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Automation leads to significant gains through optimal raw mix

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D L Kantham, Director – Technical, Penna Cement, discusses the use of alternative raw materials and fuels in making green cement, along with the use of technology and automation, to ensure that the industry moves towards Net Zero goals.

Tell us about the importance of going green for the Indian cement industry.
Globally cement production capacity stands at 4.2 billion tonnes per annum. Cement production, a source of anthropogenic CO2, accounts for 8 per cent of global emissions. Indian production capacity currently stands at about 550 million tonnes per annum with annual production of around 370 million tons per annum. Annual cement production is expected to reach about 480 million tons annually by 2028-29. Hence, the cement industry in India must ‘Go Green’ to be aligned with the Net Zero Target by 2050. This target is aligned with the Paris Agreement to limit global warming to 1.50C.

What are the key alternative raw materials used to manufacture green cement?
We use fly ash, slag and other pozzolanic materials as key alternative raw materials to manufacture greener cement.

What is the role of fuel in making cement green? How does the use of alternative fuels impact the productivity and efficiency of the manufacturing process?
Using alternative fuels like pharma wastes and municipal solid wastes, leads to reduced fossil fuel (coal) usage, thereby reducing carbon emission. Alternative fuel utilisation in the cement industry reduces production costs and reduces CO2 emissions in the atmosphere.

Tell us about the cement blends or products from your organisation that are lower in their carbon content.
Penna Power (Portland Pozzolana Cement) conforming to IS 1489:2015 (32-35 per cent fly ash blended), Penna Suraksha (Portland Slag Cement) conforming to IS 455:2015 (38-48 per cent GGBS Blended) and Concrete Guard, a premium blended product conforming to IS: 1489:2015 aimed to motivate and supply 100 per cent blended cement in retail markets satisfying the customer requirements in IHB market segments.

Tell us about your Net Zero goals. How much have you achieved so far?
Our Net Zero goal is to increase our blended cement production ratio to 75 per cent from the 40 per cent level in 2015. Currently, blended cement production constitutes about 55 per cent.

How do you incorporate sustainability in your cement manufacturing process

  • Increasing Clinker to Cement Ratio (Higher use of PFA/GGBS in the mix).
  • Alternative fuels like pet coke, pharma waste and municipal waste.
  • Energy efficiency technologies, such as Waste Heat Recovery to reduce fossil fuel requirements and adaptation of better cement grinding systems (Roller Press), grinding aids, etc.

What is the role of automation and technology in making cement an eco-friendly product?
Automation leads to significant gains through optimal raw mix, better product output in quantity and quality through minimal human involvement and saves time in decision making on end product quality by quicker analysis of raw materials.

What are the major challenges in reducing the carbon content of cement manufacturing, and how can they be resolved?
Two key areas for reducing the carbon content from cement include:
Reduction in clinker to cement ratio through greater uptake of blended cement in all the key consumption segments – housing, government projects, precast cement products and ready-mix concrete. This involves developing new blended cement to suit the requirements in segments where OPC is still preferred for specific reasons, and to adapt to a higher percentage of alternative fuels in the process.
Following actions may be taken to improve greater uptake of blended cements, which leads to a reduction in the clinker cement ratio:

  • We need to enhance market awareness and acceptability because users are reluctant to select blended cement over portland cement in some regions, though substantial progress has happened in India over the past two decades.
  • Need to involve all the key stakeholders – cement manufacturers, government policymakers – national standards, consultants, key end users, and related allied products, e.g., chemical admixtures used in concrete production for exchange of experience on reducing clinker to cement ratio, promote training events with national standardisation bodies and accreditation institutes etc.
  • Independent organisations to develop cement and concrete standards and codes that allow the widespread use of blended cements while ensuring product reliability and durability at final applications to promote the use of blended cement. For example, additional types of blended cement with a higher blending ratio for specific end applications.
  • Government to promote blended cement in sourcing and public procurement policies and the private big project consultants.
  • Industries and universities conduct R&D into processing techniques for potential cement blending materials that cannot be used due to quality constraints, for example, rice husk ash.
  • Introducing a freight subsidy for transporting supplementary cementitious materials from surplus areas to cement clusters is desirable where SCM availability is limited.
  • Deploying innovative technologies (including carbon capture, usage and storage (CCUS)). Government can stimulate investment and innovation in these areas through funding for R&D.

Broadly, CCUS prevents CO2 from being released into the atmosphere by capturing it and either using it or injecting it in geological formations for permanent storage. CCUS will be crucial to reduce cement sector CO2 emissions, particularly the process emissions released during limestone calcination. While the commercial deployment of CCUS is currently limited, several innovative efforts have been underway in recent years.

How do you measure the impact of your green cement on the environment and society, and what steps do you take to continuously improve its sustainability?
Resource and environmental protection agencies use specific indicators to track and enforce
changes. Today, one of the critical measurement techniques is footprint evaluation. The three common footprint indicators are carbon, ecological, water and soil footprint.
Green concrete produced from green cement has been proven to have enhanced the structure’s durability. This ensures a reduction in demand for natural resources (limestone in particular), thereby improving the sustainability, associated energy consumption, and a corresponding decrease in GHG (GreenHouse Gas) emissions.
Additional cement product profiles, for example, Composite Cement and LC3 Cement (Limestone Calcined Clay Cement), are being researched and developed to suit the market requirement, which will help us further improve on sustainability.

-Kanika Mathur

Concrete

Cement Makers Positive on H2 Demand Outlook

Major producers expect stronger sales in the second half of FY26.

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The leading cement producers have posted high single-digit volume growth and better sales realisation in the July–September quarter, setting a positive tone for the second half of FY26. Companies are upbeat on demand prospects, supported by a strong housing sector and continued government spending on major infrastructure projects.

