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AFR has become integral to our fuel mix

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Sanjay Joshi, Chief Projects and Manufacturing Officer, Nuvoco Vistas Corp, discusses the integration of alternative fuels and raw materials (AFR) into cement manufacturing.

Tell us about the alternative fuels and raw materials (AFR) used by your organisation in cement manufacturing.
The AFR usage can decrease environmental impacts, lower consumption of fossil fuels to reduce the economic impact to the cement industry. Fast depleting natural resources like limestone, increased cost of conventional fuels like pet coke and coal, have become a matter of great concern for cement industry all over the world. The high temperature and adequate retention time makes cement kilns most suitable for disposing of alternative fuels. Utilisation of AFR in the cement industry, helps in reduction of the carbon footprint, substituting consumption of fossil fuels and reducing its associated higher cost.
Nuvoco has been a pioneer in this regard, utilising substantial quantities of non-recyclable hazardous wastes, plastics, tire wastes, surplus biomass and RDF as alternative fuels since 2014. To support this initiative, Nuvoco has established comprehensive AFR storage, handling, and feeding facilities in all its plants. Additionally, Nuvoco incorporates alternative raw materials into its cement and clinker raw mix, sourced from industrial and mineral wastes in metallurgy, petrochemicals, chemicals, paper and pulp sectors. These materials include fly ash, slag, metallurgical slags, phosphogypsum and red mud, contributing to a reduced carbon footprint and decreased reliance on fossil fuels and natural conventional raw material.

What factors do you consider when selecting alternative fuels and raw materials?
The selection of AFR for usage in a cement kiln involves a thorough assessment of their potential impacts on clinker and cement manufacturing operations, product quality and the environment. Several important factors must be considered before finalising the choice of AFR.
Among these, key parameters include alkali, sulphur, chloride, trace element content, heat (calorific) value and moisture content. Regular reviews of the acceptance criteria are conducted in accordance with local regulations to ensure ongoing alignment with environmental standards and manufacturing requirements. This comprehensive evaluation
process ensures that the selected AFR optimally contributes to the cement kiln process while
minimising adverse effects on both the product and the surrounding environment.

What is the impact created on the environment by use of AFR in your organisation?
Concerning the co-processing of AFR, the cement industry is actively working towards reducing greenhouse gas emissions and preserving natural resources by incorporating a variety of AFRs in the cement kiln.
To ensure responsible handling, plants have implemented essential infrastructure, including AF storage sheds with impermeable flooring, leachate collection pits, firefighting arrangements and deodorisers, effectively mitigating the environmental impacts of AFR usage. The handling and feeding systems for alternative fuels are centrally operated from the Control Room (CCR), minimising manual interventions throughout the process. Rigorous monitoring and systematic storage procedures are in place for all wastes intended for co-processing in the cement kiln, ensuring a continuous and well-managed approach to environmental sustainability.

Have you faced any challenges or barriers when using AFR in cement production, and if so, how have you overcome them?
Certainly, when incorporating alternative fuels and raw materials, numerous challenges emerge throughout the process. These challenges span from the storage areas, where issues related to non-uniform quality of alternative fuel are encountered, to the pyro system, which has to adapt to process changes and blending during alternative fuel feeding.
In essence, the primary challenges faced in the utilisation of AFR can be succinctly summarised
as follows:

  • Non-homogeneity of the waste: Wastes received by cement plants have varying chemical compositions, which initially result in operational disturbances.
  • Coating, build-ups and refractory issues: The high content of chlorine and alkalis in hazardous solid waste combined with pet coke sulphur results in coating formation. Circulation of volatile salts increases and clogging arises in lower preheater cyclones and riser pipes.
  • Availability of odour control system at storage sites.
  • Wear and tear of equipment used for waste processing: AFR has different foreign materials like silt, glass, metal pieces so it makes heavy wear and tear of pre-processing equipment like shredder, trommel, belt conveyor, etc.
  • Inhouse testing laboratory facilities not being available to check the quality of received material.
  • CCR operators not being trained on operational parameters for alternative fuel usage.
  • All these issues have been analysed systematically, discussed with suppliers and plant original equipment manufacturers (OEM). Some modifications have been made in the feeding system to avoid operational issues. Process related improvements are executed after discussion with OEM, which results in smooth burning of alternative fuels in the system.

How do you see the use of AFR in cement production evolving in the future, and what role do you think your company will play in this process?
In the current landscape of fuel availability and cost considerations, AFR has become integral to our fuel mix. Government initiatives have played a leading role in raising awareness about AFR usage, resulting in a notable uptick. The proliferation of pre-processing facilities, coupled with in-depth research and consultations with cement industries facilitated by catalyst bodies like Confederation of Indian Industry (CII) and Cement Manufacturers Association (CMA), has positioned co-processing as the preferred choice. This approach not only reduces production costs but also contributes significantly to resource conservation on a broader scale.
At Nuvoco Cement, we have embraced co-processing of AFR in all our integrated cement
plants. Our commitment to sustainability is evident through the adoption of new technologies aimed
at increasing the utilisation of AFR. We remain dedicated to continuously exploring and implementing innovative technologies across all our plants, demonstrating our proactive stance towards environmental responsibility.

  • 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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Concrete

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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