Environment

NCB: The force behind sustainable best practices

Published

14 years ago

November 30, 2011

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Next year, in 2012, the National Council for Cement and Building Materials (NCB) completes 50 years of service to the industry. During the last five decades, NCB has helped achieve enhanced sustainability in cement and concrete production, contributed towards Quality Management and Standardization to the industry, assisted the industry in continual improvement in testing, and helped the Indian cement industry operations to become highly energy efficient.NCB has been contributing towards Quality Management and Standardization to the industry with its upgraded facilities and NABL accredited laboratories. During the year 2010-11, NCB calibrated around 2000 equipment for various parameters such as force, pressure, dimension, temperature, revolution, mass and volume etc. 6300 vials of various Certified Reference Materials (CRMs) were also supplied to testing laboratories of cement and allied materials. NCB also conducted a study on proficiency of testing laboratories through inter-laboratory comparisons and a workshop on Inter-laboratory Comparisons and Proficiency Testing (PT) on PPC and Fly ash was organized to assist the industry in continual improvement in testing.Ashwani Pahuja, Director General, NCB, elaborates on NCB’s role and functions in this emailed interview.As a support organization providing research, technology development and transfer, education and industrial services for the cement and building material industries what are the current concerns?Following areas of concern where R&D is required, have been identified for taking up specific projects:

Research for newer methods of manufacturing such as application of Nanotechnology to cement and concrete.
Investigations for geo-polymeric cements, Portland Limestone Cement
Improved Refractory engineering practices
Bench marking of quality parameters in Indian Cement Industry.
Processing of flyash for enhanced use in cement/concrete.
R & D work to identify new pozzolanic materials for use as additives in cement.
Development and finalization of standards for composite cement for utilizing all types of pozzolanic materials to clinker for cement making.
R & D studies for reduction of green house gases (GHG’s) in cement manufacture such as
adaptation of best available Technology for reduction of NOx and SO2; and sequestration of carbon-dioxide in Alage culture.
R & D studies for use of alternate source of energy/ fuels and raw materials.
Studies for exploration / identification of new limestone reserves for Greenfield Cement plants and upgradation of low grade limestone and mines rejects for cement manufacture.
Use of high performance concrete to enhance durability and reduce use of cement and other materials.

On the environmental front what has been done/is being done to ensure that cement plants manage to operate with the least amount of damage to the environment? Tell us something about new technologies that are helping cement plant.Indian cement industry has been working on the issue of its GHG emissions and has brought down the CO2 emission level from 1.12 tonne of CO2 / tonne of cement in 1996 to 0.82 tonne of CO2 tonne of cement at present.Some of the mitigation measures adopted for reduction of GHG emissions by Indian cement industry are

Production of Blended cement by substitution of clinker by Fly ash and blast furnace slag
Use of Alternate Fuels and raw materials
Improving Energy Efficiency
Waster Heat Recovery
Use of Solar and Wind Energy
Carbon Sequestration

Particulate Matter (PM)Cement plants have provided APCEs like ESP, bag house with PTFE membranes and ESPs modified with bag filters – (Hybrid filters.) to control dust emissions.Gaseous emissions – NOx and SO2For reduction of NOx emissions, some of the cement plants have started using low NOx Burner, Low NOx calciner, optimization of the clinker burning process with computer based high level expert control system, multi stage combustion.In Indian cement plants, there are no significant SO2 emissions from clinkerisation due to inherent properties of absorption of SO2 by alkalis.Fugitive EmissionsIndian cement plants are taking various measures to reduce fugitive emissions comparable to the "Best practice" elsewhere in the world.Energy is a major component of the cost of cement production. How has the organization helped the industry in energy conservation and maximizing efficiency?NCB has taken many initiatives since 1984 for making Indian cement industry highly energy efficient. Various efforts initiated by NCB directed towards energy conservation and improving operational efficiency are:

During last 20 years, 170 energy diagnostics and audit studies have been completed which have total annual potential savings of about 260 million units of power and 0.50 million tonnes of coal (savings potential of Rs 140 crores per annum)
National awards for energy efficiency in Indian cement industry, since 1986-87 have been instituted with an objective of motivating competitive improvement in energy performance. These awards are being given annually since then to the best performing plants. The case studies of best performing plants are disseminated enabling other plants to emulate them.

