Concrete

Our large motors are engineered to boost productivity

Published

5 days ago

September 23, 2024

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Neeraj Kulkarni, Regional Division President – India, MEA and LatAm, Large Motors and Generators Division, ABB India, talks about opportunities for advanced, energy-efficient electrical equipment to support sustainable development across various sectors.

What are the growth trends in the Large Motor and Generator market in India, and what future opportunities does it hold?
Fueled by India’s rapid industrialisation and urbanisation, we are witnessing robust growth in the manufacturing and industrial sector. With India’s real GDP projected to expand between 6.5 per cent and 7 per cent in fiscal year 2024-25, there is a significant upsurge in demand across various sectors. This accelerating urbanisation is amplifying our reliance on essential materials such as steel, copper, and concrete and this trend underscores the critical need for advanced, energy-efficient electrical equipment to support the infrastructure that underpins our modern way of life – spanning residential, commercial, and transportation sectors.
Some of the key drivers of this growth include major infrastructure projects and smart city initiatives, which require high-capacity and reliable motors. Additionally, the priority to modernise and replace aging infrastructure with cutting-edge solutions is further pushing demand for advanced Large Motors and Generators offerings. As we transition towards cleaner energy sources, the need for efficient, high-performance electrical equipment and grid stability becomes even more pronounced. ABB is well-positioned to address these needs through our cutting-edge technology and tailored solutions for large motors, generators and synchronous condensers, ensuring that we continue to meet the evolving demands of the Indian market effectively.

How does ABB’s Large Motors and Generators technology specifically contribute to improving energy efficiency in the cement industry?
Energy efficiency is critical for developing a sustainable and cost-effective energy system. ABB’s Large Motors and Generators technology is pivotal in advancing energy efficiency within the cement industry by delivering exceptional performance and operational benefits.
Our high-efficiency induction motors, used in key applications such as crushers, mills, and kilns, significantly reduce energy consumption, leading to lower operational costs and reduced carbon emissions. By integrating these large motors with Variable Speed Drives, we provide precise control over motor speed and torque, optimising performance to meet the specific demands of the cement production process. Furthermore, ABB’s advanced condition monitoring solutions continuously monitor and manage motor and generator performance. These systems detect inefficiencies or variances in real time, enabling predictive maintenance and minimising downtime. This proactive approach ensures that equipment operates at peak efficiency, thus reducing overall energy consumption. Our large motors and generators are designed using advanced techniques such as high-efficiency sheet steel and optimised winding designs to help in minimising energy losses and enhancing overall system efficiency.

What are the key challenges faced by cement manufacturers in implementing energy-efficient technologies, and how does ABB support to overcome these challenges?
While the cement industry has been quick to adopt high-efficiency motors, implementing energy-efficient technologies presents several challenges. These include the complex and resource-intensive process of accurately measuring energy savings and benefits, as well as a gap in awareness and concerns about the affordability and accessibility of new technologies. Additionally, manufacturers often face difficulties optimising existing assets, such as choosing to replace old motors with similar models instead of upgrading to more efficient ones, balancing short-term convenience with long-term ROI and sustainability. Variations in energy costs, financial constraints, split incentives among stakeholders and an absence of supportive policies further complicate the adoption of energy-efficient technologies.
We are addressing these challenges with a comprehensive strategy designed to facilitate the adoption of higher efficiency technologies. Our solutions are crafted to deliver measurable improvements in energy efficiency while ensuring reliability and safety. We provide tailored integration and customisation services that align with existing systems, optimising performance. A testimonial to this solution is when we replaced a 30-year-old, 2.7MW synchronous motor that was driving a cement mill with a slipring motor, enhancing uptime, reliability and efficiency. ABB also offers extensive service support and training to help customers fully leverage our technologies. Additionally, we assist in evaluating the financial aspects and ROI of retrofit projects, providing expert guidance to navigate financial and regulatory obstacles. Through these efforts, our endeavour is to empower cement manufacturers to overcome barriers, leading to enhanced operational performance and sustainability.

Could you provide examples of how ABB’s solutions have been successfully integrated into cement plants to enhance operational efficiency and reduce energy consumption?
ABB has successfully integrated its advanced solutions into cement plants in India, significantly enhancing operational efficiency and reducing energy consumption. A notable example is of a cement plant in the central part of India with production capacity of approximately 2.6 MTPA, which sought to improve its energy efficiency and reliability while maintaining high production standards. To address these demands, we provided high-efficiency modular induction motors to replace older, less efficient units. This upgrade resulted in substantial improvements in energy efficiency. Additionally, we installed variable speed drives to precisely control the speed of motors driving critical equipment such as mills and fans. This integration allowed for optimal motor performance, finely regulated energy usage, and significant reductions in overall energy consumption. For grinding units, our tailored offerings of large induction motors and drives for high pressure grinding rolls have brought significant operational efficiencies to our clients.

