Concrete

Waste Heat Recovery System is a key area for cement producers

Published

3 years ago

June 12, 2023

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Guilherme Mendonca, Head Energy Business, Siemens, elaborates about co-creating innovative technology solutions for the cement industry.

What are the key features of your Waste Heat Recovery System that make it an eco-friendly solution for cement manufacturing?
Steam turbines are the heart of every power plant. In waste heat recovery (WHR), steam turbines act as an essential piece of the whole system. Our modular design concept ensures high flexibility, availability, and efficiency, playing a significant role in many industrial plants for waste heat recovery and cogeneration application. In India different technologies exist to convert thermal heat into power like Steam Rankine Cycle (SRC), Organic Rankine Cycle (ORC) and Supercritical Carbon Dioxide Cycle (sCO2). However, only SRC and ORC are fully commercialised with SRC being a more popular technology with decades of proven results. Through efficient use of our steam turbines our customers can extract high power output with the available waste heat, enabling them to reduce their carbon footprint. Siemens Energy WHR solutions are capable of meeting all these requirements which are specific to the Indian
cement industry.

How does your system help reduce carbon emissions during the cement production process?
Waste Heat Recovery System (WHRS) is a key area for cement producers to improve plant efficiency and reduce their carbon footprint by utilising the waste heat from the cement manufacturing process. Siemens Energy’ waste heat recovery system is highly efficient with Heat ReCycle Power Plants offsetting the emissions when compared to other technology that is typically used to generate equivalent power, like diesel generators and reciprocating engines or small coal fired power plants. This results in overall reduced emissions and reduction in dependability on fossil fuels.

What are the estimated energy savings that can be achieved by installing your system in a cement plant?
These plants are highly customised solutions and savings can vary depending upon various factors such as source of upstream power generation, plant configuration and degree of waste heat available. Given ideal conditions, waste heat recovery power plants can offset approximately 30 per cent of total electricity requirement of a typical cement plant in India. In 2012, the Rohrdorf cement works in Germany commissioned the first waste heat and gas power plant in Europe. The plant produced over 30 per cent of the site’s power while saving 12,000 tpa of fossil fuels and reducing CO2 emissions by 30,000tpa. We have come a long way since then in terms of technology adoption and benefits. In practical applications, plants that have implemented waste heat recovery systems have been proven to reduce carbon intensity by as much as 25kg/t of clinker produced.

How long does it take for the system to pay for itself through energy savings?
The pay-off is faster than conventional grid-connected power plants by up to 40 per cent in an ideal situation. This return-on-investment calculation considers 30 per cent electricity offset and variations in energy prices as well as carbon credits and cost of decarbonisation.

What is the expected lifespan of the system, and what maintenance is required to keep it functioning optimally?
Generally, the operating lifespan of steam-based WHRS is 20 years. Typically, it works for 8,000 operating hours per year. The availability and adoption of digital solutions such as remote diagnostic services that allow proactive, predictive maintenance and minimises forced outages.

Can your system be customised to meet the specific needs of different cement plants?
Yes. This is a fully customised solution taking into account all the cement plant constraints and available waste heat sources and quality of waste heat.

What are the major challenges of a WHRS when installed in a cement plant?
Some key challenges of installing WHRS are design limitations due to available technologies and constraints such as source of heat, space available and integration. With these being mostly brownfield projects, the integration with minimum downtime and minimum process disruption also add to the challenges. However, this can be planned and mitigated with efficient project management from Siemens Energy.

How do you envision your collaboration with the cement industry in the decade to come?
We envision a strong collaboration with the cement industry in the decade to come, which is primarily driven by a shared commitment to sustainability and reducing carbon emissions with WHRS at the centre. We see WHRS as a key technology that can help cement manufacturers achieve their sustainability goals while also providing energy savings and cost reductions. Looking to the future, our collaboration with the cement industry will continue to be focused on co-creating innovative technology solutions that are tailored to the specific needs of individual cement plants in India.

