Economy & Market

Green Cement Plant: Hurdles in the way of a green cement plant

Published

3 years ago

October 14, 2021

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The Indian cement industry has realised that strong business growth can be achieved by sustaining manufacturing in an eco-friendly manner. As the industry is moving ahead to embrace green technologies, SP Deolkar, a veteran in the field, lists out some of the obstacles in its path.

Cement entrepreneurs have to face many challenges while setting up new cement manufacturing plants on greenfield sites. Emphasis on sustainable development is a new dimension to consider while designing the plant. The cement industry is committed to reducing emission of Greenhouse Gasses (GHG) and to save limestone reserves and fossil fuels, while simultaneously maintaining the quality of the ambient air.

All new cement plants are adopting green processes. This means they would be making blended / composite cements, using alternate fuels (AF),using waste gasses to co-generate power or to even make cement and using renewable sources of power like wind and sun.

The challenges

The challenges in setting up a cement plant can be broadly divided into technical challenges and external challenges.

Technical challenges include those related with processes, preparation of raw materials, fuels and semi- finished products for processing, availability of machinery, plant and equipment for various operations, instrumentation and process control management for plant operation at optimum levels.

External challenges are related to deciding on the most suitable location for the plant with respect to access to raw materials, fuel, power, and of course, the market.

Technical challenges Processes

There are hardly any technological challenges with respect to process or machinery; even for current sizes of plants with more than 10,000 tpd kiln capacity. Machinery of required design and capacity is available to be used as single units. Out of necessity, cement mills are installed as multiple units to produce different types of cements simultaneously. Multi -stream pre-heaters and calciners are used on 10,000 tpd production lines. Calciners have been developed to permit multi- stage feeding of raw meal and fuel, and to keep NOx levels down within permissible limits. Both the kiln and calciner can be fired simultaneously with coal/oil and alternate fuels; several designs of highly efficient clinker coolers are available. Vertical mills, roller presses and ball mills of required sizes and capacities are available; the industry has already reached fuel efficiency levels of ~ 650 kcal/kg clinker and power consumption of ~ 80 kwh/tonne of cement.

Alternative fuels

The only new element is the preparation of alternative fuels for firing in kiln/calciner. AFs come from myriad sources in many different forms and are widely different from each other and from coal. Fuel preparation systems have to be designed to suit selected AFs for use on a continuous basis. This could involve crushing, drying, pulverising petcoke, shredding tyres, briquetting rice husk, gasification of biomass, etc. The process may require special equipment like briquetting press, shredders, gasification plant and machineries like hot disc, multi-channel burners to fire oil, coal and gas simultaneously. Such versatile systems are at the disposal of modern cement plants today.

What is most necessary for use of AFs is rigorous quality control at all stages, right from the source, to the point of firing. It is also necessary to monitor chlorine, dioxins, heavy metals, etc, in specific cases. In some cases, it may be necessary to install a kiln bypass system at the kiln inlet. Some AFs are hazardous and need special care in their handling and storage.

Waste heat recovery systems

A wide range of options are available in waste heat recovery systems (WHRS). This wide range makes it crucial to select the system most appropriate. There are many ways in which a WHRS can be installed. Suitable machinery is available for every type of requirement.

External challenges

Apart from the challenges arising from financial angles, setting up a plant would require attention to several other factors. These challenges are common for all types of cements as much as for green cement.

Some external challenges include:

Selecting location for the proposed cement plant.
Acquisition for land for factory and colony.
Obtaining mining lease.
Obtaining environmental clearances.

Land acquisition

Acquisition of land can be a big problem particularly if the land is under cultivation. A 10,000 tpd clinkering unit producing ~ 6.5 mtpa of slag cement, along with a railway siding, would require about 300 hectares just for its factory. The selection of the right location for a proposed cement plant is based on access to market, location of mineral deposits, sources of power and fuel, infrastructural facilities like rail and road links, availability of manpower, etc. Now a new dimension is added to this; a sources of AF.

The final location ought to be selected in a way that it balances the pros and cons and veer strongly in favour of the plant. If an ISP (Intermediate Service Provider) is available to supply AFs in ready use form, the problem is resolved to a great extent.