In what ways do ABB’s products contribute to the long-term sustainability and cost-effectiveness of cement manufacturing operations?
ABB’s products play a crucial role in enhancing the long-term sustainability and cost-effectiveness of cement manufacturing operations by prioritising safety, reliability, maintainability, and efficiency. Our large motors are engineered to boost productivity while minimising energy consumption, extending equipment lifespan, and reducing downtime. By adhering to stringent safety regulations and technical requirements, our offerings are designed to meet specific customer needs, thereby lowering carbon footprints and operational costs. ABB was the first company in India to launch IE4 motors for LV motors many years ago. We are now the first company in India to offer IE4 class efficiency for HV motors as per the new IEC standards IEC/EN 60034-30-3 for direct on-line high voltage motors.
Also, ABB’s commitment to sustainability is reflected in our optimised designs that offer a competitive total cost of ownership (TCO). Our advanced digital offerings, including remote monitoring, preventive and predictive maintenance, and diagnostic solutions, provide comprehensive lifecycle support. This blend of local expertise and global experience ensures that cement plants can achieve operational excellence and sustainability over the long term.

How does ABB’s customer-centric innovation approach ensure that the energy efficiency solutions provided meet the specific needs of the cement industry?
Our customer-centric approach is pivotal in ensuring solutions are precisely aligned with the unique needs of the cement industry. With deep industry and domain expertise, our technical teams fully understand the specific challenges and requirements inherent in cement manufacturing. This knowledge allows us to offer tailored solutions that address the operational demands of the sector effectively. We engage closely with our customers to gain insights into their specific needs and operational contexts, leading to the creation and implementation of customised solutions. These solutions, designed with flexibility, allow seamless integration with existing plant infrastructure and processes and minimises disruptions during implementation, ensuring that new technologies enhance rather than disrupt current operations. Furthermore, our commitment to continuous improvement is reflected in our iterative innovation process. By actively seeking and incorporating customer feedback, we refine and enhance our solutions to address emerging challenges and capitalise on new opportunities within the cement industry
Recently, we launched the ABB MV Titanium, the world’s first medium voltage, speed-controlled motor concept designed for 1-to-5-megawatt motors. This innovative solution represents a major step in our commitment to energy efficiency and sustainability, potentially achieving up to 40 per cent energy savings in applications like pumps, compressors, and fans. Given that these motors account for about 10 per cent of global electricity use, retrofitting with this technology could significantly cut CO2 emissions, equivalent to taking over 1000 coal-fired power
stations offline.

– Kanika Mathur

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Concrete

World’s biggest cement producers bet on green alternative

Holcim and CRH announced a $75 million investment.

Published

9 hours ago

September 27, 2024

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Two of the world’s biggest cement producers, Holcim AG and CRH PLC, are investing in a startup attempting to decarbonize the cement production process. Cement and concrete are responsible for about 8% of emissions, more than any other industrial sector.

Holcim and CRH announced a $75 million investment into Sublime Systems, including a promise to purchase green cement from the startup’s pilot facilities and to work with Sublime on additional plant sites. (CRH invested through its venture arm.) Somerville, Massachusetts-based Sublime has developed an electrochemical method of cement production that avoids the process of heating up limestone with kilns powered by fossil fuels.

Reducing cement emissions has long been a technological and economic challenge. Cement is essential to making concrete, and to roads, buildings and other critical infrastructure. But the material’s production generates carbon dioxide emissions from burning fuel (often coal) to heat kilns, from the decomposition of limestone and from quarrying, grinding and transforming the materials.

In tests at its 250-ton-per-year pilot plant, Sublime has been able to demonstrate a 90% reduction in CO2 emissions compared to traditional concrete, according to Leah Ellis, co-founder and chief executive officer. The company is developing a commercial plant in Holyoke, Massachusetts, that would have a capacity of 30,000 tons per year and is set to be completed in 2026. The Energy Department’s Office of Clean Energy Demonstrations will fund up to 50% of that plant’s construction.

Ellis said Sublime’s goal is to provide its technology to larger cement companies with existing infrastructure and supply chains, which would either build new cement plants with the tech or retrofit old ones.

