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.