Economy & Market

Gunning for lower downtime

Published

8 years ago

August 31, 2018

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For minimising downtime, techniques like gunning and shotcreting are being adopted, instead of using pre-fired bricks in refractories.

Portland cement manufacturing is an energy intensive operation, and a refractory lining that can withstand high temperatures, alkalinity and corrosive conditions is absolutely essential.

Refractories play a critical role in both the rotary kiln lining, and the lining of the high volume static equipment areas that comprise a modern pre-calciner kiln system. The refractory kiln process involves pyro-processing of raw material, and extremely high temperature in rotary kilns. Often the kiln feeds are alkaline in nature, generate corrosive reactants. Hence the importance of refractories with strong resistance to such characteristics and having robust thermal efficiencies in cement manufacturing. ‘After two years of depressed market, currently refractory market has stabilised a bit and it seems that recovery is underway in 2018,’ says Ish Mohan Garg, Managing Director, Calderys.

While iron and steel industry is the major consumer of refractories with 65-75 per cent share, cement is the second major consumer of the equipment with 10-15 per cent share of total refractory consumed, followed by glass, non-ferrous metals, petrochemicals and hydrocarbons, which also involve high temperature processes.

Imports
About 30 per cent of refractories consumed in India is imported, mostly from China. ‘The primary driver for these imports is the abundant availability of raw material there, especially magnesite. To that extent, we cannot wish away the role of China and this is also the reason why refractory companies have set up plants in China,’ says Sameer Nagpal, CEO, Dalmia-OCL. However, the recent raw material crisis in China provides immense opportunity for India to bolster its domestic refractory industry by allowing it to source and secure raw materials from other countries with zero import duty.

But, certain policy anomalies have to be corrected to achieve this, says Garg. ‘Refractory is essentially a "Make in India" business model where we import raw materials and create value-added products in India. But while import duty on raw material is 5 per cent, that on finished product is 2.5 per cent. This import duty has to be increased to encourage domestic manufacturing activity.’

With India becoming the world’s second largest steel and cement producer, it should also be a leading refractory producer to support these industries. ‘Indian companies have the wherewithal to emerge as a globally competitive player and we are actively pursuing this direction. We are looking at acquisitions in Europe that can help us build scale and access latest technologies,’ says Nagpal.

‘Due to its low-cost and highly skilled workforce, India is a competitive market for refractory manufacturing and is also a sourcing base for Americas and Europe,’ Nagpal adds. Dalmia-OCL has a network spread across different countries and exports constitute 15 per cent of its revenue.

However, Garg differs on competitiveness of the Indian refractory industry. ‘Raw materials being 60-70 per cent of the total cost of refractory makes it difficult for Indian refractory industry to become globally competitive, due to sheer dependence of Indian manufacturers on imported raw materials. As a country, our ability to tap into global/ regional market is very much restricted,’ he points out.

Technology
As cement demand picks up and capacity utilisation goes up, cement manufacturers may want to minimise the downtime for replacing refractory lining. ‘This is giving rise to demand for higher performing bricks with higher life and shorter application time. Techniques like gunning and shotcreting using monolithic refractory, which is in powder form and takes shape after being applied, instead of using pre-fired bricks, is also gaining currency,’ says Nagpal.

Dalmia-OCL has formed a joint venture with a leading European refractory company for bringing to India the latest in gunning and shotcreting products, and is setting up the most modern monolithic plant in Katni, Madhya Pradesh.

Also, Indian cement makers use a lot of alternative fuels, which puts tremendous thermochemical pressure on refractory. Hence second or third generation spinels, hybrid refractories are coming up to take care of the increased thermochemical loads. Another trend is the effort towards reduction of thermal losses by introducing energy-saving refractories. New concepts are also coming up on thermal insulation of pyro system.

In the past, the major focus had been on the kiln performance, primarily productivity but with stricter environmental norm there has been major shift on the cement kiln system refractories too. ‘Well known hexavalent chrome problem associated with Mag Chrome refractories has made them unusable in cement kiln. In the kiln burning zone, Mag Chrome bricks have been substituted by wide range of alternate spinel products, e.g. MagAl, Hercenyte and others like zirconia containing magnesia, etc.,’ says Garg of Calderys.

Ammonia injection, once stricter NOx and SOx norms is implemented, would put significantly more stress on the refractory in the cement kiln system. Refractory manufacturers need to gear up for these upcoming regulatory norms.

Cement kilns in India are virtually being used as incinerator, where pharma and municipal wastes are common feed as fuel. This obviously has changed the kiln operating environment. This has resulted in increased coating build in kiln inlet as well as Spurrite ring formation within the kiln. On many occasions, the clinker is dustier compared to the past. ‘These changes obviously have called for refractories with different features. Incorporation of the requisite features has turned out to be much easier in monolithic, primarily castables, compared to bricks. Against this backdrop, castable in kiln inlet, tip casting, bull nose and cooler bench has become a standard practice. With the advent of shotcrete installation process, for identical castable formulations, faster installation extension of refractory life, by repair, has been possible,’ says Garg.

Boost domestic manufacturing
While emphasising the need to boost local refractory manufacturing, Nagpal of Dalmia-OCL suggested reduction of duties on raw material import; enabling mining policies for minor minerals like bauxite, quartzite, magnesite, etc., which are critical refractory raw materials, to reduce dependence on external sources; and support to refractory and ceramics R&D to boost local innovation, for this purpose.

The primary support from government should be on the following three fronts – ‘technology development, developing young talent and sustainability,’ says Garg of Calderys.

On behalf of IRMA, Calderys has set up Centre of Excellence at IIT BHU aimed at technological advances for making industry globally competitive. ‘We need to accelerate such advances in multiple Institute of repute,’ Garg adds.

For decades, the industry has been dumping used refractory in landfills, however, more sustainable way is to extract key raw materials from the same, use it again for refractory. ‘We trust Government should work with user industry to enable reverse supply chain of used refractory,’ says Garg.

-BS SRINIVASALU REDDY

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

6 days ago

June 5, 2026

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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.

Concrete

Building a Greener Future Together

Published

1 week ago

June 4, 2026

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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.

Concrete

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

Published

3 weeks ago

May 25, 2026

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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.