Technology

Clinker cooler replacement delivers improved productivity at Rain Cements

Published

7 years ago

July 22, 2018

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Rain Cement’s South India-based Ramapuram plant has achieved impressive performance results following the successful replacement with FLSmidth Cross-Bar? cooler.

Rain Cements Limited (RCL) has been producing cement since 1986 at an annual output of up to 3.6 million tonnes. Its two integrated plants located in South India are self-sufficient in all critical raw materials – limestone, additives and coal.

RCL made an important decision to address inefficiencies in one of its existing systems at the cement plant based in Ramapuram, Mallacheruvu, Kodad in Nalgonda. The project team paid particular attention to the grate cooler, which was an older generation with low thermal efficiency, and high-energy consumption and requiring more maintenance.

Mr. VM Moorthy, VP (Technical) at RCL, comments: "We previously had an old-generation grate cooler, which was becoming problematic for us. We wanted to improve thermal efficiency, so it was necessary to move to a new-generation cooler."

With a complete FLSmidth production line already implemented at one of its plants, RCL approached FLSmidth to audit the cooler system in 2016. The audit involved taking detailed measurements of the existing cooler’s performance. The findings identified the potential to reduce cooler losses and create thermal and electrical energy savings, and as a result, FLSmidth recommended replacing and installing a more reliable, efficient cooler.

Making the right choice
The RCL project team emphasised that the quality of the equipment, including its durability, was key, along with delivery of the equipment in time for its efficient installation within the planned shutdown period. They sought a commitment to performance guarantees along with ongoing service support after the upgrade.

The Cross-Bar? cooler met the needs of RCL in terms of possessing high thermal efficiency, reduced power consumption, relatively low maintenance requirements and low civil construction and operating costs. The optimised design is flexible enough to enable partial or complete upgrades of most existing old-generation clinker coolers. The return on investment for RCL can be realised within an estimated four-year period, just from the energy benefits and fuel savings alone. It was clear that this was the solution for RCL, and FLSmidth’s extensive experience in retrofits gave a certain boost of confidence.

Ambitious but achievable timelineThe project team comprised of two FLSmidth supervisors, whose role was to supervise the upgrade, together with a team of RCL employees who were responsible for the civil construction and erection of the new cooler.

A crucial aspect of the project was that it needed to be completed within the planned shutdown period, which encompasses delivery, civil works, dismantling, installation, refractory works and start-up. The timeline of the project was ambitious but necessary to minimise production downtime. Together, RCL and FLSmidth displayed collaborative efforts to ensure plant start up as scheduled in the stipulated short timeline.

"Despite requiring extensive civil structure modifications, the project was completed on time thanks to the support and experience of FLSmidth in completing retrofits," says Mr. Moorthy, Vice President, RCL.

Reaping performance benefits
Following the upgrade, the new Cross-Bar? cooler has run well without any issues, according to Mr. Moorthy, and the performance guarantee results showcasing the success of the project.

begin{table}[] begin{tabular}{lll} textbf{Performance parameter} & textbf{Before} & textbf{After} \ Production (Mtpd) & 2,864 & 2,910 \ Recuperation efficiency (%) & 68 & 77 \ Actual cooler loss (Kcal/Kg Clinker) & 149 & 110 \ Standard cooler los (Kcal/Kg Clinker) & 131 & textbf{92} \ Clinker temperture (Celsius) & 147 & 92 \ Specific power consumption fans, drives and breaker (Kwh/t) & 4.6 & 4.4 end{tabular} end{table}

FLSmidth believe guarantees achieved on performance parameters is seen as an indication of the Cross-Bar? cooler’s exceptional performance and reliability.

"It pays to make the initial investment to reap the performance benefits well into the future. The success of this project demonstrates FLSmidth’s commitment to deliver impressive results through collaboration with our valued customers."
Realising customer ambitions
FLSmidth Cross-Bar? cooler design features have made it possible to realise customer ambitions. Maximum value is delivered to cement producers through the practical application of innovative technologies. Cement producers choose FLSmidth Cross-Bar? cooler so as have faster payback of investment and lower total cost of ownership.
Key benefits:

Increased reliability and availability

Improved thermal efficiency

Reduced cooler losses

Lower clinker temperature

Low specific power consumption
Author: G Renga Prasad, Product Line Manager-Pyro, FLSmidth.
(Communication by the management of the company)

Technology

ARAPL Reports 175% EBITDA Growth, Expands Global Robotics Footprint

Affordable Robotic & Automation posts strong Q2 and H1 FY26 results driven by innovation and overseas orders

Published

3 weeks ago

October 15, 2025

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Affordable Robotic & Automation Limited (ARAPL), India’s first listed robotics firm and a pioneer in industrial automation and smart robotic solutions, has reported robust financial results for the second quarter and half year ended September 30, 2025.
The company achieved a 175 per cent year-on-year rise in standalone EBITDA and strong revenue growth across its automation and robotics segments. The Board of Directors approved the unaudited financial results on October 10, 2025.

