germany?? grid. California has gone further, though: Utility battery developers have actually undercut the prices of gas companies to provide back-up capacity to the state?? energy system. California energy authorities expect that storage coupled with deft energy management and renewables will replace natural gas and coal-fired generations across the American West.
Most importantly, according to climate experts, is the broad, rapid rollout of renewables??ive to 10 times what Germany now has??ncluding geothermal, bioenergy, hydroelectric, and wave/tide energy, all of which are less weather dependent than solar and wind. Until then, even environmental groups like Friends of the Earth and Greenpeace acknowledge that natural gas is going to be part of the solution??hough exclusively as reserve capacity that may run just 5 or 10 percent of the time. ??as will be like a fire brigade,??said grids expert Werner Neumann of Friends of the Earth. ??here for when we need it and compensated accordingly.??/p>
Cross-border trade in energy is another way to compensate for shortfalls. Policymakers in the European Union have sketched visions of a long-distance smart transmission network that would extend from the Arctic Circle to the Mediterranean Sea, capable of seamlessly balancing shortfalls and surpluses??ventually with 100 percent green energy. Trans-European energy grids will be linked to decentralized small-scale grids and plants, making the dream come true of an EU-wide energy market. Although the project is in motion and already helps shift power between Germany and Denmark, as well as France and the United Kingdom, it won?? cover all of Europe anytime soon.
ABOUT THE AUTHOR:
Paul Hockenos is a Berlin-based journalist. His recent book is Berlin Calling: A Story of Anarchy, Music, the Wall and the Birth of the New Berlin (The New Press).
SEEPEX introduces BN pumps with Smart Joint Access (SJA) to improve efficiency, reliability, and inspection speed in demanding rock blasting operations.
Designed for abrasive and chemical media, the solution supports precise dosing, reduced downtime, and enhanced operational safety.
SEEPEX has introduced BN pumps with Smart Joint Access (SJA), engineered for the reliable and precise transfer of abrasive, corrosive, and chemical media in mining and construction. Designed for rock blasting, the pump features a large inspection opening for quick joint checks, a compact footprint for mobile or skid-mounted installations, and flexible drive and material options for consistent performance and uptime.

“Operators can inspect joints quickly and rely on precise pumping of shear-sensitive and abrasive emulsions,” said Magalie Levray, Global Business Development Manager Mining at SEEPEX. “This is particularly critical in rock blasting, where every borehole counts for productivity.” Industry Context
Rock blasting is essential for extracting hard rock and shaping safe excavation profiles in mining and construction. Accurate and consistent loading of explosive emulsions ensures controlled fragmentation, protects personnel, and maximizes productivity. Even minor deviations in pumping can cause delays or reduce product quality. BN pumps with SJA support routine maintenance and pre-operation checks by allowing fast verification of joint integrity, enabling more efficient operations.
Always Inspection Ready
Smart Joint Access is designed for inspection-friendly operations. The large inspection opening in the suction housing provides direct access to both joints, enabling rapid pre-operation checks while maintaining high operational reliability. Technicians can assess joint condition quickly, supporting continuous, reliable operation.
Key Features
- Compact Footprint: Fits truck-mounted mobile units, skid-mounted systems, and factory installations.
- Flexible Drive Options: Compact hydraulic drive or electric drive configurations.
- Hydraulic Efficiency: Low-displacement design reduces oil requirements and supports low total cost of ownership.
- Equal Wall Stator Design: Ensures high-pressure performance in a compact footprint.
- Material Flexibility: Stainless steel or steel housings, chrome-plated rotors, and stators in NBR, EPDM, or FKM.
Operators benefit from shorter inspection cycles, reliable dosing, seamless integration, and fast delivery through framework agreements, helping to maintain uptime in critical rock blasting processes.
Applications – Optimized for Rock Blasting
BN pumps with SJA are designed for mining, tunneling, quarrying, civil works, dam construction, and other sectors requiring precise handling of abrasive or chemical media. They provide robust performance while enabling fast, reliable inspection and maintenance.With SJA, operators can quickly access both joints without disassembly, ensuring emulsions are transferred accurately and consistently. This reduces downtime, preserves product integrity, and supports uniform dosing across multiple bore holes.
With the Smart Joint Access inspection opening, operators can quickly access and assess the condition of both joints without disassembly, enabling immediate verification of pump readiness prior to blast hole loading. This allows operators to confirm that emulsions are transferred accurately and consistently, protecting personnel, minimizing product degradation, and maintaining uniform dosing across multiple bore holes.
The combination of equal wall stator design, compact integration, flexible drives, and progressive cavity pump technology ensures continuous, reliable operation even in space-limited, high-pressure environments.
From Inspection to Operation
A leading explosives provider implemented BN pumps with SJA in open pit and underground operations. By replacing legacy pumps, inspection cycles were significantly shortened, allowing crews to complete pre-operation checks and return mobile units to productive work faster. Direct joint access through SJA enabled immediate verification, consistent emulsion dosing, and reduced downtime caused by joint-related deviations.