Careful investigations of prospective deposits in terms of quality and quantity to suit the selected process and the the final capacity of the plant is very important. The most promising deposit may not be readily available for exploitation, or if available, it may not be large enough. Thus, finalising the deposits and acquiring a mining lease can be a long drawn-out process. It becomes even more difficult if the deposits are in reserved areas like in forests or in sanctuaries.

Statutory clearances

Clearances for setting up a cement plant must be obtained from the MoEF (Ministry of Environment and Forests) and Pollution Control Boards. These clearances are issued only after various conditions stipulated by government norms are met.

Important conditions linked to: Mining operations, so as to leave as small a footprint as possible.

Greening of slopes, use of ground water in mines and afforestation.
Water management; recharging groundwater by rainwater harvesting, system of garland canals and check dams in specific cases, ETP, zero waste water discharge.
Green belts and landscaping in and around the factory and colony.
Monitoring and adhering to emission norms for particulates from stacks and for fugitive dusts as laid down by State and Central Pollution Control Boards.

New dimension

Though not mandatory at the moment, the industry is expected to monitor emissions of greenhouse gasses. These stipulations are to be met by all proposed cement plants, green or grey. Since the cement industry is committed to the principle of sustainable development, it will willingly comply with these stipulations and do necessary planning in advance.

Green buildings

Norms have been developed for green buildings that make maximum use of sun and wind to reduce dependence on lighting and air- conditioning. Though not mandatory, adopting them would make the existing plants greener. The Bureau of Energy Efficiency has issued norms for lighting fixtures and cooling media to be used in refrigerators and air- conditioners. It would be best to keep these in mind right from the planning stage.

Benefits of meeting these challenges

There are several real and tangible benefits of accepting the challenges and in greening the cement plants.

GHG emissions can be reduced from ~0.76 t/t for OPC to 0.30 t/t for slag cement with AF and WHR..
Substantial savings can be achieved by conserving reserves of limestone and fossil fuels. Capital costs of annual capacity can come down by 30 to 40 per cent even after allowing for additional costs for AF and WHR. Costs of production of naked cement excluding works also come down by 20 to 25 per cent in case of blended cements with AF and WHR.

Renewable energy

Power plants based on renewable sources such as wind and solar power will soon become an integral part of new cement plants, making them greener as these sources of energy are totally free of GHG emissions. The necessary technology to meet these goals is now available and very reliable.

However, the main problem associated with these sources is that the generation of wind and solar power is not consistent. The capacity factor is also very low compared to that of thermal power plants. Secondly, it may not always be possible to locate the wind or solar power plants close to the cement plant. A cement plant would have to manage several sources of electrical energy, grid, captive power plant, WHRS and power from renewable energy. A sound strategy must be in place to ensure continuity of power at optimum cost.

Future challenges

Cement industry will have to gear up itself to meet new challenges in the future such as upgrading its technologies for carbon capture and storage. GHG emissions cannot be pulled down to the targeted levels merely by making blended cements and by using AF. There are technologies for separating CO2 from waste gases on the horizon. It could be used by other industries or it can also be used for making new cements substitutes such as those made by Calera Corporation (http://www.calera.com). Several cement substitutes like Calera, Novacem, Aether, are in various stages of development.

All the new cements are green cements. The cement industry should be watchful and examine how these green products could be made in their existing production facilities.

SP Deolalkar, Director, Deolalkar Consultants, Reference- Author’s forthcoming book : Designing Green, Cement Plants.

Concrete

Lohia Corp Expands Global Footprint With Acquisitionof J.j. Jenkins Inc and Strategic Joint Venture With Omgm

Published

2 weeks ago

October 22, 2024

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Lohia Corp Limited (LCL) is pleased to announce two significant milestones that mark our
expansion in the global market.

We have successfully acquired J.J. Jenkins Inc. a respected name in machine manufacturing for
high-tech industries, through our US subsidiary, Leesona Corp, a 130-year-old pioneer in winding
machines. This acquisition aligns perfectly with our strategic vision to expand our specialty yarns
and tapes portfolio in medical and defence applications.

