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

Up Next

Durable Concrete

Don't Miss

Green Procurement

Concrete

Ramco Cements’ Hard Worker Campaign Wins Seven Awards

Campaign earns honours for direction, editing and cinematography

Published

45 minutes ago

June 15, 2026

admin

The Hard Worker campaign by The Ramco Cements has secured seven honours at the Good Ads Matter Awards 2026, adding to its growing list of accolades and reinforcing its standing among the year’s most recognised advertising campaigns.

The awards were presented during the Good Ads Matter Awards Night 2026 held at Mehboob Studios in Mumbai. The campaign received recognition across multiple categories, highlighting excellence in direction, editing, cinematography and storytelling.

Among the honours, the campaign won Silver in the Campaign of the Year – Direction category, while filmmaker Prakash Varma was named Director of the Year for the films Tortoise & Hare and Eco Plaster. Tortoise & Hare also received Silver awards for Best Editing and Best Colour Grading, along with a Bronze award for Best Cinematography. Eco Plaster earned Bronze awards in the Best Direction – Narrative and Best Direction – Humour categories.

Both films extended their award-winning run, with Eco Plaster being recognised for its narrative centred on water conservation through innovative construction solutions, while Tortoise & Hare was honoured for its storytelling and craft execution.

The Hard Worker campaign was built around the idea that hard work deserves recognition and respect. Through culturally rooted and emotionally engaging stories, the campaign has connected with consumers, engineers, masons and the wider construction community across the country.

Commenting on the achievement, A V Dharmakrishnan, CEO of The Ramco Cements Limited, said that the continued recognition across leading creative platforms reflects the company’s commitment to meaningful and authentic communication rooted in the values of the people it serves.

Balaji K Moorthy, Executive Director – Marketing, The Ramco Cements Limited, said the awards recognise the craftsmanship behind the storytelling, from direction and cinematography to editing and narrative execution.

Following recognition at both the Kyoorius Creative Awards and the Good Ads Matter Awards, the Hard Worker campaign continues to demonstrate the impact of purpose-driven storytelling combined with strong creative execution and consumer relevance.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

1 week ago

June 5, 2026

admin

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.

Concrete

Building a Greener Future Together

Published

2 weeks ago

June 4, 2026

admin

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.