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Energy efficiency through ‘false air reduction’

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In the present environmental scenario, due to energy crisis and steep increase in the cost of energy and other input materials, it has become imperative to give a serious thought on how to make operations and equipment efficient towards use of energy and adopt latest technology equipment to retain the requisite competitive edge in the market, discusses KK Sharma of Invotech Industrial Solutions.

India was the second largest cement producer in the world in terms of cement capacity during 2020. Therefore, one can easily assume the amount of energy being consumed in cement production facilities and its wastage attributed to non-availability of proper technology to plug the leakages. We can find hundreds of research papers/case studies discussing the effect of different factors on energy consumption in cement manufacturing facilities. Some researchers also discuss this issue with the help of mathematical models. However, all the researchers more or less agree to the fact that ??alse air??not only but may be one of the factors of more energy consumption in cement industry. Further, based on the several studies in the field of operational audit, it can be concluded that production level can be improved and energy consumption minimised by reducing ??alse air??as well as improving energy efficiency.

What is false air?

False air is any unwanted air entering into the process system. The exact amount of false air is difficult to measure. However, an indicator of false air can be, increase of % of oxygen between two points (usable for gas stream containing less than 21 per cent of oxygen). Due to unwanted air, the power consumption increases and system?? temperature decreases. Therefore, to maintain the same temperature fuel consumption has to be increased.

  • Impact of false air in cement plant.

  • Increase of power consumption

  • Increase the fuel consumption

  • Unstable operation

  • Reduction in productivity

  • Higher wear of fans

False air intrusion points

In a cement plant, generally false air intrudes in kiln section through kiln outlet, inlet seal, TAD slide gate, inspection doors and flap box. Similarly, in mill section false air intrudes through rotary feeder at mill inlet, mill body, mill door, flaps, expansion joints, holes of ducts and tie rod entry point.

In a power plant, generally false air intrudes in CPP section through air pre-heater casing, boiler main door, fan casing, inspection doors, ESP main doors, ESP hopper doors, expansion bellows, ducts. Similarly, in GPP section false air intrudes through main holes, hammering, bellows, rotary air locks, damper casing, expansion bellow, etc.

How to measure false air

The formula used for measuring false air is as under:

Atmospheric air normally has a content of 0% CO and 20.99 % O2

How to measure false air across pre-heater and mill: Based on the oxygen content and flow measurement at particular location, we can find out amount of false air across the pre-heater and mill circuit. For this purpose, % of O2 is measured at different locations i.e., pre-heater inlet and outlet, cyclone inlet and outlet, mill inlet and outlet, mill outlet to fan inlet, across bag-house or ESP.

False air detection through ultrasonic leak detector: Ultrasonic Leak detectors often called sniffer, especially designed to find small leaks, are being used in power plants. However, cement plants are still lacking use of ultrasonic leak detector. Since ultrasonic leak detectors search for the sounds of leaks rather than escaping gases, they are able to detect leaks of any gas type. Though the device is unable to measure gas concentration, it is able to determine the leak rate of an escaping gas because the ultrasonic sound level depends on the gas pressure and size of the leak.

Functioning of ultrasonic leak detector: When gas escapes a pressurised line, it generates a sound in the range of 25 kHz to 10 MHz, well above the frequencies, the human ear is sensitive to but in a range easily identifiable to ultrasonic sensors. When the detector senses ultrasonic frequencies, they are isolated from normal background noise, amplified, and converted to a frequency audible to humans.

Detection principle: When a gas passes through a restricted orifice under pressure, it goes from a pressurised laminar flow to low pressure turbulent flow. The turbulence generates a broad spectrum of sound called ??hite noise?? There are ultrasonic components in this white noise. Since the ultrasound is loudest at the leak site, it can be detected very easily.

False air arresting in cement and power plants

Usually cement and its associated power plants use conventional methods to arrest false air, but these conventional methods are not reliable or permanent in nature. In fact, it works more like a silencer, and just after a few days, it gets damaged.

Therefore, Invotech Solution & Systems now Invotech Industrial Solutions, a Rajasthan-based company has come up with a unique product range after their years of extensive research, which are being used in many cement manufacturing facilities and their associated power plants. Their client list figures renowned names like JK Cement, Dalmia Bharat, Nirma Group (Nuvoco Vistas), UltraTech, India Cements, Sagar Cements, Birla Corporation, The Mehta Group, Shree Cement, Chettinad Cement, Tata Chemicals, Jindal saw and many more in pipeline.

Invotech Industrial Solutions provides innovative and cost-effective industrial solution for arresting false air in cement plants i.e., pyro-process, raw mill, coal mill, cement mill section and bag-house and its associated power plants. The ??rrest Master??(Product Name) is user friendly and safe to use.

