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Combating Material Accumulation in Cement Plants

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A state-of-the-art cement plant has resolved material accumulation issues in its limestone silo by combining high-efficiency cleaning techniques with powerful, strategically-placed air cannons to prevent further build-up.

The Drake Cement facility to miles north of Paulden, AZ was experiencing clogging issues on a weekly basis, forcing maintenance personnel to spend up to 12 hours to clear the blockage using tools and compressed air. During damp weather, the problem worsened, and at times the large structure would fill in as little as two hours, forcing operators to use CO2 blasting tubes every 15 to 30 minutes.

Technicians from Martin Engineering were able to clear the blockage on a short-notice visit, and then revised the site’s air cannon system to prevent the issue from recurring.

Drastic Measures
A key component of Drake’s dry-process manufacturing is efficient material flow. Excessive rain in the months of January through March caused the limestone being extracted from the nearby quarry to have elevated moisture levels. Not only does the rain cause standing water, but the limestone is also wetter coming out of the ground.

Little of that water is lost in the crushing process, and dry material can absorb moisture as it is reduced in size. So in the winter months, by the time the material lands in the 536-tonne (486 metric tonne) limestone silo, it is nearly saturated. In prior years, the silo had not experienced a single flow disruption, nor had it required cleaning due to the aid of two Martin? XHV air cannons. Adequate in previous years to keep material flowing at required volumes through all seasons, the air cannons were unable to prevent clogging at such high moisture levels.

"This plant is one of the most advanced operations of its kind, with advanced operating and pollution controls found in only a few other facilities in the world," explained Jose Venegas, Maintenance Manager, Drake Cement. "I had a Martin representative coming out to look at another part of the plant, but when the silo clogged, that took immediate priority. The problem had become disruptive, expensive and hazardous. We needed it solved once and for all."

Limestone Snowballs
When Martin Engineering’s National Business Development Manager Doug Brown arrived at the plant, he found a silo so compactly clogged that it had halted the entire production process. "Inspecting the silo for a solution, we realized that the limestone could be packed like snowballs, dense enough to stick to the wall when thrown," said Brown, adding "This demonstrated just how serious the problem was. We luckily had a silo cleaning crew that had just finished a job in Tucson, AZ, so they were quickly dispatched north to the plant."

The experienced two-man crew immediately set up a Martin? Heavy Duty Whip. Powered by compressed air, the device can be equipped with a variety of flails and cutting edges to knock down accumulated material without damaging the silo’s walls or support structure. Requiring no confined space entry, the device was set above the manhole opening at the top of the vessel and maneuvered by remote control. "Working together with the electrical and maintenance departments, we were able to continue operations during the cleaning process," Venegas said. "This really helped us avoid what could have been some costly downtime."

Long Term Prevention
Once the silo had been completely evacuated, Brown – a flow aid specialist – realized that the ongoing problem could be remedied by utilising Drake’s current stockpile of air cannons. Using an innovative placement strategy, Brown was certain that the cannons could safely prevent buildup and promote efficient high-volume material flow, no matter how moist or dense the limestone.

Rather than the two cannons at the bottom of the limestone silo firing across the cargo flow, five cannons were strategically placed around the vessel. Three 70-litre Martin? Tornado Air Cannons were placed on the lower incline of the cone at a 30? downward angle against the 60? slope in the 6 and 12 o’clock positions (one side of the silo was inaccessible). In the 3 o’clock position, one air cannon was situated at the 2-foot – wide shaft, and another was added to the upper silo to aid in loosening material.

Already fitted with 53 XHV and Tornado Air Cannons throughout the plant, a programmable logic control (PLC) system centrally placed in the facility coordinates and monitors the timing and firing sequence of each unit at all locations, including the limestone silo. During the wet winter and monsoon months, the cannons are activated approximately every hour, but throughout the rest of the year the system has a firing sequence of only 4-5 times per day. This pattern can also be manually activated from the weigh feeder, at the solenoid panel or in the control room.

Results Demonstrated
Since installation, plant production has returned to normal levels. Material flow is ongoing, and the silo has not been shut down for cleaning. There has been no unscheduled downtime due to clogging, which has greatly increased production, especially through heavy weather periods. The use of CO2 tubes has been ceased altogether. When a buildup is detected, workers no longer are required to get close to the area to resolve it, increasing plant safety and reducing the number of man-hours required to maintain the silo.

"This equipment upgrade has paid for itself many times over," Venegas said. "We are extremely happy with the results. The service was fast, responsive and well coordinated. During our next scheduled outage, we’re going to have a Martin Engineering team out here to consult on other areas where we might need air cannons, so that we can maximize production. We look forward to an ongoing and productive relationship."

