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Acryterna beyond heat: The importance of dimensional stability

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Performance and material selection in industrial filtration

Filtration plays a critical role in improving air quality, particularly in industries such as steel, cement and mining. In these sectors, filter cost and service life are key performance indicators. Premature failure of filter bags leads to increased costs, production losses, and environmental concerns, while frequent replacement also raises labour and operational expenses. Therefore, durability and extended service life are central to the evaluation of filtration systems.
Baghouse filtration systems are among the most effective industrial separation technologies for capturing fine particulates. However, evaluating performance solely based on initial filtration efficiency is insufficient. Parameters such as pressure drop, cleanability, dimensional stability, and bag lifetime must be considered together to ensure long-term efficiency and reliability.
Polyacrylonitrile (PAN) fibres are widely used in industrial filtration due to their high thermal stability, low shrinkage, resistance to many organic solvents, and strong hydrolysis resistance. These properties make PAN-based materials particularly suitable for demanding process environments such as cement plants, where acidic conditions are prevalent.

Operating conditions and material performance in cement plants
In the cement industry, hot gas filtration is characterised not only by high temperatures but also by dynamic conditions involving fluctuating humidity and chemical loading. These factors directly affect both filtration performance and material durability.
For this reason, homopolymer acrylic fibres have been developed to provide long-term mechanical and chemical stability under elevated temperatures and harsh operating environments.
The preference for homopolymer fibre-based filter bags in cement plants is driven by several factors, including stable performance within the medium temperature range of 120–140 °C, strong chemical resistance in acidic environments, and cost-effectiveness achieved through extended service life. These characteristics help reduce maintenance frequency while supporting operational continuity.
While homopolymer fibres are recognised in the literature for their chemical and thermal stability, the performance of filter media in cement applications extends beyond particulate capture. Materials must also withstand aggressive process gases, humidity fluctuations, and continuous mechanical stress. Therefore, material selection should not be limited to temperature resistance alone, but should also consider the ability to maintain mechanical, chemical, and dimensional integrity under real operating conditions.

Impact of dimensional stability on filtration performance
Dimensional stability is a critical performance parameter in practical applications. Changes such as shrinkage, elongation, or deformation during service can negatively impact filtration efficiency. These changes may increase friction between the bag and cage, cause stress concentration at seams, and lead to sealing issues at the bag opening.
Acryterna homopolymer fibre has been specifically engineered to minimise these risks through its ‘no dimensional change’ characteristic. This stability ensures predictable bag behaviour, balanced load distribution, and more efficient maintenance planning.

Conclusion
The performance of materials used in hot gas filtration in the cement industry should be evaluated from both polymer chemistry and field performance perspectives. PAN-based structures offer a balanced combination of mechanical strength, thermal stability and chemical resistance, while known degradation mechanisms under hydrolysis highlight the importance of proper material selection. In this context, homopolymer acrylic fibres stand out as a reliable and sustainable solution for demanding filtration conditions.

(Communication by the management of the company)

Concrete

CII Calls for Greater Alternative Fuel Use in Cement Industry

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The Confederation of Indian Industry (CII), through its Green Business Centre and Energy Efficiency Council, inaugurated the 16th Conference on Alternative Fuel and Raw Material Usage (AFR) in Goa on 27 October 2026. The two-day conference brought together more than 350 industry leaders, policymakers, waste management experts and technology providers to explore strategies for accelerating alternative fuel adoption in India’s cement industry.

Held under the theme ‘Preparation for Net-Zero: Alternative Fuels & Raw Material in Cement Manufacturing’, the conference focused on reducing dependence on conventional fuels, improving waste utilisation and strengthening circular economy practices across cement manufacturing operations.

E R Raj Narayanan, Chairman, AFR Conference 2026, and Business Head and Chief Manufacturing Officer, UltraTech Cement, highlighted the industry’s progress in alternative fuel adoption. He emphasised the need to scale implementation, strengthen supply chains and extend circularity beyond fuel substitution to alternative raw materials through technological innovation and industry collaboration.

Harish Adconkar, Managing Director, Goa Waste Management Corporation, highlighted Goa’s progress in scientific waste management and refuse-derived fuel (RDF) production. He stated that approximately 765,000 tonnes of RDF had been supplied to cement plants, contributing to an estimated displacement of 320,000–560,000 tonnes of coal. He emphasised the importance of consistent RDF offtake and stronger coordination between urban local bodies, waste management agencies and cement manufacturers.

Dr L P Singh, Director General, National Council for Cement and Building Materials, identified AFR as an important opportunity for decarbonisation and resource efficiency. Drawing parallels with the industry’s successful utilisation of fly ash, he stressed the need to address quality, technological and economic challenges to expand alternative fuel adoption.

Dr Sharad P Kale, Special Advisor to the Chief Minister of Goa and former Head of Technology Transfer and Collaboration at BARC, emphasised treating waste as a resource. He highlighted decentralised biodegradable waste processing, reduced food waste and improved resource recovery as essential measures for minimising landfill dependence.

