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A refractory should be able to withstand high abrasion

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Mayank Kamdar, Marketing Director, Lilanand Magnesites, gives details about development in refractories that affect cement production.

Tell us about the refractories made and delivered by your organisation.
We are manufacturers of special and high performance castable and gunning refractory. These are manufactured at our Gujrat factory. We also have an integrated R&D centre there with all types of testing facilities. We primarily manufacture these castable, gunning refractories and anti-coating paints material there.

How do your refractories impact the productivity of the cement plants?
The refractory cost is less compared to the total expenditure of a cement plant – it might be 0.2 per cent to 0.4 per cent of the total expenditure. Refractory efforts can improve efficiency of the plant by up to 60 per cent. It plays an important role as far as productivity of a cement plant is concerned. Nowadays, cement plants are switching focus from the cost of the material to the absolute cost of the material. You need to be ready to spend on the extra life of the refractory to ensure that efficiency and productivity is increased. As the demand of cement is increasing day by day, all the companies are focused on better refractory life at affordable costs.

What is the lifespan of your refractories?
It depends on the area. Usually in the critical areas that we are catering to, the lifespan varies from around 12 to 24 months. We provide unshaped refractories, and not bricks or pre-cast shapes. We manufacture gunning and castable refractories and they have a life of up to 24 months.

Tell us about the maintenance and quality standards for your refractories.
Our process is ISO certified. As a premium refractory manufacturer, we are particular about choosing our raw materials. We conduct a lot of tests on our finished goods before they are despatched. So, there is rigorous testing of our raw material and finished goods as far as refractories are concerned.

How do you contribute towards sustainability or being environment friendly?
Refractory material is made using a lot of fuel. Minerals need to be extracted from the raw materials. In aluminium-based refractory, high grade boxes are made. Since this process requires a lot of fuel, it is our perception that if the refractory gives better life not only does the customer get benefitted because of better costs but the environment is also positively impacted. A medium quality refractory castable would more or less require the same energy or fuel as high performance refractories.
If the life of high performance refractory is doubled, the overall impact on the environment can be reduced by 50 per cent by way of improving life and by using better refract one can contribute to environment sustainability.
Again, our factory has an integrated solar power plant where we are able to generate more electricity than is used by our refractory. Our factory is power positive. We have also introduced false air ceiling putty, which ensures that the false air ceiling draft is positive inside the preterm area. So, the environmental air rushes towards the preterm area where there are small holes, gaps and air pockets. We have developed one putty that will seal the small and big gaps and not allow atmospheric air to get trapped inside the preterm area. This increases the efficiency by reducing the false air. Savings in terms of money amount to approximately Rs 2 – 4 crores annually. A normal cement plant can save on this amount by regulating the false air.

New fuels and materials are being used for the making of cement. Do they have an impact on your product or the product is adaptable to all kinds of fuels and materials?
The refractory should be able to withstand high abrasion and chemical attacks. You can get it right if the refractory is chemically not very reactive. There would be an effect of AFR and other fuels but the effect could be minimised and controlled with the use of good refractories. Some companies are facing the problem of coating and maybe cyclones are getting jammed in the plant, so if they use anti-coating castable paints that we manufacture, which is applied over the castables, it provides extra protection against chemical attacks and abrasion. Companies are using such innovative products to minimise the effect of the alternative fuels.
All refractories are obtained from mining the earth and natural resources are depleting. The biggest challenge for any refractory manufacturer is to maintain the same quality of products. With depleting resources, they have to get new mixed designs in such a way that the quality is sustained.

Is there a way to making refractories that will not deplete the natural resources?
As such there is no solution. But it can be used in a conservative way. If you use a good refractory with better life and overall tonnage, it will help produce the same amount of cement.

Tell us about the innovations and new developments in refractories.
This year there is a continuous improvement in the quality and products that we are producing. If you consider castable, we have increased our range of constables, with more focus on inlet refractories where more and more companies are using
AFR, PET coke and other alternative fuels. We have developed refractories that minimise chemical abrasion. Even with the use of AFR and other deteriorating fuels, we are able to increase the life of inlet refractories considerably.

-Kanika Mathur

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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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Concrete

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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