UltraTech, Ambuja Cement, Shree Cement, Dalmia Bharat and Nuvoco Vistas recorded revenue growth of up to 18 per cent in the September quarter. The rise was driven by firm realisations, softer input costs and an increased share of premium products.

With coal prices easing and diesel rates remaining stable year-on-year, companies expect margins to improve further in the coming months despite a rise in petcoke costs. In recent earnings calls, cement makers highlighted that the individual home builders segment across rural and urban markets is likely to drive demand, aided by favourable monsoon conditions, recent tax benefits and GST reforms.

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Fornnax Unveils the World’s Largest NPD and Demo Centre to Accelerate Global Recycling Innovation

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A 12-acre innovation campus enables Fornnax to design, test and validate high-performance recycling solutions at global standards in record time.

Fornnax has launched one of the world’s largest New Product Development (NPD) centres and demo plants, spanning more than 12 acres, marking a major step toward its vision of becoming a global recycling technology leader by 2030. Designed to accelerate real-world innovation, the facility will enable faster product design cycles, large-scale performance validation, and more reliable equipment for high-demand recycling applications.

At the core of the new campus is a live demo plant engineered to support application-specific testing. Fornnax will use this facility to upgrade its entire line of shredders and granulators—enhancing capacity, improving energy efficiency, and reducing downtime. With controlled test environments, machines can be validated for 3,000 to 15,000 hours of operation, ensuring real-world durability and high availability of 18–20 hours per day. This approach gives customers proven performance data before deployment.

“Innovation in product development is the key to becoming a global leader,” said Jignesh Kundariya, Director and CEO of Fornnax. “With this facility, we can design, test and validate new technologies in 6–8 months, compared to 4–5 years in a customer’s plant. Every machine will undergo rigorous Engineering Build (EB) and Manufacturing Build (MB) testing in line with international standards.”

Engineering Excellence Powered by Gate Review Methodology

Fornnax’s NPD framework follows a structured Gate Review Process, ensuring precision and discipline at every step. Projects begin with market research and ideation led by Sales and Marketing, followed by strategic review from the Leadership Team. Detailed engineering is then developed by the Design Team and evaluated by Manufacturing, Service and Safety before approval. A functional prototype is built and tested for 6–8 months, after which the design is optimised for mass production and commercial rollout.

Open-Door Customer Demonstration and Material Testing

The facility features an open-door demonstration model, allowing customers to bring their actual materials and test multiple machines under varied operating conditions. Clients can evaluate performance parameters, compare configurations and make informed purchasing decisions without operational risk.

The centre will also advance research into emerging sectors including E-waste, cables, lithium-ion batteries and niche heterogeneous waste streams. Highly qualified engineering and R&D teams will conduct feasibility studies and performance analysis to develop customised solutions for unfamiliar or challenging materials. This capability reinforces Fornnax’s reputation as a solution-oriented technology provider capable of solving real recycling problems.

Developing Global Recycling Talent

Beyond technology, the facility also houses a comprehensive OEM training centre. It will prepare operators and maintenance technicians for real-world plant conditions. Trainees will gain hands-on experience in assembly, disassembly and grinding operations before deployment at customer sites. Post-training, they will serve as skilled support professionals for Fornnax installations. The company will also deliver corporate training programs for international and domestic clients to enable optimal operation, swift troubleshooting and high-availability performance.

A Roadmap to Capture Global Demand

Fornnax plans to scale its offerings in response to high-growth verticals including Tyre recycling, Municipal Solid Waste (MSW), E-waste, Cable and Aluminium recycling. The company is also preparing solutions for new opportunities such as Auto Shredder Residue (ASR) and Lithium-Ion Battery recovery. With research, training, validation and customer engagement housed under one roof, Fornnax is laying the foundation for the next generation of recycling technologies.

“Our goal is to empower customers with clarity and confidence before they invest,” added Kundariya. “This facility allows them to test their own materials, compare equipment and see real performance. It’s not just about selling machines—it’s about building trust through transparency and delivering solutions that work.”

With this milestone, Fornnax reinforces its long-term commitment to enabling industries worldwide with proven, future-ready recycling solutions rooted in innovation, engineering discipline and customer collaboration.

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Concrete

India’s Steel Imports Drop 34 Per Cent, Exports Rise 25 Per Cent In April–October

Consumption grows despite weak prices and subdued demand

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India’s finished steel imports fell 34.1 per cent year-on-year to 2.5 million tonnes in the first seven months of the financial year, according to government data. Despite the decline, the world’s second-largest crude steel producer remained a net importer of finished steel during the April–October period. The fall in imports came alongside a 7.4 per cent rise in domestic consumption, which reached 92.2 million tonnes.

South Korea emerged as India’s largest source of finished steel imports, supplying 1.4 million tonnes. It was followed by China, Japan and Russia. Although total imports declined sharply, the figures show a continued inflow of foreign steel into the Indian market.

Domestic production remained strong. Finished steel output stood at 91.6 million tonnes for April–October, while crude steel production reached 95.7 million tonnes, underscoring the scale and resilience of India’s steel industry despite external competition.

In contrast to the fall in imports, India’s finished steel exports jumped 25.3 per cent year-on-year to 3.5 million tonnes. Europe was a major destination, with Italy and Belgium leading as top importers of Indian steel, followed by Spain. This highlights the growing global competitiveness of Indian steel in select markets.

The government noted that domestic steel prices have come under pressure due to weak demand and high supply. Trading activity also remained subdued during the festival season. This challenging environment has been particularly difficult for smaller steel producers, as previously reported.

Overall, the combination of declining imports, rising exports and increasing domestic consumption reflects the complex landscape of the Indian steel sector as it navigates muted internal demand and evolving international trade dynamics.

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