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Dalmia Cement (Bharat) Limited: Scaling New Heights

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Dalmia Cement (Bharat) Limited (DCBL) is one of the first cement companies in India to be awarded the ISO 9000 certification. A leader in cement manufacturing since 1939, DCBL is a multi-spectrum cement player with double-digit market share and a pioneer in super-speciality cements used in oil wells, railway sleepers and air strips. Read on …

Dalmia Cement was started as a venture towards building a self-reliant India. Dalmia Cement was started in 1939, one of India’s first cement plants with an installed capacity of 250 tonne per day (tpd). Today, the plant has grown manifolds in terms of capacity. DCBL is also one of the leaders in the production of high strength speciality cement required for air strips and for the manufacture of concrete railway sleepers.

Genesis Founded in 1935 by Jaidayal Dalmia, the group was the third largest industrial group in the 1940s after the Tatas and the undivided Birlas. Since inception, DCBL has grown phenomenally and currently it holds a total cement capacity of 14.3 mtpa. The Group is also involved in other businesses including sugar, ethanol, energy, travel agency, magnesite, refractory and electronics. However, cement and sugar are its core products with over 90 per cent share in the group’s total income. DCBL has not only pioneered the cement manufacturing in the country, but it has also sustained the path to growth for seven long decades through innovations and adoption of new technologies.

Planting growth

The company originally had four cement plants in pre-independence years, two of which were affected by the partition. The remaining two plants in India were operated as Dalmia Cement in Tamil Nadu and OCL India Limited in Orissa.Today, the company has three cement plants, located in Tamil Nadu and Andhra Pradesh with a combined capacity of 9 mtpa. It also has a 45.4 per cent strategic investment in OCL India, formerly Orissa Cements Limited, which has a capacity of 5.3 mtpa.
The year 2009 was a landmark year for Dalmia Cement. During this year, the company increased the number of cement plants from one to three and the capacity from 4 mtpa to 9 mtpa by adding two green-field plants. At present, it has three cement plants, two in Tamil Nadu at Dalmiapuram and Ariyalur, and one in Andhra Pradesh at Kadapa. The Dalmiapuram plant, 40 km from Trichy, was the company’s first cement plant set up in Tamil Nadu. In 1951, the plant had two kilns, one of 250 tpd of semi-dry single pass based process and the other of 508 tpd, based on wet-dry process. Since then, the plant has been completely modernised, and by the year 2007, its capacity increased to 4 mtpa, making it the largest cement plant in Tamil Nadu. With Kadapa plant in Andhra Pradesh, the company increased its footprint in south India. The company acquired the Hyderabad-based Eswar Cements Pvt Ltd and in April 2007, it was merged with Dalmia Cement.

Commissioned in March 2009, the Kadapa plant is equipped with the latest technology and equipment like Robolab, which collects samples at each stage of manufacturing and calibrates the equipment to attain the desired output. The plant’s technological highlights include – variable voltage frequency drives (VVFDs) and dust control system, among others. The plant with a capacity of 2.5 mtpa, has set a new benchmark in emission norms and energy efficiency.

Ariyalur plant, the company’s second in Tamil Nadu and third cement plant in all, is strategically located at Thamaraikulam, 40 km from the Dalmiapuram plant. Located amidst a limestone rich belt, it was commissioned during the year 2009 with a capacity of 2.5 mtpa. This plant is also equipped with advanced technologies such as Robolab, VVFD and dust control system.

