Concrete

We have a state-of-the-art AFR lab

Published

2 years ago

June 14, 2024

Roshna

Tushar Khandhadia, Senior General Manager – Production, Udaipur Cement Works Limited (UCWL), elaborates on the benefits, challenges and future prospects of integrating environmentally friendly practices in the cement manufacturing process.

Tell us about the alternative fuels and raw materials used in your organisation.
Our organisation employs a variety of alternative fuels and raw materials (AFR) to enhance sustainability and reduce our carbon footprint. These include:

Alternative fuels: Waste-derived fuels such as municipal solid waste (MSW), tire-derived fuel (TDF), biomass, and industrial waste, waste mix for co-incineration LCV.
Alternative raw materials: Industrial by-products like fly ash, F.F slag, jarosite chemical gypsum, granulated slag, Bf dust, chemical sludge (waste water treatment, ETP sludge-solid, spent carbon, waste mix (solid).

What are the key parameters considered while selecting raw materials for the manufacturing of cement?
When selecting raw materials for cement manufacturing, we consider several key parameters:

Chemical composition: Ensuring the materials provide the necessary elements (calcium, silica, alumina, and iron) required for clinker production.

Availability and consistency: Reliable supply chains and consistent quality to maintain production efficiency.
Environmental impact: Minimising carbon footprint and environmental disruption.
Cost-effectiveness: Balancing raw material costs with production costs to maintain economic viability.
Regulatory compliance: Adhering to local and national standards and regulations.

How are the alternative fuels used by your organisation contributing to your decarbonisation goals?
The use of alternative fuels contributes to our decarbonisation goals by:

Reducing fossil fuel dependency: Lowering CO2 emissions associated with traditional fossil fuels. In general, 65 per cent of CO2 generated during clinker formation is through process emission which comes from the calcination of limestone and 35 per cent is through burning of fuel. The AFR contributes to reducing the CO2 emitted from fuel combustion. Generally, at every 1 per cent increase in TSR, there is reduction of around 2kg CO2/T of clinker. As there is no substitute to the limestone for the clinker formation, increasing the TSR in clinker formation is
the only option to reduce CO2 emission during clinker formation.
Waste management: Diverting waste from landfills and reducing methane emissions.
Energy efficiency: Some alternative fuels have higher energy content, leading to more efficient combustion.
If the hazardous waste is not co-processed in our cement kiln, then it’s diverted to an incinerator for disposal. Burning hazardous waste in an incinerator requires temperatures up to 1000oC, which occurs with the help of traditional fuels such as coal and this leads to further CO2 emissions into the atmosphere. So, cement industries are serving dual purpose for reduction in CO2 emissions in the cement manufacturing process itself as well as at the TSDF site.

What are the government regulatory and policy support that you get for the use of AFR?
We benefit from several forms of government regulatory and policy support, including:

Regulatory frameworks: Policies that encourage the use of AFR in cement production.
Research and development grants: Funding for innovation in sustainable materials and processes.
Exemption in total energy count in PAT calculation.
Permission for usage of hazardous waste in cement kiln by CPCB and SPCBs with regular monitoring protocol to controls emissions.

How do you ensure the quality and safety of alternative fuels and raw materials used in cement production?
We have a state-of-art AFR lab in our plant for regular testing and monitoring of incoming AFR. In testing, we follow all important parameters required to maintain the quality of the product, safety of men and machines as well as environmental impact. We classify the incoming materials into solid, liquid and sludge and perform testing of moisture, ash, volatile matters, fixed carbon, ultimate analysis, grindability for solid, viscosity for liquid, flashpoints, etc.
Safety protocols are also strictly implemented. Comprehensive safety standards and training for handling and processing AFR include prohibition of mobile phones, barricading the area for only authorise person entry and proper earthing of the entire unloading vehicle along with the standard PPEs for all manpower dealing with AFR.