“The inspection opening gives immediate confidence that each joint is secure before proceeding to bore holes,” said a site technician. “It allows us to act quickly, keeping blasting schedules on track.”
Framework agreements ensured rapid pump supply and minimal downtime, supporting multi-site operations across continents
Concrete
Digital process control is transforming grinding
Published
3 weeks agoon
February 20, 2026By
admin
Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, delves into how digital intelligence is transforming cement grinding into a predictive, stable, and energy-efficient operation.
Grinding sits at the heart of cement manufacturing, accounting for the largest share of electrical energy consumption. In this interview, Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, explains how advanced grinding technologies, data-driven optimisation and process intelligence are transforming mill performance, reducing power consumption and supporting the industry’s decarbonisation goals.
How has the grinding process evolved in Indian cement plants to meet rising efficiency and sustainability expectations?
Over the past decade, Indian cement plants have seen a clear evolution in grinding technology, moving from conventional open-circuit ball mills to high-efficiency closed-circuit systems, Roller Press–Ball Mill combinations and Vertical Roller Mills (VRMs). This shift has been supported by advances in separator design, improved wear-resistant materials, and the growing use of digital process automation. As a result, grinding units today operate as highly controlled manufacturing systems where real-time data, process intelligence and efficient separation work together to deliver stable and predictable performance.
From a sustainability perspective, these developments directly reduce specific power consumption, improve equipment reliability and lower the carbon footprint per tonne of cement produced.
How critical is grinding optimisation in reducing specific power consumption across ball mills and VRMs?
Grinding is the largest consumer of electrical energy in a cement plant, which makes optimisation one of the most effective levers for improving energy efficiency. In ball mill systems, optimisation through correct media selection, charge design, diaphragm configuration, ventilation management and separator tuning can typically deliver power savings of 5 per cent to 8 per cent. In VRMs, fine-tuning airflow balance, grinding pressure, nozzle ring settings, and circulating load can unlock energy reductions in the range of 8 per cent to 12 per cent. Across both systems, sustained operation under stable conditions is critical. Consistency in mill loading and operating parameters improves quality control, reduces wear, and enables long-term energy efficiency, making stability a key operational KPI.
What challenges arise in maintaining consistent cement quality when using alternative raw materials and blended compositions?
The increased use of alternative raw materials and supplementary cementitious materials (SCM) introduces variability in chemistry, moisture, hardness, and loss on ignition. This variability makes it more challenging to maintain consistent fineness, particle size distribution, throughput and downstream performance parameters such as setting time, strength development and workability.
As clinker substitution levels rise, grinding precision becomes increasingly important. Even small improvements in consistency enable higher SCM utilisation without compromising cement performance.
Addressing these challenges requires stronger feed homogenisation, real-time quality monitoring and dynamic adjustment of grinding parameters so that output quality remains stable despite changing input characteristics.
How is digital process control changing the way grinding performance is optimised?
Digital process control is transforming grinding from an operator-dependent activity into a predictive, model-driven operation. Technologies such as online particle size and residue analysers, AI-based optimisation platforms, digital twins for VRMs and Roller Press systems, and advanced process control solutions are redefining how performance is managed.
At the same time, workforce roles are evolving. Operators are increasingly focused on interpreting data trends through digital dashboards and responding proactively rather than relying on manual interventions. Together, these tools improve mill stability, enable faster response to disturbances, maintain consistent fineness, and reduce specific energy consumption while minimising manual effort.
How do you see grinding technologies supporting the industry’s low-clinker and decarbonisation goals?
Modern grinding technologies are central to the industry’s decarbonisation efforts. They enable higher incorporation of SCMs such as fly ash, slag, and limestone, improve particle fineness and reactivity, and reduce overall power consumption. Efficient grinding makes it possible to maintain consistent cement quality at lower clinker factors. Every improvement in energy intensity and particle engineering directly contributes to lower CO2 emissions.
As India moves toward low-carbon construction, precision grinding will remain a foundational capability for delivering sustainable, high-performance cement aligned with national and global climate objectives.
How much potential does grinding optimisation hold for immediate energy
and cost savings?
The potential for near-term savings is substantial. Without major capital investment, most plants can achieve 5 per cent to 15 per cent power reduction through measures such as improving separator efficiency, optimising ventilation, refining media grading, and fine-tuning operating parameters.
With continued capacity expansion across India, advanced optimisation tools will help ensure that productivity gains are not matched by proportional increases in energy demand. Given current power costs, this translates into direct and measurable financial benefits, making grinding optimisation one of the fastest-payback operational initiatives available to cement manufacturers today.
Concrete
Refractory demands in our kiln have changed
Published
3 weeks agoon
February 20, 2026By
admin
Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, points out why performance, predictability and life-cycle value now matter more than routine replacement in cement kilns.
