Connect with us

Concrete

A cement plant is a high energy intensive unit

Published

on

Shares

Pankaj Kejriwal, Managing Director, Star Cement, delves into the importance of optimising refractories to make cement manufacturing more cost efficient and eco-friendly.

Tell us about the role of energy in the manufacturing of cement? What is the volume of energy consumption?
A cement plant is a high energy intensive unit. For manufacturing of cement, both thermal energy and electrical energy is required. In the year 2022-23, thermal energy consumption was 27.50 lakh mKcal (82 per cent of total energy) and electrical energy consumption was 5.97 lakh mKcal (18 per cent of total energy). In the cement industry, about 60 kWh of electrical energy is consumed to produce one ton of cement.
The power consumption pattern is as follows:

What are the various modes of energy sources used by your organisation for its manufacturing needs?
The electrical power is taken from various sources such as IEX through open access from state electricity grid and our own captive coal/biomass fuel based thermal power plant, bamboo chips and AFR like RDF is also being used in our plants. We have recently commissioned a 12.3 MW waste heat recovery system (WHRS) plant, and another 12.5 MW WHRS plant is in the pipeline. We are also installing about 15 MW of solar power plant.
The thermal energy is produced by coal in kiln. Linkage coal is utilised in kiln along with various local or purchased coal.

Which of the said energy sources yields maximum productivity for the plant and which yields the least?
Coal, pet coke and electricity are the dominant energy sources used in cement plants, although plants will burn a variety of other fuels, including tires, biomass, RDF and other waste fuels.
As per the mentioned energy sources, WHRS with CPP is our first priority whereas grid (IEX) power is the least priority energy source. As an AFR, we are using bamboo chips, bamboo briquettes and waste plastic bags in our plant. The green energy sources have large impact on the productivity and cost of cement manufacturing. It reduces the carbon emission. As a cost impact, it reduces power cost by 12 per cent in CPP and 1.5 per cent in process plant approximately.

What are the alternative energy sources that are being adapted by the cement industry and your organisation?
The main alternative fuels used in cement industry are residue oil and solvents, contaminated garbage, process waste from food industry / pharma industry, used tires and rubber waste, plastic waste, sewage sludge and waste animal meal. Star Cement uses alternative energy sources such as biomass like municipal waste, bamboo chips and are also installing a 15 MW solar energy plant.

What is the impact of greener energy sources on the productivity and cost of cement manufacturing?
Alternative fuels utilisation in cement industry reduces the production cost and also reduces the coal requirement, coal handling/grinding etc.

How does automation and technology help in optimising the use of energy in cement plants?
By leveraging the power of automation and AI-driven analytics, the cement industry can reduce maintenance costs, enhance equipment reliability, and achieve higher energy efficiency, ultimately leading to improved productivity and profitability.
We are also focusing on automation and technology up gradation to optimise the use of energy in cement plants. To achieve this, various steps has been taken towards energy conservation and technology absorption, few are as mentioned below:
• Installed VFD in Primary Air blower by which control the rpm of blower as per process requirement and saved the energy 86,000 kWh per year.
• Optimisation of RABH purging operation. Total power saving is 2,80,000 kwh per year.
• VFD installed in VRM bag filter of 55 Kw motor, by which saving achieved 7920 kWh per year.
• Increased clinker production and optimised
the running of the different circuits, by which specific power consumption is reduced by 1.08 kwh/MT clinker.
• Optimised the coal firing system and higher clinker production reduced the specific heat consumption by 7 Kcal/kg clinker.
• Installed tertiary crusher in raw mill circuit, thereby increasing ball mill output and reducing power consumption b 2 KW / tonne of raw meal.

What are the major challenges your organisation faces in managing the energy needs of cement manufacturers?
The major challenges for our organisation in managing the energy needs for the cement manufacturing process is the less availability of alternative fuels in plant locality. The segregation of waste is yet to improve and also the Polluter Pay Principle is not being implemented effectively,
thereby increasing the cost of alternative fuel at our factory gate.
Cement industry have a long way to go as far as alternate fuel and raw material usage is concerned.
In spite of several policy, regulatory or technological barriers that industry is facing, now is the opportune time for the Indian cement industry to focus all its efforts in furthering AFR utilisation in its processes.

Tell us about the compliance and standards followed by you to maintain energy use and efficiency in the organisation?
Our organisation is a designated consumer under PAT cycle 2 and 3. We are following all the compliance and standards as per BEE guidelines to achieve our Specific Energy Consumption targets as directed by Bureau of Energy Efficiency, Ministry of Power, Government of India.
As per BEE guidelines Mandatory Energy Audit, monitoring and verification audits are conducted to ensure optimum use of energy after every three years. We have also conducted detailed energy audit by CII, Hyderabad, in May 2023 as an additional exercise.

What kind of innovations in the area of energy consumption do you wish to see in the cement industry?
Use of solar power, hydrogen fuel and maximising the use of AFR are the areas of innovations, we wish to see in the cement industry in near future. Also increasing the efficiency of WHR boilers will help in better recovering the waste heat.
Along with cheaper and greener fuel sources, we would like technology to further reduce the
energy consumption in the grinding process.
Usage of alternative materials, which reduce the overall clinker component in blended cement like LC3 will also go a long way in reducing the
energy requirements.

-Kanika Mathur

Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

Published

on

By

Shares



FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

 

Continue Reading

Concrete

Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

Published

on

By

Shares



Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

Continue Reading

Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

Published

on

By

Shares



Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

To read the full article Click Here

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds