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Safety is a top priority when handling alternative fuels

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Indrendra Singh Raghuwanshi, Sales Head – Cement Division, ATS Conveyors talks about how advanced bulk material handling solutions enables cement plants to optimise alternative fuel integration, enhance efficiency and drive sustainability.

As the cement industry transitions toward sustainability, efficient handling of alternative fuels has become a critical focus. In this interview, ATS experts share insights into their cutting-edge technologies, safety measures, and future-focused developments that are transforming bulk material handling in the cement sector.

Can you summarise ATS Group’s expertise in bulk material handling for the cement industry?
ATS Group is a recognised leader in bulk material handling solutions for the cement industry, offering a comprehensive range of services and equipment designed to optimise the efficiency and safety of cement production. Our expertise lies in providing innovative, reliable, and cost-effective systems for storage, dosing, conveying and feeding a wide range of AFR materials. Providing support at every stage, from engineering and design to installation, commissioning, and ongoing maintenance. With decades of experience in the cement industry, ATS Group’s innovative material handling technologies enable cement manufacturers to achieve smoother operations, higher Thermal Substitution Ratio (TSR) and long-term operational success.

How does your WMH department help cement plants adopt alternative fuels effectively?
The Walter Material Handling Division of ATS Group plays a crucial role in helping cement plants adopt alternative fuels by providing tailored solutions that ensure the safe, efficient, and cost-effective handling of these materials. As the industry moves towards sustainability, alternative fuels such as Municipal solid waste (MSW), Biomass and Refuse-derived fuel (RDF) are used more commonly in cement production processes. Our expertise enables cement plants to incorporate these fuels with minimal disruption and maximum benefits by the Customised Fuel Handling Systems, AFR storage handling solutions, safety and environmental, expert consultation and support provided by ATS team.

What innovations set your bulk material handling solutions apart in addressing challenges like precision dosing and storage?
Our bulk material handling solutions stand out due to several innovations that address key challenges such as precision dosing and storage. These innovations are designed to enhance efficiency, accuracy, and flexibility, ensuring optimal performance even in complex and demanding environments like cement production. Precise dosing is done using equipment like Weigh Belt Feeder and TWIN Doseahorse whereas storage challenges are easily addressed by the fully automated Grab Crane of ATS.

How do you ensure your systems handle diverse alternative fuels reliably?
Ensuring that our systems handle diverse alternative fuels reliably is at the core of our engineering approach. Alternative fuels, such as biomass, MSW, RDF and industrial waste vary significantly in terms of composition, size, moisture content, and combustibility. All our systems are designed with flexibility and robustness to meet the unique challenges posed by these heterogeneous fuels while maintaining operational efficiency and safety. Also, before deployment to site, we conduct extensive testing for our equipment to ensure that they can reliably handle alternative fuels under a variety of conditions. This includes testing different fuel types, moisture levels, and feeding rates to identify any potential challenges. Our systems are then fine-tuned during the commissioning phase to ensure optimal performance in real-world conditions.

What safety measures are in place for secure alternative fuel handling and kiln feeding?
Safety is a top priority when handling alternative fuels, especially given the potential hazards such as dust generation, flammability and variations in material properties. Our systems are designed with comprehensive safety measures to ensure the secure handling of alternative fuels throughout the entire process, from storage and transport to kiln feeding. The key safety measures foreseen in ATS machines include provision for ATEX components, Temperature sensors, sprinklers and using high temperature material of construction as and where required. Also, ATS supplied machines are integrated with the central control room of cement plants for centralised monitoring, control and diagnosis on real time basis.

How does ATS Group’s material handling support sustainability goals in the cement sector?
The cement industry is energy-intensive and traditionally relies on fossil fuels, but ATS Group’s material handling systems are designed to help cement plants transition to more sustainable practices while maintaining operational efficiency. ATS systems plays a key role in supporting sustainability goals within the cement sector through innovative solutions that optimise alternative fuels handling and integration to maximise energy efficiency, reduce carbon emissions and promote environmental responsibility by waste reduction to contribute for the circular economy.

What future trends in bulk material handling is ATS Group focusing on for the cement industry and have you designed any new innovative product to meet the futuristic demands?
ATS Group, through its Walter Material Handling division, is focused on several key trends in AFR material handling for the cement industry to stay ahead of evolving industry demands, technological advances, and sustainability goals. As cement plants increasingly shift towards more sustainable practices, the efficient handling of AFR materials is becoming more important. By focusing on these trends, ATS Group is actively developing solutions that not only support cement industry’s shift toward sustainable practices but also enhance operational efficiency and reduce environmental impact these solutions include Walt’Air (Air Floating Belt Conveyor). This machine is engineered to address some unique challenges like, accommodating a new conveying system using minimal space utilisation and with minimum changes in the existing plant infrastructure, ensuring safe and spillage-free transportation of AFR for long distances with reduced power consumption as well as low CAPEX and OPEX. Additionally, ATS has developed TWIN Doseahorse which was awarded with the prestigious Product of the year Award in 14th Cement EXPO 2023. This is a specialised solution having common inlet and dual outlet for consistent and accurate division of AFR material to feed in, two different feeding points for individual Kiln or for dual kiln feed, enhancing both economic and environmental performance in cement plants.

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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