Concrete

Our new technology is key to utilise max AFR percentage

Published

5 years ago

July 1, 2021

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Fives Combustion Systems is a subsidiary of Fives Pillard. Fives Combustion Systems designs and installs process automation controls such as process burners, elevated flares, combustion chambers, and Pillard Fuel System. Vikas Damle of ICR had a conversation with Rahul Rajgor, MD ??India operations, Fives Combustion Systems.

What measures have you taken while designing this burner so that it is able to meet the requirements on NOx emissions and improvements in clinker quality?

Fives has always been ahead of its time regarding the development of kiln burners with low emissions. This time on the eve of a century in kiln burner solutions, we have prepared a special treat, combining all the feedback we received from our customers and our practical experience in the field and brought it to our R&D labs in France. Thanks to dedicated research, intense engineering and analysis, we have come up with a new champion in the form of the Pillard NOVAFLAM^? Evolution, to deliver unparalleled performance in terms of clinker quality, emissions reduction and reduced primary air delivery.

Our Pillard NOVAFLAM^? Evolution, which has just been launched, is already operational in over 40 locations around the globe and is showing fantastic results.

Pillard NOVAFLAM? Evolution, the latest innovation for the cement industry.

In India, more and more cement plants are starting to use alternate fuels (AFR). In that context, what type of burners are you offering to the Indian Industry? Will the same burner be suitable as the AFR percentage increases?

India is a booming market for the cement industry and one priority for Fives Combustion Systems. Indeed, it offers many opportunities for replacing old generation burners with new and more improved models, delivering more benefits to the customers, including efficient AFR firing capability. The cement industry has come to us with a challenge on alternative fuels substitution to pharma waste, liquid waste as a low CV, electronic waste, agro waste, etc. We understand that demand and have delivered on our challenge. The Pillard NOVAFLAM^? Evolution is the answer to utilise maximum alternative fuel percentage while maximising the clinker quality at the same time.

The Pillard NOVAFLAM^? Evolution burner enables the central injection of ASF by means of dedicated injectors, specially engineered to prevent the ??ouble flame??effect thus avoiding flying particles on the fire. The injection method is adapted according to the various ASF criteria such as density, moisture, size, combustion kinetics, etc. thus enabling us to custom design the ASF injector for each plant. Various arrangements of ASF injection are possible to achieve the best combustion, thermal efficiency and enhance higher ASF substitution.

What are the new innovations and patents being introduced in your Pillard NOVAFLAM^? Evolution kiln burner?

To enhance thermal efficiency, we introduced the V type nozzle technology for axial and radial air impulse pattern.
Introduction of replaceable insert tips: One can replace axial air injectors very easily enhancing operational flexibility (increase or decrease primary air flow by replacing insert tip) and the maintenance cost is lower than replacing a full tip.
RST Swirler technology with better efficiency and adjustability from 0 to 45 degrees.
Lower primary air flow (4 to 8 per cent)
Introduction of an ??lternative fuel injection system??with an enhanced burning efficiency for solid fuel.
Airless stabilizer with a reduced primary air requirement for cooling.
Special alloyed heavy-duty burner tips with an Air Cooling arrangement resilient to heat expansion thus enhancing the burner lifespan.
Introduction of 4.0 smart functions with an optimised monitoring of kiln burning activities.

Does your factory in India manufactures burners in India or do you assemble it here?

In India, we do complete design, engineering, manufacturing and supply for all type of burners and control systems under Fives Pillard license and complying with Fives R&D guidelines.

We are a global manufacturing unit for a majority of burners products for various of the group Fives subsidiaries including Fives ITAS, Italy, Fives North American Combustion, USA and Fives Stein, France.

Our facility in Vadodara, Gujarat covers 1,25,000 square feet of area and is certified ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018.

Fives Combustion Systems primarily serves the cement, oil and gas, steel, aluminum and power industries. We operate at the upper crest of the technology of combustion solutions and have been at the forefront in providing premium equipment manufactured in India complying with international standards.

Our technological edge, an increase of global customer outreach and our renown expertise explain the success of our products. To achieve high standard quality and customer satisfaction, Fives Combustion Systems has streamlined the entire product manufacturing value chain, from R&D through production including customer delivery and support.

Concrete

Ultra Concrete Age

Prof. A. S. Khanna (Retd., IIT Bombay) on how Ultra-high performance concrete (UHPC) improves strength, durability and lifecycle performance.