Have you faced any challenges or barriers when using alternative fuels and raw materials in cement production, and if so, how have you overcome them?
We have encountered several challenges when using AFR:

Technical challenges: Variability in material properties, due to which CO2 generation and jamming issues are created inside the pyro system affecting production processes.
For this, we have installed a liquid AFR tank of 700kl for proper mixing of liquid AFR coming from different sources.
For each truck of AFR arriving at the plant, we take a sample, and only if the sample is within the permissible range, we accept the material for use.
We also use Karl Fischer titration machine from Metrohm for measuring bound water content and chloride.
The second challenge is the increase in the specific heat consumption as the high moisture content in the AFR needs more heat to evaporate the moisture. In general, at every 1 per cent TSR there is increase in the specific heat content by around 0.8-1.2 Kcal/Kg clinker.
Supply chain issues: Ensuring a consistent supply of high-quality AFR. We overcome this by establishing long-term partnerships and diversifying our sources.
Regulatory hurdles: Navigating complex regulations and obtaining necessary permits. We maintain active communication with regulatory bodies and advocate for supportive policies.

Do you collaborate with other companies or organisations to identify and implement best practices in the use of alternative fuels and raw materials in cement production?
Our organisation collaborates with various stakeholders to identify and implement best practices:

Industry associations: Participating in industry forums and working groups.
Academic partnerships: Collaborating with universities for research and innovation.
Cross-industry initiatives: Partnering with other sectors to develop and share sustainable practices Like Hindustan Zinc, RSPL, PI industries, GEPIL, UPL, Phonix, Deccan, Cadila, Meghmani Speciality Che. LLP etc.

How do you see the use of alternative fuels and raw materials in cement production evolving in the future, and what role does your company play in this process?
We see a significant evolution in the use of AFR in cement production, driven by:

Technological advancements: Improved processing technologies and material innovations.
Stricter environmental regulations: Increasing pressure to reduce emissions and environmental impact.
Circular economy models: Greater emphasis on waste valorisation and resource efficiency.

Our company aims to lead this transition by:

Innovating continuously: Investing in R&D for new AFR and efficient production processes.
Scaling sustainable practices: Expanding our use of AFR across all operations.
Advocacy and leadership: Promoting sustainable practices within the industry and influencing
policy development.

Banned wastes for co-processing in cement kiln
Refuse the listed ‘banned wastes’
x Anatomical Hospital Wastes
x Asbestos-containing Wastes
x Bio-hazardous Wastes
x Electronic Scrap
x Entire Batteries
x Explosives
x High-concentration Cyanide Wastes
x Mineral Acids
x Radioactive Wastes
x Unsorted Municipal Garbage

Main Reasons for Waste co-processing
• Sustainable Development
• Economical Benefits
– Substitution of Fossil fuels or natural raw materials
– Income from co-processing service
• Environmental Benefits
– Reduction in CO2 emissions
– Safe and optimal waste disposal
– Reduction in extraction rate of natural materials
– Reduction in overall emissions
• Social Benefits
– Effective contribution to waste management at local / regional levels
– Regional job creation in waste collection and pretreatment etc.
– Saving of public funds in building alternative infrastructure.

Aspect HW Incinerator Cement Kiln
Temperature 850-1200 °C 1400-2000 °C
Residence Time >2 sec @>1200 °C 4-6 sec @>1800 °C
Turbulence Induced in SCC Induced in Kiln
Gas Cleaning Alkaline scrubbing Alkaline Env. in Kiln
Residues Ash / Fly ash In clinker product
Fuel Fossil fuel used Fossil fuel saved

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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

20 hours ago

January 31, 2026

admin

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

Concrete

JK Cement Commissions 3 MTPA Buxar Plant, Crosses 31 MTPA

Company becomes India’s fifth-largest grey cement producer

Published

2 days ago

January 30, 2026

admin

JK Cement has commissioned its new 3 MTPA grey cement plant in Buxar, Bihar, taking the company’s total installed capacity to 31.26 million tonnes per annum (MTPA) and moving it past the 30 MTPA milestone. With this addition, JK Cement now ranks among the top five grey cement manufacturers in India, strengthening its national presence.

Commenting on the development, Dr Raghavpat Singhania, Managing Director, JK Cement, said, “Crossing 31 MTPA is a significant turning point in JK Cement’s expansion and demonstrates the scale, resilience, and aspirations of our company. In addition to making a significant contribution to Bihar’s development vision, the commissioning of our Buxar plant represents a strategic step towards expanding our national footprint. We are committed to developing top-notch manufacturing capabilities that boost India’s infrastructure development and generate long-term benefits for local communities.”

