Economy & Market

Energy optimisation is an ongoing process

Published

2 years ago

February 12, 2025

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Ashok Dembla, President and Managing Director, KhD Humboldt, in conversation with Kanika Mathur about the use of technology in the grinding process.

The cement industry, responsible for nearly seven per cent of global CO2 emissions, faces a pressing challenge: balancing growth with sustainability. As companies strive for net-zero emissions, innovations in alternative fuels, carbon capture, and energy efficiency are reshaping the sector. From blended cement to cutting-edge kiln electrification, the industry is moving toward a future beyond carbon. In this interview, ICR explores the evolving technologies and strategies driving cement’s decarbonisation journey.

Tell us about cement beyond carbon.
The cement industry contributes approximately 7 per cent of global carbon dioxide emissions, making it one of the largest industrial contributors to climate change. This places a great responsibility on the industry to reduce emissions and promote sustainability. It becomes a moral obligation for us to work toward carbon neutrality or even carbon negativity to protect the environment and ensure a sustainable future for humanity.
Many companies in the cement industry have already pledged to achieve net-zero emissions by 2050 or beyond. At KHD, our focus is on technological innovation to achieve the vision of cement beyond carbon. Cement remains an essential material for infrastructure development and economic growth, and the challenge is to meet this demand while minimising its carbon footprint.
Currently, conventional methods like producing blended cement, which uses less clinker and more fly ash or slag, have been instrumental in reducing emissions. Additionally, technologies like Waste Heat Recovery (WHR) systems have seen significant adoption in India. WHR systems allow plants to recover and reuse heat, improving efficiency. Another method is the use of Alternative Fuels and Raw materials (AFR). While the industry was at just 4 per cent usage of AFR previously, we have now reached around 7 per cent, with an ultimate goal of surpassing 35 per cent, which is the global benchmark.
However, these conventional methods alone will not suffice to achieve complete decarbonisation. Advanced technologies are being explored, such as capturing carbon dioxide from exhaust gases, improving system efficiencies, and implementing oxy-fuel combustion or electrification of kilns. While these technologies are still in various stages of development, I believe they will become economically viable after 2030. The industry’s focus is on continuous research and development to integrate these technologies into our processes effectively.

How is your technology adapting to changing fuels and raw materials?
The use of alternative fuels and raw materials (AFR) is continuously evolving within the cement industry. As a machinery supplier, we are adapting to these changes by providing advanced solutions for handling and processing AFR. One of our most significant innovations is the PyroRotor, an equipment designed specifically for feeding up to 85 per cent of alternative fuels into the pyroclone, which is far beyond what conventional methods can achieve. This has greatly enhanced our ability to replace traditional fuels with more sustainable alternatives.
In addition, we have developed solutions to address nitrogen oxide (NOx) emissions, a critical environmental concern. Our NOx reduction equipment significantly minimises NOx generation during the production process, helping plants meet stringent regulatory requirements.
Optimisation is another critical focus area. Through digitisation and advanced process control systems like PRO-MAX, we are able to optimise the entire cement production process. This system includes kiln and mill control modules, allowing plants to operate more efficiently and reduce both thermal and electrical energy consumption.
Globally, the industry is also moving toward more advanced technologies, such as increasing oxygen content in fuel firing and capturing carbon dioxide directly from flue gases. While these technologies are already being implemented in some European plants, they require significant capital investment and governmental support. India is also taking steps in this direction, with plans for model plants to showcase the viability of these advanced solutions.

Do any of your solutions have an impact on energy utilisation in cement plants?
Energy utilisation in cement plants involves two main types: thermal energy and electrical energy. On the thermal energy front, significant progress has been made over the past decade. Previously, plants required around 750 kilocalories per kilogram of clinker. Today, this has been reduced to 685 kilocalories or even lower, thanks to continuous improvements in process efficiency.
For electrical energy, we have optimised systems like the roller press, which enhances the efficiency of raw material grinding and cement grinding. These advancements have significantly reduced energy consumption per ton of clinker produced.
Energy optimisation is an ongoing process. By integrating advanced technologies and optimising plant operations, we aim to achieve even greater reductions in energy consumption, contributing to both cost savings and environmental sustainability.

How do you see the journey toward net zero unfolding, and what is your perspective on this?
The journey toward net zero is both challenging and rewarding. One of the critical areas we have focused on is the increased use of alternative fuels and raw materials (AFR). The technology to utilise AFR is available, but its successful implementation depends on a well-organised system for waste collection and processing.
In India, progress has been made in cities like Indore and Bengaluru, where systems for waste segregation and preparation are more developed. However, there is still a long way to go to make this a common practice across the country. Government support is crucial in this regard, especially in establishing efficient logistics systems to transport waste from its generation point to cement plants for use as fuel.
Collaboration between industries, government bodies, and city administrations is essential to achieve the full potential of AFR utilisation. The ultimate goal is to make the use of AFR economically viable while ensuring that the logistics and supply chain challenges are effectively addressed.
Net zero is not just a technological goal; it is a systemic change that requires the entire ecosystem to work together. While the industry has made significant strides, much work remains to be done to make net zero a reality.

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Economy & Market

Leonard Unveils Dual-Head Robotic Arm for Hazardous Industrial Demolition

Published

5 days ago

October 30, 2026

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Leonard unveils Descender Duo, a dual-head robotic demolition arm designed to improve industrial safety and reduce shutdown time by up to 50 per cent.

