Concrete

Climate change and pollution are undeniable realities

Published

1 month ago

January 15, 2025

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Björn Fahle, Technical Sales and Project Engineer, Westeria, in conversation with Kanika Mathur about the innovative use of alternative fuels and waste management solutions.

Westeria is at the forefront of sustainable solutions, transforming waste into alternative fuels for the cement industry. Through innovative machinery and fuel feeding systems, the company enables efficient waste management while promoting greener practices in cement production. Read on to know more about its endeavours in establishing a sustainable ecosystem.

How are you associated with the cement industry, and how do you help better the operations of cement manufacturers?
We operate in two key areas to support the cement industry. On one side, we focus on creating value from waste materials such as municipal solid waste (MSW) and legacy waste. We are helping to reduce the massive waste mountains that are a challenge in India. Our machinery facilitates the sorting, screening, and size reduction of waste to produce alternative fuels, which can be utilised in the cement calciner. This process plays a significant role in waste management while providing a sustainable energy source.
On the other side, we provide alternative fuel feeding lines to the cement industry, enabling the transportation of alternative fuels from the ground to the calciner, which is often located 40 to 50 meters high and up to 200 meters away. These efforts not only address waste management issues but also contribute to reducing carbon emissions. By decreasing the dependency on coal and substituting it with alternative fuels, we are helping the cement industry adopt greener practices. Alternative fuels have a lower calorific value compared to coke or pet coke, and their integration into operations plays a pivotal role in reducing the industry’s carbon footprint.

Speaking of alternative fuels, how do you customise your offerings to address evolving needs?
Most of our current requests revolve around legacy waste and municipal solid waste, as these are the primary challenges India faces. The massive amounts of daily MSW and the existing mountains of waste make this area our main focus. While the use of alternative fuels is gradually evolving, the immediate priority is managing and utilising waste effectively.
Additionally, our shredders are versatile and cater to various applications beyond MSW and legacy waste. For instance, we offer shredders for tiles, wood, and plastic, allowing us to support recycling efforts across multiple industries. By processing wooden logs, plastics, and other materials, we add value to these waste streams, enabling their reuse or recycling into alternative products. This approach reflects
our commitment to sustainability and innovation in waste management.

How do you support the cement industry in becoming more sustainable?
Sustainability is a critical concern for the cement industry, especially in the context of reducing CO2 emissions. India has made remarkable progress in achieving its 2030 carbon emission targets, and the cement sector has been a significant contributor to this effort. By integrating alternative fuels into their operations, cement producers can significantly lower their carbon footprint.
We also foresee advancements in green cement production, with materials such as clay coming into the picture. Our work helps the cement industry transition towards greener practices by promoting the use of alternative fuels and improving the efficiency of fuel feeding systems. Sustainability is no longer optional—it is imperative for long-term environmental and industrial health. By reducing coal consumption and utilising alternative raw materials, we are
steadily contributing to the industry’s shift toward sustainable operations.

What challenges do you face in collaborating with the cement industry?
There are two primary challenges we face in India. First, the type of waste available here is highly contaminated, making the preparation of refuse-derived fuel (RDF) much more labour-intensive compared to other Asian countries. The contamination levels of waste in India demand higher efforts for segregation and processing, which adds complexity to our operations.
Second, the maintenance of machinery poses a significant challenge. Indian workers often do not prioritise proper care and maintenance of expensive machinery. These machines require regular maintenance and proper handling to ensure their longevity and performance. However, the tendency to push materials through the machines without adequate maintenance can lead to wear and tear, reducing their lifespan and efficiency. Segregation of waste—separating
dry waste from wet waste—is another critical aspect that is often overlooked. Proper planning and maintenance are crucial to preserving the functionality of these machines.

What role does technology play in maintaining and operating your machinery?
The alternative fuel recycling (AFR) sector is still in its early stages and operates on an open circuit system. Unlike closed systems used in traditional cement processes, where input materials are well-defined and controlled, AFR operations deal with unpredictable and variable input. This lack of standardisation poses challenges in designing systems that can adapt to such variability.
Currently, cement producers are primarily focused on cement production rather than waste recycling. As a result, recycling machinery often receives less attention and care. This mindset needs to change for the successful integration of recycling into cement production. Advanced technologies and processes must be developed to handle variable inputs effectively and establish more sustainable systems.