Kiran Ananth, Executive Director, Energy Efficiency, Renewable Energy and Green Entrepreneurship, CII-Green Business Centre, noted that India’s cement production reached approximately 491 million tonnes in FY2025-26, while the industry’s thermal substitution rate (TSR) stood at 7.5 per cent, with around 7 million tonnes of alternative fuels utilised annually.

He added that the industry had invested over Rs 12 billion in co-processing infrastructure during the past six years. Improving RDF supply reliability and quality assurance would be crucial to maximising the utilisation of existing infrastructure and accelerating industrial decarbonisation.

The conference also featured discussions on advanced AFR co-processing technologies, waste pre-processing solutions and industrial best practices for improving fuel substitution and resource recovery.

A publication titled ‘From Waste to Kiln: Scaling the Use of MSW-Derived RDF in Indian Cement Plants’ was launched during the inaugural session. The report identified inconsistent RDF supply and quality as major barriers to achieving higher thermal substitution rates.

According to the publication, many cement kilns already possess the technical capability to achieve higher alternative fuel substitution. However, variations in RDF availability, moisture content, particle size and calorific value continue to limit utilisation. The report emphasised the need to strengthen waste segregation, pre-processing and aggregation systems to establish reliable RDF supply chains.

The conference’s second-day agenda includes discussions on innovative domestic and industrial waste management solutions, alternative raw materials for low-carbon cement and strategies to increase alternative fuel utilisation across India’s cement manufacturing sector.

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Concrete

Sameera Group Enters Industrial and Logistics Real Estate

Rs. 1.5 bn project to support manufacturing and supply-chain firms

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Sameera Group has entered the industrial and logistics real estate segment with a 450,000 sq ft development in Sriperumbudur, Chennai. The group will invest Rs. 1.5 bn in the project, expanding beyond residential plotted developments into business-to-business real estate.

The proposed park will serve light manufacturing, e-commerce, third-party logistics and other supply-chain businesses. Building plan approvals have been secured, with construction expected to begin shortly. The development is scheduled to become operational within 12 to 15 months.

Sameera Group Managing Director and Chief Executive Officer Jayakumar Murugesan said the project marked the next stage of the company’s growth after nearly four decades in land acquisition and real estate development. He attributed the choice of Sriperumbudur to its industrial activity and growth prospects.

The Grade A development will include internal movement routes and shared infrastructure for modern manufacturing and logistics operations. The group is pursuing Indian Green Building Council (IGBC) Platinum certification and plans to provide rooftop solar readiness, rainwater harvesting, wastewater recycling, energy and water monitoring, and electric vehicle charging facilities.

The project is being developed amid increased demand for industrial and warehousing space in Chennai. Knight Frank’s India Warehousing Market Report 2026 recorded 8.3 mn sq ft of warehousing transactions in the city during 2025, up 42 per cent from the previous year, with manufacturing accounting for 59 per cent of demand. The Sriperumbudur-Oragadam cluster contributed 77 per cent of transactions.

Sameera Group plans to develop 5 to 6 mn sq ft across a larger industrial and logistics portfolio over the next five years, involving an estimated investment of Rs. 18 bn. Land has been acquired for projects in Chennai, Hosur and Bengaluru. Established in 1982, the group has developed more than 900 acres, sold over 13,700 residential plots, and currently has 35 projects under development and 28 in its pipeline.

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Concrete

UltraTech Cement Expands in Andhra Pradesh with Rs. 26.5 bn

Petnikota plant adds 3.6 MTPA cement dispatch capacity

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UltraTech Cement has expanded its manufacturing footprint in Andhra Pradesh with the commissioning of Petnikota Cement Works, an integrated cement plant built with an investment of around Rs. 26.5 bn. The facility is located in Petnikota village in Kolimigundla mandal of Nandyal district, in the Rayalaseema region.

Construction of the plant began in May 2025. The facility has a clinkerisation capacity of 3.3 MTPA and a cement dispatch capacity of 3.6 MTPA, strengthening the company’s production and distribution presence in the State.

The plant is expected to provide direct employment to 650 people and indirect employment to another 2,000. It has been designed to operate entirely on green energy and does not have a captive thermal power plant. The project also uses no groundwater, according to information released by the Andhra Pradesh Government.

Nara Lokesh, Andhra Pradesh Minister for Information Technology, said in the release that the facility was taken from groundbreaking to commissioning in 14 months. He described the project as a state-of-the-art addition to the company’s operations in the State and said it would create 2,650 direct and indirect employment opportunities.

Petnikota Cement Works adds to UltraTech Cement’s manufacturing capacity in Andhra Pradesh while supporting industrial activity in Nandyal district. The plant’s energy design and stated groundwater-use policy are also intended to reduce the environmental impact of its operations. The company has identified the facility as part of its continuing capacity expansion in the Indian cement market.

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