In addition, we have formed a strategic Joint Venture with Italy’s O.M.G.M. sas, leading to the
creation of OMGM Extrusiontechnik Srl. With LCL holding the majority stake. This JV represents
a significant diversification of our product portfolio, introducing solutions in Extrusion and
Winding systems for a variety of technical applications.

These advancements are not just about growth; they’re about bringing cutting-edge solutions to
our customers and contributing to industries that make a difference. Stay tuned for more updates
as we continue to push the boundaries of technology and engineering excellence.

Mr. R K Lohia, Chairman & Managing Director of Lohia Corp Limited, expressed his enthusiasm
about the new ventures “Both these new partnerships are a pivotal move that will broaden our
product offerings and provide our customers with even more choices and will enhance our
presence in the North America and European market, at the same time strengthen our presence
in all other global markets.”

About Lohia Corp Limited
Lohia Corp Limited (LCL) stands as a testament to the power of innovation and commitment to
excellence. As the flagship company of the Lohia Group, LCL has established itself as a global
leader in providing comprehensive solutions for the raffia industry.

With an impressive installation base of over 2,250 extrusion lines and 95,000 Circular Looms
across more than 100 countries, LCL’s influence in the plastic woven fabric and bag sector is
unparalleled. The company’s dedication to quality and efficiency has resulted in an astounding
plastic processing capacity of 7.7 million metric tons per annum of PP & PE.

LCL’s products, ranging from packaging systems for solid bulk materials to roof underlays and
tarpaulins, are not just industrial applications; they are the building blocks of industries
worldwide.

The company’s commitment to sustainability and innovation is the driving force that makes it the
world’s largest producer of machines for the raffia sector. As we look to the future, LCL’s legacy
of excellence is more than just a benchmark; it is a continuous journey towards pushing the
boundaries of possibility.

About J. J. Jenkins, Inc
J. J. Jenkins Inc. is a very respected name based out of North Carolina, USA. They remain at the
forefront of the synthetic fiber and monofilament industries. Their unwavering commitment to
innovation, quality, and customer satisfaction has not only set industry standards but also
fostered enduring partnerships with Fortune 500 companies including some in the medical and
defence industries.

Their holistic approach, combining state-of-the-art technology with unparalleled after-sales
support, exemplifies their dedication to client success. With a vast inventory ensuring rapid
response times, J. J. Jenkins, Inc. is synonymous with reliability and efficiency.

About OMGM sas
Since 1965, OMGM sas is a distinguished Italian leader and has been at the forefront of the plastic
processing industry, pioneering in Monofilament Extrusion, straps, ropes and various other niche
applications. Their commitment to excellence is evident in their advanced technologies and
versatile extrusion lines, handling a variety of materials for diverse industries.

As we look ahead, it’s clear that OMGM Extrusiontechnik Srl will continue to lead and transform
the industry with their precision, innovation, and bespoke solutions. They are more than a
company; they are a trusted partner in progress.

Concrete

Adani acquires Orient Cement at INR 8,100 crore equity value

Published

2 weeks ago

October 22, 2024

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Acquisition adds 16.6 MTPA capacity (8.5 MTPA operational, 8.1 MTPA Ready to Execute).

Accelerates Ambuja’s journey to achieve 100+ MTPA operational capacity in FY 25

Provides 6 MTPA potential additional capacity in North India, leveraging OCL’s high quality limestone reserves in Rajasthan

EDITOR’S SYNOPSIS

Ambuja enters into a binding agreement to acquire 46.8% stake in Orient Cement Ltd (OCL). The acquisition helps to move towards target capacity of 140 MTPA by 2028.
OCL has an existing 5.6 MTPA clinker and 8.5 MTPA cement operational capacity, 95 MW CPP, 10 MW WHRS, 33 MW Renewable Energy spread across the states of Telangana, Karnataka and Maharashtra. It improves Adani Group’s market share pan-India by 2% in the cement industry.
OCL has secured a concession from Madhya Pradesh Power Generating Company Ltd (“MPPGCL”) to set up 2.0 MTPA Cement GU within the premises of Satpura Thermal Power Station in Sarni, MP.
OCL also has a large high quality limestone mining lease in Chittorgarh, Rajasthan, providing the potential to set up additional 6 MTPA capacity in North India.
The acquisition of OCL complements Ambuja’s existing cement footprint, reducing overall lead distances and logistics costs for the cement business and improving market share in our core markets.
Acquisition will be funded through internal accruals, Ambuja remains debt free.