As Indian cement plants push for higher throughput, increased alternative fuel usage and tighter shutdown cycles, refractory performance in kilns and pyro-processing systems is under growing pressure. In this interview, Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, shares how refractory demands have evolved on the ground and how smarter digital monitoring is improving kiln stability, uptime and clinker quality.
How have refractory demands changed in your kiln and pyro-processing line over the last five years?
Over the last five years, refractory demands in our kiln and pyro line have changed. Earlier, the focus was mostly on standard grades and routine shutdown-based replacement. But now, because of higher production loads, more alternative fuels and raw materials (AFR) usage and greater temperature variation, the expectation from refractory has increased.
In our own case, the current kiln refractory has already completed around 1.5 years, which itself shows how much more we now rely on materials that can handle thermal shock, alkali attack and coating fluctuations. We have moved towards more stable, high-performance linings so that we don’t have to enter the kiln frequently for repairs.
Overall, the shift has been from just ‘installation and run’ to selecting refractories that give longer life, better coating behaviour and more predictable performance under tougher operating conditions.
What are the biggest refractory challenges in the preheater, calciner and cooler zones?
• Preheater: Coating instability, chloride/sulphur cycles and brick erosion.
• Calciner: AFR firing, thermal shock and alkali infiltration.
• Cooler: Severe abrasion, red-river formation and mechanical stress on linings.
Overall, the biggest challenge is maintaining lining stability under highly variable operating conditions.
How do you evaluate and select refractory partners for long-term performance?
In real plant conditions, we don’t select a refractory partner just by looking at price. First, we see their past performance in similar kilns and whether their material has actually survived our operating conditions. We also check how strong their technical support is during shutdowns, because installation quality matters as much as the material itself.
Another key point is how quickly they respond during breakdowns or hot spots. A good partner should be available on short notice. We also look at their failure analysis capability, whether they can explain why a lining failed and suggest improvements.
On top of this, we review the life they delivered in the last few campaigns, their supply reliability and their willingness to offer plant-specific custom solutions instead of generic grades. Only a partner who supports us throughout the life cycle, which includes selection, installation, monitoring and post-failure analysis, fits our long-term requirement.
Can you share a recent example where better refractory selection improved uptime or clinker quality?
Recently, we upgraded to a high-abrasion basic brick at the kiln outlet. Earlier we had frequent chipping and coating loss. With the new lining, thermal stability improved and the coating became much more stable. As a result, our shutdown interval increased and clinker quality remained more consistent. It had a direct impact on our uptime.
How is increased AFR use affecting refractory behaviour?
Increased AFR use is definitely putting more stress on the refractory. The biggest issue we see daily is the rise in chlorine, alkalis and volatiles, which directly attack the lining, especially in the calciner and kiln inlet. AFR firing is also not as stable as conventional fuel, so we face frequent temperature fluctuations, which cause more thermal shock and small cracks in the lining.
Another real problem is coating instability. Some days the coating builds too fast, other days it suddenly drops, and both conditions impact refractory life. We also notice more dust circulation and buildup inside the calciner whenever the AFR mix changes, which again increases erosion.
Because of these practical issues, we have started relying more on alkali-resistant, low-porosity and better thermal shock–resistant materials to handle the additional stress coming from AFR.
What role does digital monitoring or thermal profiling play in your refractory strategy?
Digital tools like kiln shell scanners, IR imaging and thermal profiling help us detect weakening areas much earlier. This reduces unplanned shutdowns, helps identify hotspots accurately and allows us to replace only the critical sections. Overall, our maintenance has shifted from reactive to predictive, improving lining life significantly.
How do you balance cost, durability and installation speed during refractory shutdowns?
We focus on three points:
• Material quality that suits our thermal profile and chemistry.
• Installation speed, in fast turnarounds, we prefer monolithic.
• Life-cycle cost—the cheapest material is not the most economical. We look at durability, future downtime and total cost of ownership.
This balance ensures reliable performance without unnecessary expenditure.
What refractory or pyro-processing innovations could transform Indian cement operations?
Some promising developments include:
• High-performance, low-porosity and nano-bonded refractories
• Precast modular linings to drastically reduce shutdown time
• AI-driven kiln thermal analytics
• Advanced coating management solutions
• More AFR-compatible refractory mixes
These innovations can significantly improve kiln stability, efficiency and maintenance planning across the industry.
UltraTech Appoints Jayant Dua As MD-Designate For 2027
Merlin Prime Spaces Acquires 13,185 Sq M Land Parcel In Pune
Adani Cement and Naredco Partner to Promote Sustainable Construction
Operational Excellence Redefined!
World Cement Association Annual Conference 2026 in Bangkok
UltraTech Appoints Jayant Dua As MD-Designate For 2027
Merlin Prime Spaces Acquires 13,185 Sq M Land Parcel In Pune
Adani Cement and Naredco Partner to Promote Sustainable Construction
Operational Excellence Redefined!