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Concrete

India Sets Up First Carbon Capture Testbeds for Cement Industry

Five CCU testbeds launched to decarbonise cement production

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The Department of Science and Technology (DST) recently unveiled a pioneering national initiative: five Carbon Capture and Utilisation (CCU) testbeds in the cement sector, forming a first-of-its-kind research and innovation cluster to combat industrial carbon emissions.
This is a significant step towards India’s Climate Action for fostering National Determined Contributions (NDCs) targets and to achieve net zero decarbonisation pathways for Industry Transition., towards the Government’s goal to achieve a carbon-neutral economy by 2070.
Carbon Capture Utilisation (CCU) holds significant importance in hard-to-abate sectors like Cement, Steel, Power, Oil &Natural Gas, Chemicals & Fertilizers in reducing emissions by capturing carbon dioxide from industrial processes and converting it to value add products such as synthetic fuels, Urea, Soda, Ash, chemicals, food grade CO2 or concrete aggregates. CCU provides a feasible pathway for these tough to decarbonise industries to lower their carbon footprint and move towards achieving Net Zero Goals while continuing their operations efficiently. DST has taken major strides in fostering R&D in the CCUS domain.
Concrete is vital for India’s economy and the Cement industry being one of the main hard-to-abate sectors, is committed to align with the national decarbonisation commitments. New technologies to decarbonise emission intensity of the cement sector would play a key role in achieving of national net zero targets.
Recognizing the critical need for decarbonising the Cement sector, the Energy and Sustainable Technology (CEST) Division of Department launched a unique call for mobilising Academia-Industry Consortia proposals for deployment of Carbon Capture Utilisation (CCU) in Cement Sector. This Special call envisaged to develop and deploy innovative CCU Test bed in Cement Sector with thrust on Developing CO2 capture + CO2 Utilisation integrated unit in an Industrial set up through an innovative Public Private Partnership (PPP) funding model.
As a unique initiative and one of its first kind in India, DST has approved setting up of five CCU testbeds for translational R&D, to be set up in Academia-Industry collaboration under this significant initiative of DST in PPP mode, engaging with premier research laboratories as knowledge partners and top Cement companies as the industry partner.
On the occasion of National Technology Day celebrations, on May 11, 2025 the 5 CCU Cement Test beds were announced and grants had been handed over to the Test bed teams by the Chief Guest, Union Minister of State (Independent Charge) for Science and Technology; Earth Sciences and Minister of State for PMO, Department of Atomic Energy, Department of Space, Personnel, Public Grievances and Pensions, Dr Jitendra Singh in the presence of Secretary DST Prof. Abhay Karandikar.
The five testbeds are not just academic experiments — they are collaborative industrial pilot projects bringing together India’s top research institutions and leading cement manufacturers under a unique Public-Private Partnership (PPP) model. Each testbed addresses a different facet of CCU, from cutting-edge catalysis to vacuum-based gas separation.
The outcomes of this innovative initiative will not only showcase the pathways of decarbonisation towards Net zero goals through CCU route in cement sector, but should also be a critical confidence building measure for potential stakeholders to uptake the deployed CCU technology for further scale up and commercialisation.
It is envisioned that through continuous research and innovation under these test beds in developing innovative catalysts, materials, electrolyser technology, reactors, and electronics, the cost of Green Cement via the deployed CCU technology in Cement Sector may considerably be made more sustainable.
Secretary DBT Dr Rajesh Gokhale, Dr Ajai Choudhary, Co-Founder HCL, Dr. Rajesh Pathak, Secretary, TDB, Dr Anita Gupta Head CEST, DST and Dr Neelima Alam, Associate Head, DST were also present at the programme organized at Dr Ambedkar International Centre, New Delhi.

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Concrete

JK Lakshmi Adopts EVs to Cut Emissions in Logistics

Electric vehicles deployed between JK Puram and Kalol units

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JK Lakshmi Cement, a key player in the Indian cement industry, has announced the deployment of electric vehicles (EVs) in its logistics operations. This move, made in partnership with SwitchLabs Automobiles, will see EVs transporting goods between the JK Puram Plant in Sirohi, Rajasthan, and the Kalol Grinding Unit in Gujarat.
The announcement follows a successful pilot project that showcased measurable reductions in carbon emissions while maintaining efficiency. Building on this, the company is scaling up EV integration to enhance sustainability across its supply chain.
“Sustainability is integral to our vision at JK Lakshmi Cement. Our collaboration with SwitchLabs Automobiles reflects our continued focus on driving innovation in our logistics operations while taking responsibility for our environmental footprint. This initiative positions us as a leader in transforming the cement sector’s logistics landscape,” said Arun Shukla, President & Director, JK Lakshmi Cement.
This deployment marks a significant step in aligning with India’s push for greener transport infrastructure. By embracing clean mobility, JK Lakshmi Cement is setting an example for the industry, demonstrating that environmental responsibility can go hand in hand with operational efficiency.
The company continues to embed sustainability into its operations as part of a broader goal to reduce its carbon footprint. This initiative adds to its vision of building a more sustainable and eco-friendly future.
JK Lakshmi Cement, part of the 135-year-old JK Organisation, began operations in 1982 and has grown to become a recognised name in Indian cement. With a presence across Northern, Western, and Eastern India, the company has a cement capacity of 16.5 MTPA, with a target to reach 30 MT by 2030. Its product range includes ready-mix concrete, gypsum plaster, wall putty, and autoclaved aerated fly ash blocks.

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Concrete

Holcim UK drives sustainable construction

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Holcim UK has released a report titled ‘Making Sustainable Construction a Reality,’ outlining its five-fold commitment to a greener future. The company aims to focus on decarbonisation, circular economy principles, smarter building methods, community engagement, and integrating nature. Based on a survey of 2,000 people, only 41 per cent felt urban spaces in the UK are sustainably built. A significant majority (82 per cent) advocated for more green spaces, 69 per cent called for government leadership in sustainability, and 54 per cent saw businesses as key players. Additionally, 80 per cent of respondents stressed the need for greater transparency from companies regarding their environmental practices.

Image source:holcim

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