Product range: false air arresting compound

  • Arrest Master 1001: For upper cyclones, VRM?? and power plants, shell temperature resistant up to 180 degree Celsius

  • Arrest Master 1002: For bag-house and bag-filters top doors.

  • Arrest Master 1003: For high temperature zone up to 500 degree Celsius

  • Arrest Master 1004: For high temperature zone up to 800 degree Celsius

  • Arrest Master 2001: For areas having vibrations, shell temperature resistant up to 180 degree Celsius

Properties of Arrest Master: False air arresting compound: Application of ??rrest Master series??of product brings down the level of false air and it is useful in all cement and power plants. It hugely impacts plant productivity and contributes towards better housekeeping. Its other characteristics are:

  • Gets further strong with heat

  • Once cured, Arrest Master becomes rock hard ensuring no leaks

  • High compressive strength and impact resistant, which can only be removed by hammering

  • Non-shrinkable properties and no tools required for application

CASE STUDIES

Case Study 1

  • Single string, 5-stage ILC Pre-heater, KHD

  • Annual losses due to false air- 46.26 lakh

  • Products used: 2.5 lakh

  • Payback period: 1 month

Case Study 2

  • Double string, 5-stage ILC Pre-heater, KHD

  • Annual losses due to false air: 42 lakh

  • Product used: 4.2 lakh

  • Payback period- 1.11 month


case 2

Case study 3

  • Single string, 5-stage SLC pre-heater, KHD

  • Annual losses due to false air: 79.20 lakh

  • Products used: 2.75 lakh

  • Payback period: 0.42 months


case 3

Invotech Industrial Solutions has also recently developed a product called Arrest Master ABS for enhancing energy efficiency. It can be used to cool down the area rapidly with less air consumption but gives output seven to eight times as compared to normal air consumption. It is a special design nozzle, works on COANDA EFFECT. Arrest Master ABS uses little amount of compressed air to deliver high volume output. Arrest Master ABS, a compressed air boost device, has been designed to give trouble free and maintenance free service as there is no moving part in it. It can also be used to cool down bearing housing, cutting hot material, cooling of lathe machine jobs, etc.

Product highlights of Arrest Master ABS:

  • Energy efficient device

  • Provides efficient cooling

  • User friendly and ready-to-use modules

  • Easy installation and Relocation

Invotech Industrial Solutions keeps itself abreast of latest development in cement and power industry so as to cater the need of the Industry using latest technology and quality systems. Also, with a view to retain the requisite competitive edge in the market, participated and will be participating in various seminars, details as under:

  • 15th & 16th NCB International Seminar on cement, concrete & building materials held from December 5-8, 2017 and December 3-6, 2019 at Manekshaw Center, New Delhi. Will also be participating in upcoming 17th NCB International Seminar to be held during December 2021.

  • ??ational workshop cum technology exhibition to promote energy efficient & cleaner production for sustainable industrial growth??held from March 8-9, 2018, at India Habitat center, New Delhi, where presented a Technical Paper on ??ignificant savings in energy through false air reduction??and received an award for ??pcoming entrepreneur in the field of energy efficiency??

  • 14th Green Cementech 2018 held from May 17-18, 2018 at Hyderabad International Convention Center, Hyderabad where presented a Technical Paper on ??nhancing Energy efficiency in Captive Power Plants by reduction of False Air??

  • Some of our articles also published in CMA?? Technical Journal ??ement Energy & Environment?? Vol. 17 No. 1 (January ??June 2018) and Vol. 18 No. 1 (January ??June 2019).

  • Our latest article ??ompressed air saving device: portable, economic hot spot cooling solution to plug and eliminate routine energy waste in cement plants??will be publishing in upcoming edition of CMA Technical Journal 2021.

Conclusion

Substantial potential for energy efficiency improvement exists in the cement and power industry. Persistent efforts are also being made to improve energy efficiency and reduce energy cost for the cement and power industry for survival and growth. Our baby step towards arresting ??alse air??and improving ??nergy efficiency??can contribute immensely towards cost cutting of cement and power manufacturing and improving energy efficiency. It is needless to mention that our efforts to improve energy efficiency will also minimise greenhouse gas and mitigate the environmental problems associated with cement and power production.

ABOUT THE AUTHOR

KK Sharma is a renowned Chemical Engineer, Process Expert & Founder of Invotech Industrial Solutions. Email: invotech@invotechsol.com | invotech_ajm@yahoo.com

Web: www.invotechsol.com | Tel: 8005521600 / 900145866.

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Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

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FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

 

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Concrete

Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

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Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

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Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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