–Kanika Mathur

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World Cement Association Annual Conference 2026 in Bangkok

Global leaders to focus on decarbonisation and digitisation

Published

2 hours ago

March 2, 2026

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The World Cement Association (WCA) will host its 2026 Annual Conference from 19–21 April 2026 at The Athenee Hotel in Bangkok, Thailand. The two-day programme will convene global cement industry leaders, policymakers, technology providers and stakeholders to examine strategic, operational and sustainability challenges shaping the sector’s next phase of transformation. The conference theme of shaping a sustainable future through digitisation, innovation and performance will frame sessions and networking opportunities across the event.\n\nThe programme will open with a comprehensive assessment of the global economic environment and its impact on cement markets, alongside regional outlooks across Asia and Europe. Speakers will address regulatory developments including carbon border adjustment mechanisms (CBAM) in Europe, progress in China’s carbon trading system and market dynamics in Thailand and South East Asia, and will outline practical decarbonisation pathways such as alternative fuels, next-generation supplementary cementitious materials (SCMs) and calcined clay developments. Sessions will also examine AI-enabled kiln optimisation and other digital approaches to improve plant performance.\n\nDay two will focus on overcapacity challenges and industry restructuring, using case studies and regional perspectives to provide delegates with practical insights into unlocking performance while accelerating decarbonisation. Discussions will explore digital maturity and AI-driven plant operations, manufacturing optimisation, sustainable building solutions and circular concrete models, together with evolving customer requirements across the construction value chain. The event will include the WCA Awards Ceremony at the Awards Gala Dinner on 20 April to recognise excellence in sustainability, innovation, safety and leadership.\n\nPhilippe Richart, chief executive officer of the WCA, said the sector was navigating a period of profound transformation, from managing overcapacity and market volatility to deploying AI and delivering measurable decarbonisation, and that the Annual Conference would bring global leaders together to exchange practical solutions and strengthen collaboration. Registration is open and tickets include admission to the two-day event, all sessions, refreshments and lunch, exhibition access and the Awards Gala Dinner. Further information on the programme is available via the WCA Annual Conference 2026 event page and queries on sponsorship or exhibition may be directed to events@worldcementassociation.org.

Concrete

Assam Chief Minister Opens Star Cement Plant In Cachar

New plant aims to boost local industry and supply chains

Published

2 hours ago

March 2, 2026

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Chief Minister Himanta Biswa Sarma inaugurated the Star Cement plant in Cachar on 28 February 2026, marking the opening of a manufacturing facility designed to serve the region. The event was attended by state officials and company representatives, and it was reported with inputs from ANI. The plant is positioned as a strategic addition to the industrial landscape of southern Assam and is expected to improve the availability of construction materials for local projects.

The establishment is expected to generate employment opportunities and to stimulate ancillary businesses in the supply chain, including transport and local vendors. State officials indicated that the plant will enhance logistical efficiency by reducing the need to transport cement over long distances, which may lower construction costs for public and private projects. Observers said the presence of a regional cement facility can support housing and infrastructure initiatives that are underway or planned.

Government representatives reiterated that the state seeks to attract responsible investment that complements regional priorities and that the administration will continue to facilitate infrastructure and connectivity to support industrial operations. The inauguration was presented as consistent with broader efforts to diversify the industrial base in the northeast and to create an enabling environment for small and medium enterprises that supply goods and services to larger manufacturers.

Company sources and the state leadership underlined the importance of maintaining environmental safeguards while pursuing industrial growth, and they signalled that compliance with applicable norms will be a priority at the new facility. The announcement was framed as a step towards balanced development that links job creation, regional supply chains and local economic resilience. The report was prepared by the TNM Bureau with inputs from ANI.

Concrete

Adani Cement, NAREDCO Form Strategic Alliance

Partnership to advance skills and sustainable construction

Published

2 hours ago

March 2, 2026

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Adani Cement has entered into a strategic partnership with the National Real Estate Development Council (NAREDCO) to support India’s expanding housing and infrastructure requirements aligned with the vision of Viksit Bharat 2047.

The collaboration brings together Adani Cement’s building materials portfolio, research capabilities and technical expertise with NAREDCO’s network of over 15,000 member organisations. The partnership will focus on skill development, knowledge exchange, technology adoption and sustainable construction practices across the real estate ecosystem.

Joint initiatives will include certification programmes for masons and contractors, along with training modules for site supervisors from NAREDCO member organisations to strengthen execution standards and quality control. The partners will also promote modern construction technologies, green materials and integrated building solutions, including ready-mix concrete, while exploring support for affordable housing.

Vinod Bahety, CEO – Cement Business, Adani Group, said, “This partnership reflects a shared commitment to nation-building and to creating an ecosystem where quality, innovation, and sustainability are integral to every project. By working closely with NAREDCO, we aim to equip developers with advanced materials, deeper technical support, and structured knowledge platforms that can improve performance across the entire project lifecycle.”

Dr. Niranjan Hiranandani, Chairman, NAREDCO, stated that the association aims to encourage responsible construction practices and promote adoption of green building norms across expanding urban centres.