Ahmedabad, 22 October 2024: Ambuja Cements, the cement and building material company of Adani Cement and part of the diversified Adani Group, today announced the signing of a binding agreement for the acquisition of Orient Cement Ltd (OCL) at an equity value of Rs. 8,100 crore. Ambuja will acquire 46.8% shares of OCL from its current promoters and certain public shareholders. The acquisition will be fully funded through internal accruals.

“This timed acquisition marks another significant step forward in Ambuja Cements’ accelerated growth journey, increasing cement capacity by ~30 MTPA within two years of Ambuja’s acquisition,” said Mr Karan Adani, Director of Ambuja Cements. “By acquiring OCL, Ambuja is poised to reach 100 MTPA cement capacity in FY 25. The acquisition will help to expand Adani Cement’s presence in core markets and improve its pan-India market share by 2%. OCL’s assets are highly efficient, equipped with railway sidings and well supported by captive power plants, renewable energy, WHRS and AFR facilities. OCL’s strategic locations, high-quality limestone reserves and requisite statutory approvals present an opportunity to increase cement capacity in the near term to 16.6 MTPA.”

Mr CK Birla, Chairman of Orient Cement and the CK Birla Group, said, “The CK Birla Group is continuously reallocating capital to sharpen its focus on consumer centric, technology driven and service-based businesses. I take pride in Orient Cement’s impressive track record of building premium brands and maintaining a leading market share in the geographies it operates in. We are confident that the Adani Group, with its strong focus on cement and infrastructure, is the ideal new owner to drive continued growth at Orient Cement for our people and stakeholders”.

Ms Amita Birla, Co-Chairman, CK Birla Group, added, “Orient Cement has a strong market presence, with sustainability initiatives, particularly in renewable energy, being a significant part of its DNA. I am convinced that Ambuja Cements is the right home for all our colleagues at Orient Cement, as well as our customers.”

OCL has 5.6 MTPA clinker capacity and 8.5 MTPA cement capacity along with statutory clearance to increase the clinker capacity by another 6.0 MTPA and cement capacity by another 8.1 MTPA. In addition, OCL also has a limestone mining lease in Chittorgarh for setting up an Integrated Unit (IU) with clinker of 4 MTPA and a split Grinding Unit (GU) of 6 MTPA in North India. OCL has also secured a concession from MPPGCL, Madhya Pradesh for setting up a Grinding Unit within the premises of Satpura Thermal Power Plant. Both these complement the Adani Group’s existing cement footprint. (Refer Annexure – 1 for OCL’s location wise cement capacity and other assets and Annexure – 2 for Adani Cement’s footprint post-acquisition of OCL.)

OCL has recently commissioned a WHRS in Chittapur IU and is in the final stage of commissioning 16 MW solar in Chittapur and 3.7 MW solar in Jalgaon. OCL’s efficient plants, highly motivated teams, strong balance sheet and well-distributed dealer network will be excellent additions to the Adani Group’s existing cement business. OCL’s existing dealers will move to Adani Cement’s market network, creating formidable synergies.

Ambuja plans to optimize OCL’s overall capacity utilization to enhance its cost and competitiveness and improve its operating performance while leveraging the synergies inherent in the existing cement business.