Industrial robotics and refractory services specialist Leonard has launched Descender Duo, a dual-head robotic demolition arm designed to improve safety, accelerate maintenance and reduce shutdown times in hazardous industrial environments. The system made its debut at Lisahally Power Station in Northern Ireland, removing 25 tonnes of slag material within hours.

Developed for the cement, metals, waste-to-energy and petrochemical industries, Descender Duo enables remote-controlled refractory demolition, anchor cutting and welding, and refractory spraying inside boilers, calciners and silos. Its vertical-access design eliminates the need for personnel to enter confined, high-risk spaces during these operations.

Weighing less than two tonnes, the pre-assembled system requires an access opening of just 1.2 m². Supported by an external overhead hoist, it uses electrically operated hydraulic stabilising legs to secure itself inside vessels. The robotic arm offers 360-degree rotation and is suited to vessels approximately 9 m in diameter, with its operating reach extendable through strategically positioned access points.

Equipped with two independently controlled robotic heads, Descender Duo can perform identical or different tasks simultaneously, including refractory demolition, anchor cutting and spraying. Its remote-control system incorporates live camera feeds, allowing operators to monitor operations without entering hazardous environments.

According to Leonard, the technology can deliver time savings of up to 50 per cent compared with manual methods. Its ability to operate at temperatures exceeding 100°C allows maintenance to begin as early as 24 hours after burner shutdown. An all-electric power supply further supports cleaner and more cost-efficient operations.

First Deployment Demonstrates Shutdown Efficiency

The system was first deployed at Burmeister & Wain Scandinavian Contractor’s (BWSC) Lisahally Power Station in Londonderry, Northern Ireland. The facility generates electricity from grade C waste wood, supplying approximately 40,000 homes and businesses.

Leonard and BWSC collaborated to develop a customised solution for the plant’s 26-metre furnace, where extensive external pipework created significant access challenges.

Mark Leonard, Managing Director, Leonard, said, “It required new thinking and rather than step away from the problem we were committed to solving it for the customer, with the customer. We’re relentless in our approach to tackling complex challenges, head-on. We took our years of cement plant experience, coupled with our working knowledge of the BWSC plant, and designed, engineered and tested a completely new vertical solution within just seven weeks from that initial conversation with the customer. That solution was the Descender Duo as we know it today.”

Traditionally, the furnace required a cooling period of up to 36 hours before preparatory work could begin, followed by manual slag removal using rope-access personnel. With Descender Duo, work commenced just 24 hours after shutdown, reducing downtime by up to one day.

The deployment removed 25 tonnes of slag within hours, eliminated the need for at least six workers to enter the hazardous furnace interior and saved 26 hours in the shutdown programme.

“The effectiveness exceeded expectation,” said Martin Doran, Plant Manager at Lisahally Power Station.

“When the Descender Duo concept was first discussed, we had to spend some time with the team from Leonard looking at how it was going to be moved into the furnace. Every site is different and that presented its own challenges, but nothing that the team couldn’t overcome. Once it was installed we were hugely impressed by its efficiency.”

Expanding Industrial Robotics Applications

Descender Duo joins Leonard’s existing portfolio of robotic maintenance solutions, including the Axis horizontal-access arm, Nano confined-space access arm, Charger cement mill media recharging system and Calibre cement mill media grading system.

Headquartered in Northern Ireland, Leonard provides robotic refractory demolition, installation, inspection and industrial maintenance services across the cement, metals, energy, biomass, glass and civil engineering sectors.

Formerly known as G Leonard, the company has more than 35 years of industry experience and operates across Europe, North America, the Middle East, Africa and Asia-Pacific.

The latest innovation reinforces Leonard’s focus on replacing hazardous manual processes with robotic systems that improve workforce safety, enhance operational efficiency and minimise industrial downtime.

Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

5 days ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

Concrete

Fornnax Wins AIRIA’s Special Export Award for Rubber Machinery in 2025-26

Published

2 weeks ago

October 19, 2026

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Fornnax Technology Pvt. Ltd. has been honoured with the Special Export Award – Rubber Machinery for 2025–26 by the All-India Rubber Industries Association (AIRIA), in recognition of its highest exports of tyre recycling plants to the European region.

With more than a decade of experience in India’s tyre recycling industry, Fornnax has contributed to the development of advanced recycling technologies and infrastructure. The company currently holds a 90% market share in India’s domestic tyre recycling sector, while exports account for 30% of its business, spanning markets such as Europe, Australia and the GCC.

The award marks another milestone for Fornnax, whose tyre recycling lines and advanced shredding technologies are supporting the growth of the circular economy in India and international markets.

Commenting on the recognition, Mr. Jignesh Kundaria, Founder and Director of Fornnax, said:

“This honour from AIRIA is a reflection of an incredible journey we have undertaken over the years. When we started Fornnax, there was no established recycling industry in India to follow. We chose to build for the future instead. Today, when you see India’s tyre recycling sector, it has already transformed into a dynamic, high-growth industry and we are extremely proud to have played our part in building it.”

Unlike standalone equipment suppliers, Fornnax focuses on developing complete, high-capacity recycling infrastructure. Its integrated systems combine multiple stages of shredding and size reduction to enable efficient, continuous operations. This system-level engineering approach helps recycling operators improve throughput, equipment reliability and operational consistency.

The recognition reinforces Fornnax’s commitment to developing engineering technologies that contribute to a more efficient and circular recycling ecosystem.

Looking ahead, the company aims to expand its international presence while continuing to develop advanced shredding and recycling solutions to address the growing volumes and evolving requirements of the global recycling industry.

For more information, visit: www.fornnax.com