Concrete

Cement industry should look at real time data and not just data

Published

2 years ago

October 19, 2023

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Keyur Shah, Business Manager, SB Engineers, gives a detailed account of how refractories can be made more efficient and sustainable, thereby making the manufacturing process more eco-friendly.

Tell us about the solutions you provide to cement companies to measure and monitor their processes.
We are partners with a company called Thermoteknix Systems Ltd, which is a UK-based company, located in Cambridge that has been providing thermal imaging solutions for the cement industry for over 30 years now. The thermal imaging solutions mainly are kiln shell scanning systems, the function of which is to monitor shell temperature of the rotating kiln.
We also have a burning zone monitoring system or burning zone CCTV and a clinker cooler monitoring system or clinker cooler CCTV.
These are the three major solutions in the thermal imaging area, which we have been providing to the cement industry.

How do your products help cement manufacturers optimise their processes?
Our first product category is the kiln shell scanning system, which very closely monitors the outer shell temperature of the rotating kiln. It gives information about what is the condition of the refractory inside, because there is the material passed through the kiln and the coating inside the kiln that keeps on building and collapsing. So, there is the thickness of the coating as well as thickness of the brick, which indirectly is reflected by the shell temperature of that kiln.
This system monitors the temperature and provides a reading for every single brick of the kiln. The first advantage of using this system is that it informs about the condition of the refractory. If it is too thin it gives you an early alarm to take action which helps avoid any sort of shut down. Shutdowns or any kind of breakdowns are a costly affair. Also, in parallel if there is an abnormality of temperatures along the length of the kiln or across the circumference of the kiln, which is caused by the uneven coating or the failure of the brick, there is an alert that sounds averting unwanted breakdowns, thus, saving cost.
Our second category is a kiln burning zone camera. Conventionally, the burning zone was monitored by installing a CCTV installed on the kiln, which allowed a process person to monitor what is happening in the burning zone, how the flame is doing and how the material is getting processed or condition of the material inside.
Typically for a cement plant approximately 40 to 45 per cent of the fossil fuel (coal) or any other fuel is burnt in this zone. A massive amount of money is being spent in this process of transforming raw material to clinker. The process person can only have an idea of what is happening but not any data.
Thermoteknix has introduced thermal imaging for monitoring the burning zone, as cement companies spend a lot of money in the process and having visual information is not sufficient for modern plants. Therefore, thermal imaging gives information about the temperature and at the same time gives the visual views and helps with the understanding of temperature, flame, temperature of outgoing clinker, temperature of nose ring, temperature of rising material etc. Any person monitoring this system can take appropriate action accordingly.
Data from this system gives better control to the plant and process monitoring. It allows for optimising processes. It helps with any adjustment of the fuel being pumped or to the burning zone, burner air, axil air or any other air, which is being provided to the burner. Available data also helps to make process improvements that helps optimise all critical processes at the cement plants.
Our third category is clinker cooler monitoring. Once the burning process is complete, the materials move out to cool into the clinker cooler to bring down the temperature. Conventionally, the cooler was monitored by a colour CCTV for the purpose of understanding visual aspects of cooling. This slowly became a bottle neck.
Modern cement plants, however, take hot air and feed it into the boiler for regeneration of power. In this case, if the thermal process of the cooler is monitored and the profile of the cooler bed and top are known, the pumping of the air or fan of the cooler can be controlled at the same time. The suction of air taking place from the cooler can be controlled for power generation, which in turn, helps optimise the cooler operations and the AQC boiler or cooler operations as well.

What is the impact of your solutions on the cost efficiency of cement manufacturing?
It is difficult to give a set number, but I will give the cost impact in general.
In the use of kiln shell temperature scanners, there are two aspects: to avoid breakdowns, which cost millions of dollars, and to enhance the service life of the refractory for one or two months, which again means huge money saving for the cement plants. This however, is difficult to quantify but is surely an amount that makes a difference.
Coming to the thermal imaging for burning zone monitoring system, let us say the plant can save only 0.5 per cent of the fuel being pumped or coal being pumped into the burning zone and optimise it by approximately 0.25 percent, that too is a significant amount of money.
Speaking about the cooler, when there is control on the energy given to the cooling fan and suction of air for regeneration of power is controlled, that saves a significant amount of money.

What are the major challenges you face in terms of the cement industry?
A major challenge as of now for us occurs because the cement industry is undergoing transformation from technically automation run plants to data driven running plants. This transformation furthering the adaptability of these new changes by the plant operators or by the plant operations team is a major challenge. But any transformation is painful and this transformation is slowly taking place. The challenge we face is the integration or collaboration of the plant in terms of offering them this solution and making sure it is used for effective purposes.

Are you working on any innovations that the cement industry can look forward to?
In addition to offering thermal imaging we also offer process improvement solutions and these are new and innovative solutions for the cement industry.
The particle sizing system is a measurement of the fineness of the cement by the cement plant. It was traditionally done or is still done by Blaine apparatus as an ISO requirement and is also being done on laboratory basis. We have introduced this as an innovative solution with an in-process particle sizing system, which means that the particle size of the final product is measured instantaneously and live data is available to the plant process team. They use this data for optimising their cement mill or even the raw mill.
It is said that 1 to 4 per cent of the world’s power is consumed for cement grinding. Through the use of automated systems, if this absolute power is improved by even 4 to 5 per cent, it contributes to a huge amount of cost saving for cement plants and allows to deliver consistent product quality. This is one of the most innovative solutions we have successfully introduced into various cement plants globally and in India.
Another most innovative solution we have introduced to the Indian cement industry is the gas flow measurement or the air flow measurement in a cement plant at various locations. Be it at the raw mill, tertiary duct, be it down comer, be it AQC duct, hot and dusty gas flows everywhere, which is laden with a lot of energy. This energy can be used in a modern cement plant for the generation of power.
The venturi system is a mechanical system, which is conventionally used in cement plants to measure dust in the flow of air and gas. It often gets clogged up and the results and readings are not accurate or satisfactory. We have joined hands with Promecon, a German company, and are offering a flow measurement system which works on a triboelectric system that does not involve mechanical devices. It is an electronic flow measurement system which does not require calibration, thus, giving reliable data repeatedly. This has also translated to bringing large cost savings to cement plants.
So, the cement industry should look at real time data and not just data. They used to have periodic data, laboratory data and a manual sample based collection data, and from there they should move to automated real time data, which can be used for process improvement. Going forward, this will become learning for good feeds of raw material, for machine learning and AI. These are likely to become trends in any cement plant.

-Kanika Mathur

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Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

Published

5 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

1 week 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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