Published

1 week ago

April 1, 2026

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The need of present time is stronger buildings, industrial or common utility buildings, such as Malls, Railway stations, hospitals, offices, bridges etc. For this, there is need of long durable, tough and stable concrete, which could stand under normal and seismic conditions. Tough railway bridges are required for bullet trains to pass without any damage. Railway tunnels, sea-links, coastal roads, bridges and multistorey buildings, are the need of the hour. The question comes, is the normal cement called OPC is sufficient to take care of such requirements or better combination of cements and sand mixtures is required?

Introduction

A good stable building structure can be made with a good quality of cement+sand+water system. Its quality can be enhanced by keeping the density of admixture higher (varies from 30 in normal buildings to bridges etc to 80). Further enhancement in the properties of various cements admixtures is made by adding several additives which give additional strength, waterproofing, flexibility etc. These are called construction chemicals…

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Concrete

NCB Signs MoU With Cement Manufacturer To Boost Construction Skills

Partnership to deliver nationwide training and certification

Published

1 week ago

March 31, 2026

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The National Council for Cement and Building Materials (NCB) has signed a memorandum of understanding with a leading cement manufacturer to strengthen skill development and capacity building in the construction sector. The agreement was formalised at NCB premises in Ballabgarh and was signed by the Director General of NCB, Dr L. P. Singh, and the head of technical services at UltraTech Cement Limited, Er Rahul Goel. The collaboration seeks to bring institutional resources and industry expertise into a structured national training effort.

The partnership will deliver structured training and certification programmes across the country aimed at enhancing the capabilities of civil engineers, ready?mix concrete (RMC) professionals, contractors, construction workers and masons. Programme curricula will cover material quality testing, concrete mix proportioning, durability assessment and sustainable construction practices to support improved construction outcomes. Emphasis is to be placed on standardised assessment and certification to raise practice levels across diverse construction roles.

Practical learning elements will include workshops, site demonstrations, technical seminars and exposure visits to plants and RMC facilities to strengthen applied skills and on?site decision making. The Director General indicated confidence that a large number of professionals and workers would be trained over the next three to five years under the initiative. The partnership is designed to complement flagship government schemes such as the Skill India Mission and to align training outputs with national infrastructure priorities.

By combining the council’s technical mandate with industry experience, the initiative aims to develop a more skilled and quality?conscious workforce capable of meeting rising demand in infrastructure and housing. NCB will continue to coordinate programme delivery and quality assurance while industry partners provide practical exposure and technical inputs. The collaboration is expected to support long?term capacity building and more sustainable construction practices nationwide.

Concrete

JSW Cement Commissions Nagaur Plant, Enters North India

New Rajasthan unit boosts capacity to 24.1 MTPA and expands reach

Published

1 week ago

March 30, 2026

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JSW Cement has strengthened its national presence by commencing production at its greenfield integrated cement plant in Nagaur, Rajasthan, marking its entry into the north Indian market.

With this commissioning, the company’s installed grinding capacity has increased to 24.1 MTPA, while total clinker capacity, including its joint venture operations, stands at 9.74 MTPA.

The Nagaur facility comprises a 3.30 MTPA clinkerisation unit and a 2.50 MTPA cement grinding unit, with an additional 1.00 MTPA grinding capacity currently under development. Strategically located, the plant is positioned to serve high-growth markets across Rajasthan, Haryana, Punjab and the NCR.

The project has been funded through a mix of equity and long-term debt, with Rs 800 crore allocated from IPO proceeds towards part-financing the unit.

Parth Jindal, Managing Director, JSW Cement, stated that the commissioning marks a key milestone in the company’s ambition to become a pan-India player. He added that the project was completed within 21 months and positions the company to achieve its targeted capacity of 41.85 MTPA by FY29.

Nilesh Narwekar, CEO, JSW Cement, highlighted that the expansion aligns with the company’s strategy to tap into rapidly growing northern markets driven by infrastructure development. He noted that the company remains focused on delivering high-quality, eco-friendly cement solutions while progressing towards its long-term capacity goal of 60 MTPA.

The Nagaur plant has been designed with sustainability features, including co-processing of alternative fuels and a 7 km overland belt conveyor for limestone transport to reduce road emissions. The facility will also incorporate a 16 MW Waste Heat Recovery System to improve energy efficiency and lower its carbon footprint.

JSW Cement, part of the JSW Group, operates across the building materials value chain and currently has eight plants across India, along with a clinker unit in the UAE through its joint venture.