What are your views on achieving net zero carbon emissions?
Achieving net zero carbon emissions is a gradual process that requires significant effort and commitment. Drawing from experiences in other Asian countries, such as China, we can see the transformative impact of government-led initiatives. Over the past decade, China has made substantial progress in recycling and pollution control through decisive action and enforcement. While India’s democratic system may take longer to implement large-scale changes, steady progress is possible with strong government support and public awareness.
Sustainability must become an integral part of daily life. Climate change and pollution are undeniable realities, and addressing these challenges requires collective action. Industries, governments, and individuals must align their efforts to create a sustainable future. The cement industry, given its substantial environmental impact, has a pivotal role to play in this transition. By embracing sustainable practices and technologies, we can move closer to a cleaner and greener future.

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Concrete

Global Start-Up Challenge Launched to Drive Net Zero Concrete Solutions

Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations

Published

9 hours ago

February 21, 2025

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Start-ups worldwide are invited to contribute to the global cement and concrete industry’s efforts to reduce CO2 emissions and combat climate change. The Global Cement and Concrete Association (GCCA) and its members are calling for applicants for the Innovandi Open Challenge 2025.

Now in its fourth year, the Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations that help decarbonise the cement and concrete industry.

The challenge is seeking start-ups working on next-generation materials for net-zero concrete, such as low-carbon admixtures, supplementary cementitious materials (SCMs), activators, or binders. Innovations in these areas could help reduce the carbon-intensive element of cement, clinker, and integrate cutting-edge materials to lower CO2 emissions.

Thomas Guillot, GCCA’s Chief Executive, stated, “Advanced production methods are already decarbonising cement and concrete worldwide. Through the Innovandi Open Challenge, we aim to accelerate our industry’s progress towards net-zero concrete.”

Concrete is the second most widely used material on Earth, and its decarbonisation is critical to achieving net-zero emissions across the global construction sector.

Concrete

StarBigBloc Acquires Land for AAC Blocks Greenfield Facility in Indore

The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands.

Published

2 days ago

February 19, 2025

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StarBigBloc Building Material, a wholly-owned subsidiary of BigBloc Construction, one of the largest manufacturers of Aerated Autoclaved Concrete (AAC) Blocks, Bricks and ALC Panels in India has acquired land for setting up a green field facility for AAC Blocks in Indore, Madhya Pradesh. Company has purchased approx. 57,500 sq. mts. land at Khasra No. 382, 387, 389/2, Gram Nimrani, Tehsil Kasrawad, District – Khargone, Madhya Pradesh for the purpose of AAC Blocks business expansion in central India. The total consideration for the land deal is Rs 60 million and Stamp duty.

StarBigBloc Building Material Ltd currently operates one plant at Kheda near Ahmedabad with an installed capacity of 250,000 cubic meters per annum, serving most part of Gujarat, upto Udaipur in Rajasthan, and till Indore in Madhya Pradesh. The capacity utilisation at Starbigbloc Building Material Ltd for the third quarter was 75 per cent. The planned expansion will enable the company to establish a stronger presence in Madhya Pradesh and surrounding regions. Reaffirming its commitment to the Green Initiative, it has also installed a 800 KW solar rooftop power project — a significant step toward sustainability and lowering its carbon footprint.

Narayan Saboo, Chairman, Bigbloc Construction said “The AAC block industry is set to play a pivotal role in India’s construction sector, and our company is ready for a significant leap forward. The proposed expansion in Indore, Madhya Pradesh aligns with our growth strategy, focusing on geographic expansion, R&D investments, product diversification, and strategic branding and marketing initiatives to enhance visibility, increase market share, and strengthen stakeholder trust.”

Bigbloc Construction has recently expanded into construction chemicals with Block Jointing Mortar, Ready Mix Plaster, and Tile Adhesives, tapping into high-demand segments. The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands, ensuring superior bonding, strength, and performance.