About Ambuja Cements Ltd (ACL)

Ambuja Cements Ltd is one of India’s leading cement companies and a member of the diversified Adani Group – the largest and fastest growing portfolio of diversified sustainable businesses. Ambuja, with its subsidiaries ACC Ltd, Penna Cement Industries Ltd and Sanghi Industries Ltd, has taken the Adani Group’s cement capacity to 88.9 MTPA, with 20 integrated cement manufacturing plants, 20 cement grinding units and 12 bulk terminals across the country. Ambuja has been recognized among ‘India’s Most Trusted Cement Brand’ by TRA Research in its Brand Trust Report, 2024 and among ‘Iconic Brands of India’ by The Economic Times. Ambuja has provided hassle-free, home-building solutions with its unique sustainable development projects and environment-friendly practices since it started operations. The company has many firsts to its credit – a captive port with six terminals that facilitates timely, cost-effective and cleaner shipments of bulk cement to its customers. Its innovative products like Ambuja Cement, Ambuja Plus, Ambuja Compocem and Ambuja Kawach are now listed in the GRIHA product catalogue. These products not only fulfil important customer needs but also help in significantly reducing their carbon footprints. Being a frontrunner in sustainable business practices, Ambuja Cements ranks among ‘India’s Top 50 companies contributing to inclusive growth’ by SKOCH and ‘India’s Top 50 Most Sustainable Companies’ Cross-Industry by BW Businessworld.

For further information on this release, please contact: roy.paul@adani.com

Annexure -1 | Existing Cement Assets of Orient Cement Limited

Plant	Clinker (MTPA)	Cement (MTPA)	CPP/WHRS/Solar	Railway Siding
Devapur IU, Telangana	3.5	3.5	CPP – 50 MW	Yes
Chittapur IU, Karnataka	2.1	3.0	CPP – 45 MW WHRS – 10 MW Solar – 16 MW*	Yes
Jalgaon GU, Maharashtra	–	2.0	Solar – 13.5 MW+ 3.7 MW*	Yes
Operational Capacity	5.6	8.5

* capacity is in commissioning stage

Annexure – 2 | Footprint of Adani Group – Cement business post OCL Acquisition

Economy & Market

Fornnax Announces a Major Launch With Sr Max Series: Sr-max2500 Primary Shredder a Revolutionary and Game-changer

Published

3 weeks ago

October 18, 2024

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Fornnax, a renowned shredding and recycling equipment provider with years of experience in designing and developing SR-Series dual shaft shredders, has unveiled its advanced level SR-MAX2500 shredder specially designed for the Municipal Solid Waste category.

The launch was held IFAT India 2024, a most prestigious event in the waste management industry, on October 16th, 2024, at the Bombay Exhibition Centre in Mumbai.

Fornnax’s successful track record of developing many proven machines for different types of tires, ferrous and non-ferrous metals, which are the most difficult applications has made them a pioneer in the shredding and recycling equipment manufacturing global market over the decade now. The design of the SR-Series machine, a legacy that has prevailed for over a decade, continues to be used in the design of SR-MAX series machines. The advanced SR-MAX2500 shredder features high capacity, modern engineering, and innovative technology.

The remarkable event was inaugurated by Mr Ulhas Parlikar, Ex-Director of Geocycle India; Mr Sanjay Shripatrao Katkar IAS (Municipal Commissioner and Administrator) MBMC; Mr Sharad Nanegaonkar Executive Engineer (Water Supply and Sewerage Department) MBMC; Mr Deepak Khambit (City Engineer) MBMC; Mr Jignesh Kundaria CEO & Director of Fornnax Technology Pvt. Ltd.;

Mr Manoj Kumar Sure, JK Cement Head AFR; Mr Manoj Kumar Modha, Director of Millennium Multi Trade Pvt. Ltd.

Jignesh Kundaria, CEO and Director of Fornnax, shared insights into their newly launched innovation, “With the SR-MAX2500, we’re poised to transform the waste management landscape in India and beyond. Our goal is to line up municipal waste recycling industries with a robust, efficient, and sustainable solution. Our commitment to sustainability and enhancing recycling process is a step forward towards achieving PM’s vision of a Net Zero emissions future by 2050.”

Revolutionizing Waste Reduction: The SR-MAX2500 Advantage We’re excited to introduce the Fornnax SR-MAX2500, a revolutionary primary shredder designed for efficient volume reduction of diverse materials. This high-capacity machine boasts advanced modern engineering and technology, featuring hydraulic motors driving each shaft for optimal power and torque. Its unique cutter design, replaceable cutting table, and shaft design make it an ideal solution for various applications.

