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Waste Heat Recovery System is a key area for cement producers

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Guilherme Mendonca, Head Energy Business, Siemens, elaborates about co-creating innovative technology solutions for the cement industry.

What are the key features of your Waste Heat Recovery System that make it an eco-friendly solution for cement manufacturing?
Steam turbines are the heart of every power plant. In waste heat recovery (WHR), steam turbines act as an essential piece of the whole system. Our modular design concept ensures high flexibility, availability, and efficiency, playing a significant role in many industrial plants for waste heat recovery and cogeneration application. In India different technologies exist to convert thermal heat into power like Steam Rankine Cycle (SRC), Organic Rankine Cycle (ORC) and Supercritical Carbon Dioxide Cycle (sCO2). However, only SRC and ORC are fully commercialised with SRC being a more popular technology with decades of proven results. Through efficient use of our steam turbines our customers can extract high power output with the available waste heat, enabling them to reduce their carbon footprint. Siemens Energy WHR solutions are capable of meeting all these requirements which are specific to the Indian
cement industry.

How does your system help reduce carbon emissions during the cement production process?
Waste Heat Recovery System (WHRS) is a key area for cement producers to improve plant efficiency and reduce their carbon footprint by utilising the waste heat from the cement manufacturing process. Siemens Energy’ waste heat recovery system is highly efficient with Heat ReCycle Power Plants offsetting the emissions when compared to other technology that is typically used to generate equivalent power, like diesel generators and reciprocating engines or small coal fired power plants. This results in overall reduced emissions and reduction in dependability on fossil fuels.

What are the estimated energy savings that can be achieved by installing your system in a cement plant?
These plants are highly customised solutions and savings can vary depending upon various factors such as source of upstream power generation, plant configuration and degree of waste heat available. Given ideal conditions, waste heat recovery power plants can offset approximately 30 per cent of total electricity requirement of a typical cement plant in India. In 2012, the Rohrdorf cement works in Germany commissioned the first waste heat and gas power plant in Europe. The plant produced over 30 per cent of the site’s power while saving 12,000 tpa of fossil fuels and reducing CO2 emissions by 30,000tpa. We have come a long way since then in terms of technology adoption and benefits. In practical applications, plants that have implemented waste heat recovery systems have been proven to reduce carbon intensity by as much as 25kg/t of clinker produced.

How long does it take for the system to pay for itself through energy savings?
The pay-off is faster than conventional grid-connected power plants by up to 40 per cent in an ideal situation. This return-on-investment calculation considers 30 per cent electricity offset and variations in energy prices as well as carbon credits and cost of decarbonisation.

What is the expected lifespan of the system, and what maintenance is required to keep it functioning optimally?
Generally, the operating lifespan of steam-based WHRS is 20 years. Typically, it works for 8,000 operating hours per year. The availability and adoption of digital solutions such as remote diagnostic services that allow proactive, predictive maintenance and minimises forced outages.

Can your system be customised to meet the specific needs of different cement plants?
Yes. This is a fully customised solution taking into account all the cement plant constraints and available waste heat sources and quality of waste heat.

What are the major challenges of a WHRS when installed in a cement plant?
Some key challenges of installing WHRS are design limitations due to available technologies and constraints such as source of heat, space available and integration. With these being mostly brownfield projects, the integration with minimum downtime and minimum process disruption also add to the challenges. However, this can be planned and mitigated with efficient project management from Siemens Energy.

How do you envision your collaboration with the cement industry in the decade to come?
We envision a strong collaboration with the cement industry in the decade to come, which is primarily driven by a shared commitment to sustainability and reducing carbon emissions with WHRS at the centre. We see WHRS as a key technology that can help cement manufacturers achieve their sustainability goals while also providing energy savings and cost reductions. Looking to the future, our collaboration with the cement industry will continue to be focused on co-creating innovative technology solutions that are tailored to the specific needs of individual cement plants in India.

Kanika Mathur

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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