While Sublime’s process generates far fewer emissions, there are many hurdles the company and others like it need to overcome before they can commercialize successfully. One major limitation is the significant capital costs associated with retrofitting cement plants — often large, custom operations — or building new ones.

Another is demand: Low-carbon cement remains more expensive, on average, than traditional cement, making it a hard sell for a construction industry that already operates on razor-thin margins. New regulations, including New York’s mandate for state agencies to buy clean concrete, could help boost demand, said Ash Lauth, a senior campaign strategist for the global cement initiative at Industrious Labs, a US-based nonprofit focused on industrial decarbonization. But the industry still has a long way to go: Last week, Industrious Labs published an analysis that gave Holcim a “D” grade on its sustainability efforts.

“While we’re encouraged that Holcim is investing in Sublime’s innovative technology, we also still want them to show up for the rest of the ways to decarbonize… and work towards issuing a clear and transparent plan for how they’re going to decarbonize their existing US fleets,” Lauth said. Nollaig Forrest, Holcim’s chief sustainability officer, said Holcim is among “the only players in our sector that really takes a whole value chain approach to decarbonizing building at scale.”

The investment from Holcim and CRH brings Sublime’s total funding to over $200 million since its founding in 2020. It’s another signal of confidence in the startup, which was one of six projects selected for the Energy Department’s $1.6 billion program to fund cement and concrete decarbonization.

Concrete

Govt approves FSNL to Japan Konoike Transport sale for Rs 3.2 billion

Konoike’s bid of Rs 3.2 billion surpassed the reserve price of Rs 2.62 billion.

Published

9 hours ago

September 27, 2024

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The Indian government has approved the sale of Ferro Scrap Nigam Ltd (FSNL) to Japan’s Konoike Transport Co Ltd for Rs 3.2 billion. FSNL, a 100% subsidiary of MSTC Ltd under the Steel Ministry, will see its entire equity shareholding transferred to Konoike, along with management control.

The decision was made by an Alternative Mechanism comprising Transport Minister Nitin Gadkari, Finance Minister Nirmala Sitharaman, and Steel Minister H. D. Kumaraswamy. Konoike’s bid of Rs 3.2 billion surpassed the reserve price of Rs 2.62 billion, set based on valuations by the government’s Transaction Adviser and Asset Valuer.

Two technically qualified financial bids were received for the strategic sale, with Konoike Transport emerging as the highest bidder. The second bid was from Indic Geo Resources Pvt. Ltd., a subsidiary of Chandan Steel Ltd.

Konoike Transport Co Ltd, listed on the Tokyo Stock Exchange, is a diversified Japanese company with extensive experience in steelworks operations. Its Steel Division, with over 140 years in the industry, offers a range of services including raw material acceptance, manufacturing support, slag treatment, and scrap processing. The company also specializes in recycling initiatives that aim for zero secondary waste.

FSNL, incorporated in 1979, provides steel mill services such as scrap recovery and processing from slag generated during iron and steel production across various steel plants in India.
(Business Standard)

Concrete

Relief for Birlas and cement company directors

Shrivastava had filed a criminal case in the Vadodara court, which lacked jurisdiction to entertain the matter.

Published

9 hours ago

September 27, 2024

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The Gujarat High Court has halted criminal proceedings and summons issued against Kumar Mangalam Birla, his mother Rajashree Birla, and seven other directors of UltraTech Cement by a Vadodara court, following a criminal complaint.

The summons had been issued on September 9 by the Vadodara chief judicial magistrate in connection with a case filed by Abhishek Shrivastava, the proprietor of Srimech Engineering. The directors of UltraTech Cement subsequently approached the High Court to challenge the summons. It was argued before the court that there had been a contract between Srimech and UltraTech for the supply of limestone.

This contract, related to mining in Madhya Pradesh, was later terminated by UltraTech for certain reasons, prompting Srimech to file a commercial suit in Rewa district, Madhya Pradesh, in November of the previous year.

The petitioners’ counsel argued that despite this ongoing commercial dispute, Shrivastava had filed a criminal case in the Vadodara court, which lacked jurisdiction to entertain the matter. The court was informed that the issues raised in the criminal complaint were identical to those in the commercial suit.

The counsel further argued that since the complainant had already pursued a civil remedy, the continuation of criminal proceedings would constitute an abuse of legal processes.

In response, Justice Nirzar Desai granted interim relief to the petitioners, staying the Vadodara court proceedings, and issued notices to the state government and the complainant. The case is set for further hearing on December 3.