Spread across 100 acres, the Buxar plant is located on the Patna–Buxar highway, enabling efficient distribution across Bihar and neighbouring regions. While JK Cement entered the Bihar market last year through supplies from its Prayagraj plant, the new facility will allow local manufacturing and deliveries within 24 hours across the state.

Mr Madhavkrishna Singhania, Joint Managing Director & CEO, JK Cement, said, “JK Cement is now among India’s top five producers of grey cement after the Buxar plant commissioning. Our capacity to serve Bihar locally, more effectively, and on a larger scale is strengthened by this facility. Although we had already entered the Bihar market last year using Prayagraj supplies, local manufacturing now enables us to be nearer to our clients and significantly raise service standards throughout the state. Buxar places us at the center of this chance to promote sustainable growth for both the company and the region in Bihar, a high-growth market with strong infrastructure momentum.”

The project has involved an investment of Rs 5 billion. Commercial production began on 29 January 2026, following construction commencement in March 2025. The company said the plant is expected to generate significant direct and indirect employment and support ancillary industrial development in the region.

Concrete

JK Cement Crosses 31 MTPA Capacity with Commissioning of Buxar Plant in Bihar

Published

2 days ago

January 30, 2026

admin

JK Cement has commissioned a 3 MTPA Grey Cement plant in Buxar, Bihar, taking its total capacity to 31.26 MTPA and placing it among India’s top five grey cement producers. The ₹500 crore investment strengthens the company’s national footprint while supporting Bihar’s infrastructure growth and local economic development.

JK Cement Ltd., one of India’s leading cement manufacturers, has announced the commissioning of its new state-of-the-art Grey Cement plant in Buxar, Bihar, marking a significant milestone in the company’s growth trajectory. With the commissioning of this facility, JK Cement’s total production capacity has increased to 31.26 million tonnes per annum (MTPA), enabling the company to cross the 30 MTPA threshold.

This expansion positions JK Cement among the top five Grey Cement manufacturers in India, strengthening its national footprint and reinforcing its long-term growth strategy.

Commenting on the strategic achievement, Dr Raghavpat Singhania, Managing Director, JK Cement, said, “Crossing 31 MTPA is a significant turning point in JK Cement’s expansion and demonstrates the scale, resilience, and aspirations of our company. In addition to making a significant contribution to Bihar’s development vision, the commissioning of our Buxar plant represents a strategic step towards expanding our national footprint. We are committed to developing top-notch manufacturing capabilities that boost India’s infrastructure development and generate long-term benefits for local communities.”

The Buxar plant has a capacity of 3 MTPA and is spread across 100 acres. Strategically located on the Patna–Buxar highway, the facility enables faster and more efficient distribution across Bihar and adjoining regions. While JK Cement entered the Bihar market last year through supplies from its Prayagraj plant, the Buxar facility will now allow the company to serve the state locally, with deliveries possible within 24 hours across Bihar.

Sharing his views on the expansion, Madhavkrishna Singhania, Joint Managing Director & CEO, JK Cement, said, “JK Cement is now among India’s top five producers of grey cement after the Buxar plant commissioning. Our capacity to serve Bihar locally, more effectively, and on a larger scale is strengthened by this facility. Although we had already entered the Bihar market last year using Prayagraj supplies, local manufacturing now enables us to be nearer to our clients and significantly raise service standards throughout the state. Buxar places us at the center of this chance to promote sustainable growth for both the company and the region in Bihar, a high-growth market with strong infrastructure momentum.”

The new facility represents a strategic step in supporting Bihar’s development vision by ensuring faster access to superior quality cement for infrastructure, housing, and commercial projects. JK Cement has invested approximately ₹500 crore in the project. Construction began in March 2025, and commercial production commenced on January 29, 2026.

In addition to strengthening JK Cement’s regional presence, the Buxar plant is expected to generate significant direct and indirect employment opportunities and attract ancillary industries, thereby contributing to the local economy and the broader industrial ecosystem.