In May 2024, the board of directors approved fund-raising through SME IPO or Preferential issue to support expansion plans of Starbigboc Building Material subject to requisite approvals and market conditions, Starbigboc Building Material aims to expand its production capacity from current 250,000 cubic meters per annum to over 1.2 million cubic meters per annum in the next 4-5 years. Company is targeting revenues of Rs 4.28 billion by FY27-28, with an expected EBITDA of Rs 1.25 billion and net profit of Rs 800 million. In FY23-24, the company reported revenues of Rs 940.18 million, achieving a revenue CAGR of over 21 per cent in the last four years.

Incorporated in 2015, BigBloc Construction is one of the largest and only listed AAC block manufacturer in India, with a 1.3 million cbm annual capacity across plants in Gujarat (Kheda, Umargaon, Kapadvanj) and Maharashtra (Wada). The company, which markets its products under the ‘NXTBLOC’ brand, is one of the few in the AAC industry to generate carbon credits. With over 2,000 completed projects and 1,500+ in the pipeline, The company’s clients include Lodha, Adani Realty, IndiaBulls Real Estate, DB Realty, Prestige, Piramal, Oberoi Realty, Tata Projects, Shirke Group, Shapoorji Pallonji Group, Raheja, PSP Projects, L&T, Sunteck, Dosti Group, Purvankara Ltd, DY Patil, Taj Hotels, Godrej Properties, Torrent Pharma, GAIL among others.

Concrete

World Cement Association Calls for Industry Action

The cement industry is responsible for 8 per cent of global CO2 emissions

Published

3 days ago

February 18, 2025

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The cement industry is responsible for 8 per cent of global CO2 emissions—a staggering figure that demands urgent action, particularly as 2024 marked the first year the planet surpassed the 1.5°C global warming limit. Recognising this critical juncture, the World Cement Association (WCA) has released a landmark White Paper, “Long-Term Forecast for Cement and Clinker Demand”, which projects a sharp decline in long-term cement and clinker demand. By 2050, annual clinker production is expected to fall below 1 Gt from its current level of 2.4 Gt, with far-reaching implications for global carbon emissions and the viability of carbon capture projects.

WCA CEO Ian Riley underscores the complexity of this challenge:
“Carbon capture remains a vital tool for tackling emissions in hard-to-abate sectors like cement. However, flawed demand assumptions and the fragmented nature of cement production globally could undermine the feasibility of such projects. Industry stakeholders must rethink their strategies and embrace innovative, sustainable practices to achieve meaningful emissions reductions.”

Key Findings from the WCA White Paper
The WCA White Paper provides a comprehensive roadmap for the industry’s decarbonisation journey, highlighting the following critical insights:
1. Declining Cement and Clinker Demand: Global cement demand is expected to drop to approximately 3 billion tonnes annually by 2050, while clinker demand could decline even more steeply, reaching just 1.5 billion tonnes annually.
2. Implications for Carbon Capture and Storage (CCS): With reduced clinker production, the need for CCS is expected to decline, necessitating a shift in investment and policy priorities.
3. Alternative Materials and Clinker-Free Technologies: These innovations hold transformative potential for reshaping demand patterns and cutting emissions.
4. Supply Chain Optimisation: Enhancing logistics and reducing waste are key strategies for adapting to evolving market dynamics.

A Path to Lower Emissions
Clinker production, the largest source of CO2 emissions in cement manufacturing, generates one-third of emissions from fuel combustion and two-thirds from limestone decomposition. According to our white paper, transitioning to lower-carbon fuels could reduce specific fuel emissions per tonne of clinker by nearly 70% by 2050. Overall CO2 emissions from cement production are forecast to decline from 2.4 Gt in 2024 to less than 1 Gt by 2050, even before factoring in carbon capture technologies.

Ian Riley emphasised: “This white paper provides actionable insights to help the cement industry accelerate its decarbonisation journey. By prioritising innovation and collaboration, the industry can achieve substantial emissions reductions and align with global climate goals.”