Economy & Market

Circular economy – the Promise of Green Transition

Published

4 years ago

November 18, 2022

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Anders Josefsen, Senior Vice President and Head of Projects and Upgrades, FLSmidth, discusses the evolving role of cement plants in society – from producing a key ingredient in building critical infrastructure to enabling a circular economy.

The role of cement is evolving. The industry has always been a pillar in the communities in which it operates – as an employer and as the producer of one of the world’s most widely-used products. But it has not always been the most popular of neighbours. It has had to work hard to win the trust of locals, to ensure that the benefits of its presence outweigh the disadvantages – and that those disadvantages are reduced year by year. Today, the fact remains that the industry continues to be one of the world’s largest emitters of CO2, and initiatives to decarbonise need to go beyond traditional energy savings and optimisation.
No stone is left unturned in the quest to minimise the environmental impacts from cement production, and one area in which the industry is making progress is as a valuable outlet for waste. Because of the high temperatures required to produce clinker, cement’s key ingredient, as well as the stringent regulations controlling emissions, the cement plant is well suited to co-process municipal and industrial waste, which cannot otherwise be recycled, thereby displacing traditional fossil fuels – mostly coal. In fact, we see more and more cases of producers, encouraged by local authorities, playing a beneficial role in disposing of waste that would otherwise prove problematic – including hazardous medical waste, and even solvents.

Not waste incineration, but co-processing
In waste-to-energy plants where waste is incinerated to produce electricity, there is a by-product: residues that need dealing with. In a cement plant, waste is burned in the kiln or calciner, producing the heat needed for calcination, and the remaining residues become part of the end-product. This – together with the advanced air pollution control technology and the fact that you do not need to invest in new incineration plants – is why waste-derived fuels work well in the cement industry.
In Europe, co-processing of alternative fuels such as biomass, meat and bone meal and household waste, is common practice, representing nearly 50 per cent of the fuel used in cement production. It is made easier by the availability of the required infrastructure to sort, manage and optimise waste streams, backed by sophisticated EU waste legislation. However, in regions where waste management infrastructure is not well developed, the cement industry can play an important role by helping to build waste-to-energy partnerships and address the mounting waste challenge.
This has been demonstrated recently in countries like Indonesia, where INDOCEMENT is investing in technology to co-process alternative fuels that would otherwise be landfilled. Similarly, in Vietnam, a partnership has sprung up between waste handling start-up TONTOTON and FLSmidth to help Vietnamese cement producers utilise non-recyclable plastic waste in their process. Equipment like our HOTDISC® Combustion Device enables such waste to be burned without pre-processing, significantly broadening the horizons on what can be fired in a kiln or calciner, and reducing the costs involved.

Reduce, reuse, recycle
It is true that co-processing of waste is not a magic bullet. Depending on the composition of the waste, it emits CO2 when used as a fuel. However, it does provide a useful path for non-recyclable waste that would otherwise be landfilled, littered, or burnt in the open air, as happens in many countries, causing a litany of environmental and health hazards for local communities.
The sheer quantities and varieties of non-recyclable waste are astounding – by-products from agriculture, mining, power generation, and even from construction. According to the United Nations, greenhouse gas emissions from plastics are projected to increase to approximately 6.5 gigatonnes in 2050. That represents 15 per cent of the whole global carbon budget.1
With 23 per cent of the world’s waste generation, the East Asia and Pacific region leads the statistics, reports the World Bank in their ‘What a waste 2.0’ report. The Middle East and North Africa region is producing the least in absolute terms, at six per cent. But, especially for low-income countries, materials that could be recycled account for only 16 per cent of the waste stream.2
Solid waste management is also a financial burden to municipalities in low-income countries, which are estimated to spend about 20 per cent of their budgets on waste management, on average. Yet over 90 per cent of waste in low-income countries is still openly dumped or burned.3

Closing the loop in concrete
Construction and demolition waste is one of the largest sources of waste by volume. At an annual growth rate of four per cent, it is projected to be a $143 billion business by 2028. In this lies an opportunity to close a loop. Why make more of something when you can reuse what you already have? Scientists and companies in the cement value chain, including FLSmidth, are exploring ways to break concrete down into its core components, including a fine cement paste concentrate suitable for making eco-friendly cementitious binders. This would help reduce the clinker factor – the amount of clinker that needs to be produced to meet cement demand – as well as provide a new pathway for old concrete. An economical and environmental approach to manufacturing.
According to the International Energy Association, the integration of emerging technologies such as lowering the clinker-factor in cement and carbon capture, will provide some of the largest cumulative CO2 reductions in the 2-degree Celsius Scenario (2DS).
Today, an office building has an expected lifespan of 20 years, and a residential building a lifespan of 30-50 years. That is extremely short and underlines the need for upcycling. If the industry is to support accelerating urbanisation, the winners of the construction industry will be the ones who see opportunities in waste that can be used again and again. And they will be the ones getting the building-licences from government authorities.