Key Highlights – Q2 FY2026
• Strong momentum across core automation and robotics divisions
• Secured the first order for the Atlas AC2000, an autonomous truck loading and unloading forklift, from a leading US logistics player
• Rebranded its RaaS product line as Humro (Human + Robot), symbolising collaborative automation between people and machines
• Expanded its Humro range in global warehouse automation markets
• Continued investment in deep-tech innovations, including AI-based route optimisation, autonomy kits, vehicle controllers, and digital twins
Global Milestone: First Atlas AC2000 Order in the US

ARAPL’s US-based subsidiary, ARAPL RaaS (Humro), received its first order for the next-generation Atlas AC2000 autonomous forklift from a leading logistics company. Following successful prototype trials, the client placed an order for two robots valued at Rs 36 million under a three-year lease. The project opens opportunities for scaling up to 15–16 robots per site across 15 US warehouses within two years.
The product addresses an untapped market of 10 million loading docks across 21,000 warehouses in the US, positioning ARAPL for exponential growth.

Financial Performance – Q2 FY2026 (Standalone)
Net Revenue: Rs 25.7587 million, up 37 per cent quarter-on-quarter
EBITDA: Rs 5.9632 million, up 396 per cent QoQ
Profit Before Tax: Rs 4.3808 million, compared to a Rs 360.46 lakh loss in Q1
Profit After Tax: Rs 4.1854 lakh, representing 216 per cent QoQ growth
On a half-year basis, ARAPL reported a 175 per cent rise in EBITDA and returned to profitability with Rs 58.08 lakh PAT, highlighting strong operational efficiency and improved contribution from core businesses.
Consolidated Performance – Q2 FY2026
Net Revenue: Rs 29.566 million, up 57% QoQ
EBITDA: Rs 6.2608 million, up 418 per cent QoQ
Profit After Tax: Rs 4.5672 million, marking a 224 per cent QoQ improvement

Milind Padole, Managing Director, ARAPL said, “Our Q2 results reflect the success of our innovation-led growth strategy and the growing global confidence in ARAPL’s technology. The Atlas AC2000 order marks a defining milestone that validates our engineering strength and accelerates our global expansion. With a healthy order book and continued investment in AI and autonomous systems, ARAPL is positioned to lead the next phase of intelligent industrial transformation.”
Founded in 2005 and headquartered in Pune, Affordable Robotic & Automation Ltd (ARAPL) delivers turnkey robotic and automation solutions across automotive, general manufacturing, and government sectors. Its offerings include robotic welding, automated inspection, assembly automation, automated parking systems, and autonomous driverless forklifts.
ARAPL operates five advanced plants in Pune spanning 350,000 sq ft, supported by over 400 engineers in India and seven team members in the US. The company also maintains facilities in North Carolina and California, and service centres in Faridabad, Mumbai, and San Francisco.

Technology

M.E. Energy Bags Rs 490 Mn Order for Waste Heat Recovery Project

Second major EPC contract from Ferro Alloys sector strengthens company’s growth

Published

3 weeks ago

October 15, 2025

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M.E. Energy Pvt Ltd, a wholly owned subsidiary of Kilburn Engineering Ltd and a leading Indian engineering company specialising in energy recovery and cost reduction, has secured its second consecutive major order worth Rs 490 million in the Ferro Alloys sector. The order covers the Engineering, Procurement and Construction (EPC) of a 12 MW Waste Heat Recovery Based Power Plant (WHRPP).

This repeat order underscores the Ferro Alloys industry’s confidence in M.E. Energy’s expertise in delivering efficient and sustainable energy solutions for high-temperature process industries. The project aims to enhance energy efficiency and reduce carbon emissions by converting waste heat into clean power.

“Securing another project in the Ferro Alloys segment reinforces our strong technical credibility. It’s a proud moment as we continue helping our clients achieve sustainability and cost efficiency through innovative waste heat recovery systems,” said K. Vijaysanker Kartha, Managing Director, M.E. Energy Pvt Ltd.

“M.E. Energy’s expansion into sectors such as cement and ferro alloys is yielding solid results. We remain confident of sustained success as we deepen our presence in steel and carbon black industries. These achievements reaffirm our focus on innovation, technology, and energy efficiency,” added Amritanshu Khaitan, Director, Kilburn Engineering Ltd

With this latest order, M.E. Energy has already surpassed its total external order bookings from the previous financial year, recording Rs 138 crore so far in FY26. The company anticipates further growth in the second half, supported by a robust project pipeline and the rising adoption of waste heat recovery technologies across industries.

The development marks continued momentum towards FY27, strengthening M.E. Energy’s position as a leading player in industrial energy optimisation.

Technology

NTPC Green Energy Partners with Japan’s ENEOS for Green Fuel Exports

NGEL signs MoU with ENEOS to supply green methanol and hydrogen derivatives

Published

3 weeks ago

October 15, 2025

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NTPC Green Energy Limited (NGEL), a subsidiary of NTPC Limited, has signed a Memorandum of Understanding (MoU) with Japan’s ENEOS Corporation to explore a potential agreement for the supply of green methanol and hydrogen derivative products.

The MoU was exchanged on 10 October 2025 during the World Expo 2025 in Osaka, Japan. It marks a major step towards global collaboration in clean energy and decarbonisation.
The partnership centres on NGEL’s upcoming Green Hydrogen Hub at Pudimadaka in Andhra Pradesh. Spread across 1,200 acres, the integrated facility is being developed for large-scale green chemical production and exports.

By aligning ENEOS’s demand for hydrogen derivatives with NGEL’s renewable energy initiatives, the collaboration aims to accelerate low-carbon energy transitions. It also supports NGEL’s target of achieving a 60 GW renewable energy portfolio by 2032, reinforcing its commitment to India’s green energy ambitions and the global net-zero agenda.