In a significant policy move aimed at curbing industrial greenhouse gas (GHG) emissions, the Indian government has introduced GHG emission intensity (GEI) reduction targets for high-emission sectors, including the cement industry. As per the draft notification under the Carbon Credit Trading Scheme, 2023, 186 cement plants across the country will need to lower their GEI from the baseline year 2023–24.
This policy introduces a compliance framework starting in 2025–26, wherein cement plants must meet the designated GEI targets set by the Bureau of Energy Efficiency (BEE).
Cement plants that fail to meet their GEI targets will be required to purchase carbon credit certificates from the Indian carbon market. In case of non-compliance, the Central Pollution Control Board (CPCB) will impose an environmental compensation (penalty) equal to twice the average price of the carbon credit certificate traded during the compliance year.
Pre-Processing MSW Waste: A Pathway to Compliance
To meet these stringent targets, cement manufacturers are adopting alternative fuels and raw materials (AFR) strategies, particularly through the pre-processing of municipal solid waste (MSW). Pre-processing is the process of converting waste into AFR suitable for use in cement kilns. It involves a series of steps including primary shredding, separation, screening, segregation, secondary shredding, and foreign body removal to ensure a consistent and high-quality fuel stream.
The effectiveness of this strategy relies heavily on selecting and installing the right equipment that aligns with each step of the pre-processing chain. Proper integration ensures maximum efficiency, smooth plant functioning, and consistent fuel quality that meets the kiln’s operational requirements.
By replacing conventional fossil fuels like coal and petcoke with pre-processed MSW, cement plants can significantly reduce CO₂ emissions, align with BEE’s sectoral benchmarks, and enhance their sustainability credentials.
However, there are some major pain points within industry for pre-processing of AFR material, such as:
- Improper Layout: Inefficient plant layout disrupts workflow, causing material bottlenecks and operational delays.
- High Moisture/Wet Waste: Excess moisture lowers calorific value, clogs machinery, and increases drying needs.
- Only Primary Shredder (Biting Teeth): Limits material size reduction; unsuitable for achieving RDF-grade consistency.
- Only Secondary Shredder (Chewing Teeth): Without primary shredding, secondary units face high wear and reduced efficiency.
- Output Capacity Issues: Mismatch between waste feed and equipment capacity leads to inconsistent output and underperformance.
- Missing Equipment Gap Analysis: Absence of key components like dryers, air density separator, or metal detectors hampers overall system efficiency.
- Highly Contaminated Waste: Inerts, metals, and non-combustibles damage equipment and reduce fuel quality.
- After Sales Support Issues: Delays in technical support, spares, and service lead to prolonged downtimes and operational losses.
By understanding the pain points faced by cement manufacturers and waste processors, Fornnax has built its solutions on real-world insights gathered through extensive industry engagement. Over the past few years, our team has visited most of the prominent cement plants across India, interacted closely with key stakeholders to identify challenges related to material pre-processing, operational continuity, and equipment efficiency. This first-hand experience has enabled us to deeply understand the recurring bottlenecks in handling Indian municipal solid waste (MSW), which is widely acknowledged as highly contaminated, moisture-laden, and heterogeneous.
To address these complex challenges, Fornnax offers a high-capacity AFR (Alternative Fuels and Raw Materials) plant designed specifically for the Indian market. Our system is engineered to suit the unique composition of Indian Municipal Solid Waste (MSW), which is notoriously characterized by its high contamination levels and heterogeneous composition.
The Fornnax AFR plant features a revolutionary design that combines robust primary and secondary shredding with advanced screening, separation, and contaminant removal technologies. What truly sets us apart is our round-the-clock sales and after-sales support, ensuring maximum plant uptime and long-term customer satisfaction across global installations.
With over a decade of invaluable experience and a significant role in reshaping the Indian tyre recycling market, Fornnax has firmly established itself as one of the leading players in the global waste management industry.
As the cement sector progressively moves towards achieving its stringent Greenhouse Gas Emission Intensity (GEI) targets and strives to increase its Thermal Substitution Rate (TSR) up to a tangible 30% by 2030, Fornnax AFR facility is strategically positioned to robustly support this critical mission. By ensuring meticulous compliance with prevailing emission norms, our AFR plants enable cement manufacturers to confidently avoid potential penalties while making a substantial and tangible contribution to India’s overarching climate goals.