Concrete

Our next target is to further reduce heat consumption

Published

3 years ago

January 16, 2023

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AK Dembla, President & Managing Director, Humboldt Wedag India Pvt Ltd, sheds light on the positive effect of pyroprocessing and technology in cement production, and its ultimate impact on efficiency and profitability.

Tell us about the key areas where pyroprocessing has evolved since the 1950s?
In the 1950s, pyroprocessing was at a very nascent stage. There used to be wet process plants and heat consumption used to be around 1400 to 1600 kCal/kg clinker. In 1956, the first 4-stage preheater technology was developed and KHD was a pioneer in it. This reduced the heat consumption to 800 kCal/kg clinker and subsequently there was a development of the calciner technology which further optimised the heat consumption and increased the kiln productivity. The technology since then has been developing and we have now been able to bring down the heat consumption to 680 to 685 kCal/kg clinker. This has been a major step that has been achieved by the industry.
Our next target is to further reduce heat consumption either through substitution with alternative fuels or through some low temperature cements. We are trying to make this possible with the current methodologies in place. However, if there is a technological disruption, then the case may differ.

How is your technology helping reduce the carbon footprint?
As mentioned, in the area of heat consumption, we have been able to bring it down to almost half of what it was right at the beginning (early 1950) and that has been a major step in the reduction of carbon footprint. Another major step is the use of alternative fuel which is used on an average at
6 per cent in the Indian cement industry, some plants even use it up to 20 per cent. So, whatever alternative fuel we use, equivalent heat we calculate because it comes through a circular economy. And that much heat is saved, thus, reducing the carbon footprint
as well.
The industry is also working on reducing
the clinker factor in cement. Initially there was a demand for OPC, but when PPC started being popularised in early 2000 (July 2000) when the government had allowed up to 35 per cent flyash as additive in blended cement, the clinker factor substantially reduced, thus, majorly reducing the carbon footprint of the industry. Similarly, more blended cements started getting introduced by the cement makers to reduce the carbon footprint and with advancement of technology and research, the industry is gearing up to achieve net zero in concrete (final product from cement) by 2050.

How has your equipment adapted to the changing raw mix and fuels?
The good thing about using alternative fuels is that if its use is planned initially, then the process can be designed/ adapted for it. The limitation of using alternative fuel in an existing plant is to use extra equipment like shredders, preparation units for plastic waste or municipal waste or agriculture waste or hazardous waste etc. Another limitation is that the amount of alternative fuel that can be fed in the existing system can go up to 20 per cent, beyond that there is a need to modify the calciner system or add equipment for proper combustion of waste apart from the problem of bypassing minor constituents like chloride etc. For new plants that plan to use alternative fuels, we provide them with additional equipment like combustion chamber, pyro-rotor etc. that helps cement makers accommodate a higher percentage (more than 80 per cent of calciner fuel) of alternative fuels in their manufacturing process. We also investigate environmental aspects like emission of NOx and handling of minor constituents in initial design.
How has your equipment impacting the profitability for cement manufacturers?
It is our endeavour to design our equipment on parameters that are industry standard with
state-of-the-art technology. We ensure that the power consumption and use of thermal energy should be at a minimum and the productivity of the pyro-system and the grinding systems should be at its best.
Apart from design of the system and abiding by the industry standards, we do a cost comparative analysis for coal versus alternative fuels for the manufacturer, we research on layouts to bring low civil and mechanical consumption weight-wise. There are multiple efforts taken by suppliers like us to optimise the system on all fronts as it is a competitive market. Our target is to help cement makers have a lesser capital investment to ease their financial repayments and plant operations are better in productivity and output.

What is the role of automation and technology in your workings for the pyroprocessing system?
The pandemic era nudged us to explore the use of lesser manpower and include automations in our systems. There were mainly two issues: dependency on manpower and misconception that automation means a higher cost. However, that is not true. If automation is included in systems, moving towards artificial intelligence, digitisation and Industry 4.0 Standards, experts have concluded that data can be retrieved on the go and optimise processes in real time which saves costs.
In recent years, automation and technology has become a big part of the industry with equipment and sensors being installed to get data that goes through the cloud to experts and is available globally for analysis and feedback in real time. This is helping the industry increase its productivity and reducing downtime by understanding and anticipating the attention required in a particular process at a particular time. This trend is expected to mature further with time throughout the cement industry.

How do you envision the future of the cement industry with your technology
and equipment?
At present, we are putting in a lot of effort on research and development in the area of reducing carbon footprint. The main equipment and system that we are currently installing in cement plants support alternative fuels, wastes as raw material, cogeneration and blended cements. The future holds the use of solar energy and wind energy as the source of substantial power for the cement plants. The industry must also look towards having the process of calcination without fossil fuels and with the use of electrical energy produced from green hydrogen, and use of technology like oxyfuel etc. A lot of research is on-going, which may take about 5 to 15 years to be implemented, but the alternative energy sources like green hydrogen and use of oxyfuel etc., shall have been made possible to bring down the carbon footprint to zero in concrete is a big ambition for the industry. Researchers are also working on the technology where carbon can be captured, stored, and re-used.
With our processes and systems also adapting to continuous research and evolving technology, together with the cement industry we shall build solutions that ensure sustainability and reduce carbon footprint. This is what I envision for the future.

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Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

Published

6 days ago

February 5, 2026

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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.

Concrete

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

Published

1 week ago

February 2, 2026

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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.

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.

Published

2 weeks ago

January 31, 2026

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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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