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Plant & Machinery: IR-CFB boiler technology

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The IR-CFB boiler-based captive power plant helps a cement manufacturer improve his profit lines while remaining environmentally friendly, says Vivek Taneja.

When business organisations consider moving to decisions that are sustainable – like saving electricity, recycling water or using renewable energy – the big investments required upfront would certainly impact the balance sheet here and now. However, if we were to think of a longer time-frame, all these decisions would make a lot of sense when we consider the concept of lifecycle cost – a higher capital cost, but with far lower operating costs such that it pays for itself over the life of the product. Long-term sustainability also goes hand- in- hand with the kind of decisions we make, processes we follow, policies we adopt and the values we propagate. Companies passionate about the cause of sustainable development will constantly come up with innovative solutions which, over time, will definitely add to the bottomline. If we were to redefine the success of an organisation as achieving the triple bottomline – economic, environmental and social – it would be a sustainable model and also benefit the bottomlines of the company in the long run.

In today’s competitive scenario, it is imperative for any cement manufacturer to maintain his growth and keep all shareholders happy, but at the same time, improve his profitability by improving the plant’s specific energy consumption, while remaining committed to the environment by reducing his carbon footprint. An Internal Recirculation – Circulating Fluidised Bed (IR-CFB) boiler-based captive power plant distinctively helps a cement manufacturer meet these objectives and improve his competitive positioning.

An IR-CFB is a compact boiler, with various unique features to ensure minimum maintenance, thus offering the maximum available uptime for the power plant. The design incorporates a two- stage separation system for better bed inventory control. The benefits of this patented technology include a superior combustion efficiency, high operational thermal efficiency, low emissions, low maintenance, low pressure drop, and a high turndown, resulting in an improved overall plant performance. The two-stage system includes a primary U-beam impact separator and a secondary multi-cyclone dust collector (MDC), which work together to provide a combined particle collection efficiency in excess of 99.8 per cent. The U-beams, a staggered array of stainless steel channels at the furnace exit plane, capture nearly all the solids suspended in the flue gas leaving the furnace, and internally re-circulate these solids to the lower furnace. The ceramic MDC, with small diameter 250 mm cyclones, captures the solids in the second pass and returns this material to the lower furnace in a controlled manner. The ability to regulate the secondary recycle system provides the operator with an unprecedented furnace temperature control, resulting in improved boiler performance and relatively faster load response.

Compact and simplified This two-stage particle separation system results in a compact, simplified boiler arrangement. The entire U-beam particle separator is located at the furnace exit. Compared with hot cyclone-type CFBC designs, the IR-CFBC has significantly lower furnace exit gas velocity and requires significantly less building volume. By relying on internal recirculation, the IR-CFBC design eliminates J-valves, loop seals, high-pressure blowers, and soot blowers, which are required with other CFBC designs. One goal of CFBC boiler manufacturers has been to eliminate thick, un-cooled refractory and hot expansion joints from their designs to reduce the expense and lost time associated with refractory maintenance. This goal was achieved with the development of the IR-CFBC boiler. The furnace, U-beam separator, and super-heater enclosures are constructed entirely of top-supported, gas-tight, all-welded membrane tube walls, which do not require hot expansion joints. The small amount of refractory that is used in the IR-CFBC is applied to selected areas of the water-cooled enclosure surface in a thin layer which is only 16 mm thick in the lower furnace and slightly thicker over the tube face elsewhere in the furnace. As a result, IR-CFBC requires only 10 to 25 per cent of the total refractory found in a hot cyclone CFBC design and less than 50 per cent of the refractory used in a water-cooled or steam-cooled cyclone CFBC unit. This construction has significantly reduced the need for refractory maintenance in operating CFBC units.

The patented reduced diameter zone (RDZ) tube section is another feature designed to reduce maintenance. The RDZ consists of a reduced diameter tube section mating to a specially-shaped ceramic tile. The reduced diameter tube section on each tube slopes away from the solids falling down the wall. This eliminates the solids material from building up and eroding the furnace tubes where the lower furnace refractory ends.

Erosion is a major cause of maintenance problems in CFBC boilers due to the high solids loading in the flue gas. The severity of this erosion is exponentially related to the velocity of the flue gas through the system. On hot cyclone CFBCs, the particle separator depends upon an extremely high flue gas velocity to provide the energy needed to efficiently disengage the particles from the flue gas. By comparison, the U-beam particle separator is designed to operate efficiently with much lower flue gas velocity at full-load operating conditions. The particle capture efficiency actually increases as the flue gas velocity through the U-beam separator decreases. By operating at such a low gas velocity, the potential for erosion in the IR-CFBC is significantly reduced. Proper material selection and low flue gas velocities allow reducing the erosion of U-beam separators, thus reducing the maintenance down time throughout years of operation at design load conditions.