From trash to treasure…
Mine tailings are also an area of interest. This waste product – the leftovers after the most valuable minerals are extracted during the mining process – is a significant environmental and economic burden to mine operators, and a safety risk to them and their local communities. Great pools of these tailings are left wherever mines are or have been in operation – adding up to some 282 billion tonnes worldwide that could contaminate local soils and groundwater. However, as the old adage goes, ‘one man’s trash is another man’s treasure’, and mine tailings could prove to be a valuable opportunity for cement producers.
Research suggests that tailings may hold some of the same properties as traditional supplementary cementitious materials (SCM). This would not only make a significant impact on waste in our communities, but would also save the extraction of the raw materials usually used in cement production.
The cement industry has provided a similar pathway for waste from coal-fired power generation. Fly ash has been used as an SCM for decades. Even now, as coal-fired power plants are phased out, there is the opportunity to harvest stored fly ash – that was previously landfilled – to both relieve the environmental burden and reap the benefits of a lower clinker factor and improved cement strength.

…and from pollutants to new building materials
Carbon capture is essential to achieving a sustainable global cement industry. The development of new solutions is progressing rapidly. Some are ready for deployment now; others require additional research and development. However, one solution that is already on shelves today is Carbon8 Systems’ Accelerated Carbonation Technology (ACT), which FLSmidth offers to the cement industry. The containerised system – the CO2ntainer – captures CO2 direct from process gases and combines it with cement bypass dust to form a lightweight aggregate. The solution contributes to the decarbonisation of a plant while valorising the residues produced and saving the associated landfill costs. It is a circular decarbonisation solution.
The cement industry has a lot to offer to society, both now and well into the future. This push to decarbonise combined with increasing opportunities to contribute to circularity in society is an exciting journey that will fundamentally change the way the industry will operate and be perceived. Ensuring all these opportunities are pursued will require a number of regulatory changes and financial incentives. A worthwhile investment in light of clear benefits to society.

1 https://news.un.org/en/story/2021/10/1103692
2 https://datatopics.worldbank.org/what-a-waste/
3https://openknowledge.worldbank.org/handle/10986/30317

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Economy & Market

Leonard Unveils Dual-Head Robotic Arm for Hazardous Industrial Demolition

Published

9 hours ago

October 30, 2026

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Leonard unveils Descender Duo, a dual-head robotic demolition arm designed to improve industrial safety and reduce shutdown time by up to 50 per cent.

Industrial robotics and refractory services specialist Leonard has launched Descender Duo, a dual-head robotic demolition arm designed to improve safety, accelerate maintenance and reduce shutdown times in hazardous industrial environments. The system made its debut at Lisahally Power Station in Northern Ireland, removing 25 tonnes of slag material within hours.

Developed for the cement, metals, waste-to-energy and petrochemical industries, Descender Duo enables remote-controlled refractory demolition, anchor cutting and welding, and refractory spraying inside boilers, calciners and silos. Its vertical-access design eliminates the need for personnel to enter confined, high-risk spaces during these operations.

Weighing less than two tonnes, the pre-assembled system requires an access opening of just 1.2 m². Supported by an external overhead hoist, it uses electrically operated hydraulic stabilising legs to secure itself inside vessels. The robotic arm offers 360-degree rotation and is suited to vessels approximately 9 m in diameter, with its operating reach extendable through strategically positioned access points.

Equipped with two independently controlled robotic heads, Descender Duo can perform identical or different tasks simultaneously, including refractory demolition, anchor cutting and spraying. Its remote-control system incorporates live camera feeds, allowing operators to monitor operations without entering hazardous environments.

