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Our new technology is key to utilise max AFR percentage

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Fives Combustion Systems is a subsidiary of Fives Pillard. Fives Combustion Systems designs and installs process automation controls such as process burners, elevated flares, combustion chambers, and Pillard Fuel System. Vikas Damle of ICR had a conversation with Rahul Rajgor, MD ??India operations, Fives Combustion Systems.

What measures have you taken while designing this burner so that it is able to meet the requirements on NOx emissions and improvements in clinker quality?

Fives has always been ahead of its time regarding the development of kiln burners with low emissions. This time on the eve of a century in kiln burner solutions, we have prepared a special treat, combining all the feedback we received from our customers and our practical experience in the field and brought it to our R&D labs in France. Thanks to dedicated research, intense engineering and analysis, we have come up with a new champion in the form of the Pillard NOVAFLAM? Evolution, to deliver unparalleled performance in terms of clinker quality, emissions reduction and reduced primary air delivery.

Our Pillard NOVAFLAM? Evolution, which has just been launched, is already operational in over 40 locations around the globe and is showing fantastic results.


Pillard NOVAFLAM? Evolution, the latest innovation for the cement industry.

In India, more and more cement plants are starting to use alternate fuels (AFR). In that context, what type of burners are you offering to the Indian Industry? Will the same burner be suitable as the AFR percentage increases?

India is a booming market for the cement industry and one priority for Fives Combustion Systems. Indeed, it offers many opportunities for replacing old generation burners with new and more improved models, delivering more benefits to the customers, including efficient AFR firing capability. The cement industry has come to us with a challenge on alternative fuels substitution to pharma waste, liquid waste as a low CV, electronic waste, agro waste, etc. We understand that demand and have delivered on our challenge. The Pillard NOVAFLAM? Evolution is the answer to utilise maximum alternative fuel percentage while maximising the clinker quality at the same time.

The Pillard NOVAFLAM? Evolution burner enables the central injection of ASF by means of dedicated injectors, specially engineered to prevent the ??ouble flame??effect thus avoiding flying particles on the fire. The injection method is adapted according to the various ASF criteria such as density, moisture, size, combustion kinetics, etc. thus enabling us to custom design the ASF injector for each plant. Various arrangements of ASF injection are possible to achieve the best combustion, thermal efficiency and enhance higher ASF substitution.

What are the new innovations and patents being introduced in your Pillard NOVAFLAM? Evolution kiln burner?

  • To enhance thermal efficiency, we introduced the V type nozzle technology for axial and radial air impulse pattern.

  • Introduction of replaceable insert tips: One can replace axial air injectors very easily enhancing operational flexibility (increase or decrease primary air flow by replacing insert tip) and the maintenance cost is lower than replacing a full tip.

  • RST Swirler technology with better efficiency and adjustability from 0 to 45 degrees.

  • Lower primary air flow (4 to 8 per cent)

  • Introduction of an ??lternative fuel injection system??with an enhanced burning efficiency for solid fuel.

  • Airless stabilizer with a reduced primary air requirement for cooling.

  • Special alloyed heavy-duty burner tips with an Air Cooling arrangement resilient to heat expansion thus enhancing the burner lifespan.

  • Introduction of 4.0 smart functions with an optimised monitoring of kiln burning activities.

    Does your factory in India manufactures burners in India or do you assemble it here?

In India, we do complete design, engineering, manufacturing and supply for all type of burners and control systems under Fives Pillard license and complying with Fives R&D guidelines.

We are a global manufacturing unit for a majority of burners products for various of the group Fives subsidiaries including Fives ITAS, Italy, Fives North American Combustion, USA and Fives Stein, France.

Our facility in Vadodara, Gujarat covers 1,25,000 square feet of area and is certified ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018.

Fives Combustion Systems primarily serves the cement, oil and gas, steel, aluminum and power industries. We operate at the upper crest of the technology of combustion solutions and have been at the forefront in providing premium equipment manufactured in India complying with international standards.

Our technological edge, an increase of global customer outreach and our renown expertise explain the success of our products. To achieve high standard quality and customer satisfaction, Fives Combustion Systems has streamlined the entire product manufacturing value chain, from R&D through production including customer delivery and support.

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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