Another advantage of IR-CFBC technology is that it allows the owner to specify a wide variety of fuels to optimise the profitability of the facility. Different type of fuels that can be successfully fired into an IR-CFB boiler include Indian or imported coal, lignite, petroleum coke (petcoke), washery rejects, mill rejects, agro-waste, biomass, char, etc. Other fuels such as fly ash and sludge are also candidates, depending on their percentage of heat input, moisture content and emission requirements. The IR-CFB boiler also can be designed to burn several of these specified fuels in the same unit. This provides an additional flexibility needed to respond to changes in the fuel markets.

Environmentally friendly

The design also ensures best-in-class compliance with environmental norms. The IR-CFBC boiler can control SO2 emissions by injecting limestone into the lower furnace. Relatively low NOx emissions are inherent in the IR-CFBC due to low and uniform furnace temperatures and staged combustion. NOx emissions can be further reduced by using a selective non-catalytic reduction (SNCR) system. In addition, the IR-CFBC’s patented secondary particle recycle system provides increased control, not found in other CFBC technologies, to maintain an optimum uniform furnace temperature which is essential for low SO2 and NOx emissions and for better limestone utilization.

Thus, for energy intensive sector like cement, an Internal Recirculation – Circulating Fluidised Bed (IR-CFB) boiler- based captive power plant guarantees to the cement manufacturer an improvement of his profitline as well as a reduced carbon footprint. For these organisations not in the power business, the retention of highly experienced and dedicated team of resources to set up and operate captive power plants is a challenge not related to his core business, thus exposing the business to unwanted risks. These include risks related to cost and time overruns, integration hurdles between various packages, project management to take care of unforeseen risks, ensuring quality to address issues related to reliability and availability of power from the power plant. This is where the cement industry can benefit from the services of an experienced EPCOM (Engineer-Procure-Construct-Operate- Maintain) contractor who will guarantee performance and the overall completion schedule within fixed costs. The contractor will also guarantee reliable power at the least lifecycle cost because the entire risk of operating and maintaining the power project is also outsourced to this experienced service provider.

However, it is very important that the project developer must look for the following abilities while finalising an EPC contractor:

  • Is the EPC company willing to take single- point responsibility for executing the project? This will ensure that the entire set of risks associated with the power project is effectively transferred to the EPC contractor, with matching securities, ensuring peace of mind for the developer.
  • Does the EPC company have a successful track record of executing similar types of challenging projects? This is necessary to ensure that the contractor can incorporate its learning from executing similar projects and deliver optimised solutions that would ensure minimum lifetime costs for the power project.
  • Does the EPC company have the financial strength to wade through the entire lifecycle of project execution?
  • Is the contractor aware of the local legal issues that must be adhered to, to ensure the smooth execution of the project?
  • Is the contractor a manufacturer of the key equipment that would be used in the power project? This will ensure that the contractor has a greater control over the project schedule.
  • Does the contractor provide after sales service? If the contractor also offers Operation and Maintenance (O&M) services after setting up the power plant, it would ensure minimum investment for the developer into resources for managing the power plant, thus enabling him to maximise his profits.

An EPC company that satisfies these criterions will ensure that all the risks associated with the project are identified up-front and are mitigated at the earliest to ensure on- time implementation of the project, thus providing a win – win situation for both the developer as well as the solution provider.

Vivek Taneja, Head Business Development-Power Division, Thermax Email – vtaneja@thermaxindia.com

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Economy & Market

RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways

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Roundtable discussions focus on innovation for safer highways.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.

Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.

Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.

RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.

Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.

Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.

The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.

From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.

Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.

Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.

Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.

The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.

Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.

The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.

Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.

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Economy & Market

CTS Roundtable Charts Tech-Led Roadmap for Construction

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CTS Roundtable Maps Technology Roadmap for Construction

Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.

A platform to move from discussion to deployment

Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.

Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.

Industry at a turning point

Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.

Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.

His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.

From BIM to AI, data to governance

A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.

Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.

Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.

The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.

Industrialised construction gains ground

The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.

Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.

Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.

Adoption remains the biggest hurdle

While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.

Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.

Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.

That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.

Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.

Beyond buzzwords

A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.

The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.

Setting the agenda for CTS 2026

By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.

More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.

As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.

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Concrete

Human Factor in Grinding Optimisation

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Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.

The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.

Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.

Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.

Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.

Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.


A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.

Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.

About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.

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