Achievements galore

In 1986, the company was the first to produce oil well cement (OWC) in India to API specification. In 1991, recognising DCBL as centre of excellence for transfer of technology, World Bank Danida team sponsored a regional training centre at DCBL, Dalmiapuram to cater the needs of south Indian cement industries. In the year 1993, the company was certified with ISO 9002, the first to receive in south India and second in India. In 2004, the company obtained ISO 14001 certification from BIS. DCBL is also the recipient of various awards. In 2003, the company was chosen by Confederation of Indian Industry (CII) as a model plant for energy efficiency. In 2008, the company received National Award for Excellence in Energy Management 2007 conferred by Cll – Godrej GBC. Earlier, in 1999, the company was awarded with the National Award for Energy Efficiency in Indian Cement Industry by National Council for Cement and Building Materials. In 2001, the company was the recipient of three national energy conservation awards. The first award was the National Energy Conservation Award, by Bureau of Energy Efficiency – Ministry of Power, New Delhi, and the second award National Award for Energy Efficiency in Indian Cement Industry the presented by the National Council for Cement and Building Materials. The third one was the National Award for Excellence in Energy Management by Cll In the same year, the company was placed first in energy conservation in the cement sector. In 2002, the company received National Energy Conservation Award, National Award for Excellence in Energy Management and National Award for Energy
Efficiency in Indian Cement Industry. Cll awarded the company with National Energy Management Award in 2003-04 and 2004-05. In 2003-04, the company also received Energy Efficiency Award from the National Council for Cement and Building Materials. In 2008-09, the company received National Award for Energy Efficiency & Environmental Excellence from the National Council for Cement and Building Materials. In 2003, the company also received Leadership & Excellence Award in Safety, Health & Environment from Cll.

Binding India

DCBL’s cements can be broadly categorised into cement for building houses and cement for infrastructure. In housing category, the company offers Superoof, Vajram and Coastal cement. The Superoof is specially designed to provide extra protection and strength, compared to ordinary cements. It is manufactured with CVRM technology. The coastal cement is designed for use in the corrosive and saline conditions found along Indian coasts. It has low hydration and high resistance to alkali-silica reactions, which makes it ideal for large section concrete applications in reservoirs, dams, canal piers, cooling towers etc. For infrastructure, DCBL offers airstrip cement, oil well cement and railway sleeper cement. The airstrip cement is used extensively in cementing airstrips due to its high impact load bearing capacity. The oil well cement is used for cementing the walls of on-shore and off-shore oil wells. The railway sleeper cement is developed based on special specifications and requirements evolved by the Railways. It has been used extensively to replace wooden railway sleepers for high-speed trains.

Milestones & landmarks

In 1939, the company had an installed capacity of 250 tpd kiln to manufacture cement by semi-dry process. The machinery was supplied by Polysius, Germany. In 1949, the company installed a 500 tpd wet process kiln supplied by FLS Smidth, Denmark. In 1959, expansion was undertaken with the installation of another 200 tpd wet process Folax. In 1981, the company installed raw meal vertical roller mill. In 1982, a 200-tonne vertical shaft, first of its kind in India, was installed using fuel slurry process. In 1984, the company introduced oil well cement and railway sleeper cement. In 1986, packaging was improved and cement was dispatched in poly bags. In 1987, lignite was used as fuel to reduce variable costs and in the same year, 1,500-tpd dry process kiln was installed. In 1997, cement vertical roller mill was installed and in 2002 KHD kiln was upgraded to 3,000 tpd.

R & D activities

The R & D activities of the organisation are carried out by an independent research centre set up at Salem under Dalmia Institute of Scientific and Industrial Research, a SIRO, approved by DISIR, GoI. Here, the main focus is on product development particularly special cements, energy efficiency (both power and fuel), optimisation of raw material resources, increasing inputs of blending component, particularly flyash in PPC, and improving quality of all the products made by the company to international level.

Going green

The company has taken significant step to reduce CO2 emission. DCBL has installed power control devices to run larger machines so that, part of the electrical energy consumed by the machines can be recovered, thereby reducing the consumption of electricity. The company has also installed high-efficiency separator to increase the cement grinding capacity that will result in lower consumption of electrical energy. Under afforestation programme, the company has planted 35,000 trees. Under the CSR initiatives, DCBL has taken a number of initiatives like providing loans to villagers to buy livestock, impart necessary education for better health and productivity of livestock and form milk committees to secure better realisations through sales. Similarly, a very comprehensive programme for raising agricultural productivity through extensive farmer training, establishing demo plots and increasing water availability through farm ponds are being implemented under the
CSR programmes.

Future perfect

The company is moving swiftly towards achieving new milestones, setting up new green-field plants and innovating new ways to be in the forefront of the booming cement industry. With increasing investment in Infrastructure and housing, the company is poised for a giant leap.

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Concrete

India donates 225t of cement for Myanmar earthquake relief

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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.

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Concrete

Reclamation of Used Oil for a Greener Future

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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.

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Concrete

Charting the Green Path

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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.

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