Waste Management Reimagined! SR-MAX2500 Primary Applications Our primary focus for the SR-MAX2500 is serving large-scale municipal waste recyclers, cement plants, waste-to-energy plants, mechanical biological treatment facilities, materials recovery centres, construction and demolition recyclers, aluminium recyclers, and other applications requiring highcapacity machines and robust technology.

The SR-MAX2500’s Impressive ROI Streak The SR-MAX2500 offers several commercial benefits, including increased efficiency, reduced operational costs, and enhanced productivity as it is specially designed for the Indian market. Its robust design and advanced technology ensure minimal downtime, maximizing profitability for our customers. Additionally, our commitment to quality and reliability helps build long-term relationships with clients, fostering loyalty and repeat business.

Innovation Meets Efficiency: Why Choose the SR-MAX2500? Fornnax has carved out a distinctive niche in the highly competitive market and its relevance stems from a unique, tailored approach that addresses specific needs. Thus, the SR-MAX2500 shredder differentiates itself through its versatility, catering to a diverse array of waste management and user needs, specifically designed for Indian waste, which is highly contaminated compared to global waste. Additionally, our unwavering focus on innovation, quality, and customer-centricity sets us apart from competitors and establishes our position in the market.

Turning Trash into Treasure with MSW Waste As you see due to the rapid urbanization and over population, India is among the world’s top 10 countries generating municipal solid waste (MSW) and generates around 62 million tons of waste in a year. Therefore, it is extremely critical to prioritize recycling and conversion of MSW into RDF fuel. Cement industry, which uses a significant amount of coal. Cement industries substituting coal with RDF or alternate fuel to reduce the greenhouse gas emissions, conserve natural resources like coal and more and ultimately minimise the waste disposal issues.

Fornnax’s Exceptional Contribution to India’s Sustainability Goals India has made significant strides in waste management and recycling, and with continued investment, innovation, and policy support, there’s no doubt it can achieve its goals. Fornnax is committed to contributing to India’s sustainability and waste management journey through their advanced recycling solutions, supporting the country’s transition to a more circular and environmentally conscious economy.

Fornnax’s Unwavering Commitment to R&D and Innovative Solutions Fornnax stays updated with global advancements in recycling technology and sustainability practices through several key strategies, such as we invest heavily in research and development to ensure our equipment are at the forefront of technological innovation. Our team closely monitors industry trends, emerging technologies, and regulatory changes to identify potential opportunities for improvement. We also actively seek feedbacks from our valued clients to understand their evolving needs and challenges. This input helps us identify areas where we can boost our meet market demands.

Expanding Horizons: Fornnax’s Growth Plans for the Year Ahead The SR-MAX2500 launch is a strategic step towards expanding our market presence and strengthening our position as a leading shredder manufacturer around the globe.

Also, we are optimistic about the coming year, driven by the growing demand for sustainable waste management solutions and the increasing awareness of environmental issues. We are actively investing in equipment enhancement, engineering, and strengthening our partnerships to meet the evolving needs of our customers. Fornnax’s focus areas for the next year include expanding the manufacturing capacity to meet the rising demand and we already started working on it by acquiring 23-acre land parcel in Ahmedabad, Gujarat. The new site is expected to become operational by March 2025. Its focus will be on producing high-capacity machinery applicable in tyre, cable recycling, ewaste, metal processing and more.

About Fornnax FORNNAX is one of the world’s leading shredding and recycling equipment manufacturers, offering Primary shredders, Secondary shredders and Granulators for tyres, municipal solid waste, cables, e-waste, aluminium and many other industrial applications. Quick after-sales services that increase our customer’s uptime and productivity.

We are committed to shaping the landscape for sustainable recycling solutions in the future. Because we’re not just selling equipment, we’re building business. That’s what we believe. That’s who we are. Fornnax Equipment is built with the idea that the simple, most significant and heaviest is better. Our equipment is an evolution of advanced products designed for the challenges of the recycling world.

The global sales partner network makes us successful worldwide. Our corporate culture is based on our history of providing value to our customers’ success worldwide. This motivates our employees to work together, develop innovative products, and produce high-quality equipment.