According to Leonard, the technology can deliver time savings of up to 50 per cent compared with manual methods. Its ability to operate at temperatures exceeding 100°C allows maintenance to begin as early as 24 hours after burner shutdown. An all-electric power supply further supports cleaner and more cost-efficient operations.

First Deployment Demonstrates Shutdown Efficiency

The system was first deployed at Burmeister & Wain Scandinavian Contractor’s (BWSC) Lisahally Power Station in Londonderry, Northern Ireland. The facility generates electricity from grade C waste wood, supplying approximately 40,000 homes and businesses.

Leonard and BWSC collaborated to develop a customised solution for the plant’s 26-metre furnace, where extensive external pipework created significant access challenges.

Mark Leonard, Managing Director, Leonard, said, “It required new thinking and rather than step away from the problem we were committed to solving it for the customer, with the customer. We’re relentless in our approach to tackling complex challenges, head-on. We took our years of cement plant experience, coupled with our working knowledge of the BWSC plant, and designed, engineered and tested a completely new vertical solution within just seven weeks from that initial conversation with the customer. That solution was the Descender Duo as we know it today.”

Traditionally, the furnace required a cooling period of up to 36 hours before preparatory work could begin, followed by manual slag removal using rope-access personnel. With Descender Duo, work commenced just 24 hours after shutdown, reducing downtime by up to one day.

The deployment removed 25 tonnes of slag within hours, eliminated the need for at least six workers to enter the hazardous furnace interior and saved 26 hours in the shutdown programme.

“The effectiveness exceeded expectation,” said Martin Doran, Plant Manager at Lisahally Power Station.

“When the Descender Duo concept was first discussed, we had to spend some time with the team from Leonard looking at how it was going to be moved into the furnace. Every site is different and that presented its own challenges, but nothing that the team couldn’t overcome. Once it was installed we were hugely impressed by its efficiency.”

Expanding Industrial Robotics Applications

Descender Duo joins Leonard’s existing portfolio of robotic maintenance solutions, including the Axis horizontal-access arm, Nano confined-space access arm, Charger cement mill media recharging system and Calibre cement mill media grading system.

Headquartered in Northern Ireland, Leonard provides robotic refractory demolition, installation, inspection and industrial maintenance services across the cement, metals, energy, biomass, glass and civil engineering sectors.

Formerly known as G Leonard, the company has more than 35 years of industry experience and operates across Europe, North America, the Middle East, Africa and Asia-Pacific.

The latest innovation reinforces Leonard’s focus on replacing hazardous manual processes with robotic systems that improve workforce safety, enhance operational efficiency and minimise industrial downtime.

Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

16 hours ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

Concrete

Fornnax Wins AIRIA’s Special Export Award for Rubber Machinery in 2025-26

Published

2 weeks ago

October 19, 2026

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Fornnax Technology Pvt. Ltd. has been honoured with the Special Export Award – Rubber Machinery for 2025–26 by the All-India Rubber Industries Association (AIRIA), in recognition of its highest exports of tyre recycling plants to the European region.

With more than a decade of experience in India’s tyre recycling industry, Fornnax has contributed to the development of advanced recycling technologies and infrastructure. The company currently holds a 90% market share in India’s domestic tyre recycling sector, while exports account for 30% of its business, spanning markets such as Europe, Australia and the GCC.

The award marks another milestone for Fornnax, whose tyre recycling lines and advanced shredding technologies are supporting the growth of the circular economy in India and international markets.

Commenting on the recognition, Mr. Jignesh Kundaria, Founder and Director of Fornnax, said:

“This honour from AIRIA is a reflection of an incredible journey we have undertaken over the years. When we started Fornnax, there was no established recycling industry in India to follow. We chose to build for the future instead. Today, when you see India’s tyre recycling sector, it has already transformed into a dynamic, high-growth industry and we are extremely proud to have played our part in building it.”

Unlike standalone equipment suppliers, Fornnax focuses on developing complete, high-capacity recycling infrastructure. Its integrated systems combine multiple stages of shredding and size reduction to enable efficient, continuous operations. This system-level engineering approach helps recycling operators improve throughput, equipment reliability and operational consistency.

The recognition reinforces Fornnax’s commitment to developing engineering technologies that contribute to a more efficient and circular recycling ecosystem.

Looking ahead, the company aims to expand its international presence while continuing to develop advanced shredding and recycling solutions to address the growing volumes and evolving requirements of the global recycling industry.

For more information, visit: www.fornnax.com