How contemporary is our technology (cement sector) to international standards? Has the organization been successful in ensuring that Indian companies are accessing the best technologies?The Indian cement industry has achieved an installed capacity of 300 Million tonnes at present and is anticipated to reach 600 million tonnes by 2020. With 99% of the installed through dry process, the Indian cement industry has been adopting latest technologies for energy conservation and pollution control as well as on-line process and quality control based on expert systems and laboratory automation. The Indian cement industry has access to the latest technologies of the world and the present trend is to put up state-of-the-art plants of capacities 8000 to 12000 tonnes per day, at par with world standard.What according to you have been greatest achievements of Indian cement industry? Which organizations would you recommend as being the best in their class?Single production line capacity of over 12000 tpd, average thermal energy consumption of 725 Kcal/kg clinker or average electrical energy consumption below 80 kWh / tonne of cement as at present were unimaginable 2 decades ago when these figures hovered around 3000 tpd, 880 Kcal/Kg clinker and 120 kWh / tonne of cement respectively. Similarly, the particulate emissions from stacks have considerably been brought down to below even 10 mg/cu m.On the energy conservation front, the best levels achieved by the Indian cement industry, namely of 667 kilo calories per kg of clinker and 67 kWh per tonne cement are at par with the best achieved levels in the world.The industry’s efforts towards control of emissions, preservation of ecology and voluntary initiatives such as corporate responsibility for environmental protection are laudable. The Indian cement industry deserves commendation for its long-standing efforts towards reduction of its carbon footprint by adopting the best technologies and manufacturing practices.How far is the industry adhering to the standards set by the authorities in the quality of cement they manufacture? Such as declaring the fly ash content, etc.The cement sold in the market is adhering to the requirements of BIS specifications in general.How does a consumer find out if cement is sub standard? Does the organization help in giving some kind of certification? What is the route to be followed when cement is found to be sub standard?Non conformance to BIS specifications would indicate sub-standard cement. It is possible by getting the cement tested in a laboratory. NCB also has an independent test house from where consumers can get the cement sample tested. In addition to NCB and BIS, many other NABL accredited labs in various parts of the country, test the samples. As per present directives sub-standard cement has to be destroyed.Speaking of standards can you briefly elucidate the recent most important standards set for the sector by BIS?Standards on Blended cements, different grades of OPC, Silica fume and fly ash etc are some of the recent standards for the sector.In the case of fly ash from biomass based power plants, cement plants are not interested, do you see any other use for this waste?Fly ashes having pozzolanic characteristics can only be used for blended cements. Other flyash, which do not confirm to the criteria of IS 3812, can be used only as filler materials in roads, mines or as raw materials for ceramics etc.Any important developments in studies on limestone consumption factor for cement plants?
Studies on establishing Limestone Consumption Factor (LCF) for cement plants are frequently taken up by NCB on specific requests received form the plants. So far about 138 LCF studies have been carried out.NCB and its future plans/ activities?To attain the targeted capacity addition, the industry would require 66000 additional technical personnel, including 23000 engineers & supervisors by the end of the XII plan period. Adequate training facilities need to be created to cater to the above requirement to match the requirement of training facilities of the Indian cement industry, training capabilities of National Council for Cement and Building Materials (NCB) is being further strengthened in terms of additional manpower, Additional lodging and boarding facility at Ballabgarh unit, development of Computer Based Training (CBTs) packages, Packages for e-learning, up gradation of lecture halls at Ballabgarh unit and equipping them with state-of-art training aids like simulators.

Concrete

India donates 225t of cement for Myanmar earthquake relief

Published

7 days ago

June 17, 2025

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On 23 May 2025, the Indian Navy ship UMS Myitkyina arrived at Thilawa (MITT) port carrying 225 tonnes of cement provided by the Indian government to aid post-earthquake rebuilding efforts in Myanmar. As reported by the Global Light of Myanmar, a formal handover of 4500 50kg cement bags took place that afternoon. The Yangon Region authorities managed the loading of the cement onto trucks for distribution to the earthquake-affected zones.

Concrete

Reclamation of Used Oil for a Greener Future

Published

1 week ago

June 16, 2025

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In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.

The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.

The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.

Circular economy in lubricants
In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt, and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.

Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.

Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)

The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.

On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:

Kinematic Viscosity
Flash Point
Total Acid Number
Moisture / Water Content
Oil Cleanliness
Elemental Analysis (Particulates, Additives and Contaminants)
Insoluble

The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.

Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.

About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

Concrete

Charting the Green Path

Published

1 month ago

May 13, 2025

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The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.