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Advances in Cement Analysis

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Though Blaine analysis is a time tested method of measuring fineness of cement. Today Laser Diffraction technology scores over it mainly due to more accurate and real time measurement. Dr. Michael Caves, India ? Business Development Manager of Malvern AIMIL explains the advantages of laser based particle size analysers.

The final steps in cement manufacturing involve grinding (milling) and blending in order to produce the fine powder that is recognizable as cement. Every step in the manufacture of cement is checked by frequent physical tests, as is finished product, to ensure that it complies with all necessary specifications. Cement is ground to a particular fineness since the influence of particle size on the kinetics of cement hydration and development of strength is well known. A reduction in median particle size generally produces a higher compressive strength. Consequently the fineness of Portland cements has been increased over the years to improve properties such as higher early strengths. Nevertheless, other effects of increased fineness, such as higher water demands and more rapid heat generation in the concrete cannot be ignored. Despite the availability of instrumental methods of measuring particle size distributions, the classical method of air permeametry remains.

Understanding Blaine
Many plants control cement fineness using an air permeability apparatus to measure the Blaine number, a parameter related to the cement particle size. The Blaine surface area measurement has been used since the 1940s to determine cement quality and despite its longevity the limitations of this off-line technique are widely recognized. It is slow and suffers from poor reproducibility, which can lead to significant errors, including unnecessary or inaccurate changes to the classifier speed. Blaine analysis measures the specific surface area of a sample, the surface area per unit mass. Finer particle sizes have higher specific surface area: more area per unit mass, so Blaine is an indirect measure of particle size.

But, Blaine delivers just a single averaged figure. Figure 1 shows analysis of 2 cement samples using a Malvern Mastersizer Laser Diffraction system. Sample 2 contains more fines than sample 1 but also more coarse material. These two differences cancel each other out so average specific surface area remains the same, illustrating why two quite different samples can have the same Blaine. The more important question is ?do we need to know about the difference indicated by the particle size distribution??

Size Distribution Measurements
However two cement samples with identical Blaine figures can show different particle size distributions when measured by laser diffraction. Should we classify these two cements as different or the same?

For answers, we need to look at how the data are used. Cement manufacturers measure Blaine to quantify product quality. The hydration speed of cement particles is a function of particle size and determines the strength of the set cement. Generally, finer particles hydrate more quickly, giving greater strength, and within certain limits finer cement is better cement.

Returning to our samples, these materials will behave differently when used. Very fine cement particles, in the 2 – 3 micron range can cause exothermic cracking. Conversely particles over 50 microns may not hydrate, compromising product strength. Sample 1 contains less of both types of particles and consequently is a superior cement, even though Blaine ranks it the same as sample 2. So, the size distribution data are most certainly relevant.

Switching to laser diffraction
The practicalities of switching to laser diffraction are equally compelling. Laser diffraction, however, is fast and automated. In the lab this means greater productivity and better reproducibility. For processing it means on-line instrumentation and real-time measurement.

Malvern Mastersizer 3000 (Figure 2), which has a measurement range of 0.01 to 3500 microns, is an essential component of a high-quality cement laboratory. Finished products, as well as replacement material such as fly ash and blast furnace slag and fuels, have varying size distributions and so behavioral understanding and prediction requires Mastersizer analysis.

A vital element in successful laser diffraction particle size analysis is ensuring that samples are dispersed properly. In cement manufacture it is the primary particle size of a sample that is most usually the parameter of interest, rather than the size of any agglomerated material present. When using laser diffraction, samples can be dispersed and measured wet in the form of a suspension, or as dry powders. Dry dispersion, using dry compressed air, has a number of advantages, not least its obvious suitability for water sensitive material such as cement. It also avoids the need for solvent based dispersants and is rapid, thus increasing instrument productivity. The dry dispersion accessory, Aero S, available with Mastersizer 3000 has modular dispersion nozzles with different impaction surfaces. Keeping in mind that flow of abrasive material like cement for a prolonged period of time can cause damage to metal surfaces, there are options available for ceramic coated flow paths. It is worth highlighting the value of considering an analyzer that can switch easily between different samples with a minimum of fuss. Being able to change between different types of samples without fear of cross contamination, or to move simply or quickly from dry to wet measurement (or vice versa) as required, can make a real difference to analytical productivity, helping to maximize the return of investment in the system.

Finally, another important reason to switch to laser diffraction is the possibilities the technique offers for on-line analysis. Insitec systems deliver fully automated real-time analysis of cement particle size distribution from 0.1 to 2500 microns and can be configured to suit practically every process.

Conclusion
Whilst traditional Blaine measurements have served the cement industry well since the development of the Blaine method in the 1940s, the efficiency and quality of production of modern cements can be improved greatly by using Laser Diffraction technology. Efficient data acquisition, adaptable methods, and information-rich data explain the increasing use of the Malvern Mastersizer 3000 and Insitec range of systems in cement production around the world.

For more details, pls contact: Malvern Aimil Instruments Pvt. Ltd. Tel : 011-30810244 Fax : 011-26950011, Email : delhi@aimil.com

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

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Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.

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