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Clinker grinding technology in cement manufacturing

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Clinker grinding technology is the most energy-intensive process in cement manufacturing. Traditionally, it was treated as "low on technology" and "high on energy" as grinding circuits use more than 60 per cent of total energy consumed and account for most of the manufacturing cost.

Since the increasing energy cost started burning the benefits significantly, the grinding technology came under radar of innovation and technology transformation. Focus shifted to being energy efficient and cost reduction. Population of traditional stand-alone two chamber and three chamber ball mills started slowing down getting replaced by vertical roller mills, high pressure grinding rolls (HPGR), pre-grinders, HoroMills along with high-efficiency dynamic separators, static separator (V-sep) with various innovative process combinations. Technology providers used this opportunity to create a business edge. As a result, substantial reduction in energy consumption levels was achieved successful.

Transformation in product portfolio emerged as blessing in disguise to the energy scenario. Change of traditional OPC into PPC, PSC and composite cement was a game changer. PPC captured widespread market giving breather to grinding energy situation as composition bears 35 per cent of fly ash whose grindability is much lower than clinker. This became profitable proposition not only for volume increase but also for reduced energy. Similarly, PSC proved profitable for the plants having resource logistic advantage. PSC manufacturing technology, varied from inter grinding to separate grinding, gave cost advantage due to clinker factor utilisation. The production of composite cements has been increasing for reasons concerned with process economics, energy reduction, ecology (mostly reduction of CO2 emission), conservation of resources and product quality/diversity. The most important properties of cement, such as strength and workability, are affected by its specific surface and by the fineness and width of the particle-size distribution. These can be modified to some extent by the equipment used in the grinding circuit, including its configuration and control.

Ball mill grinding
Evolution of ball mills was the starting point in communition theory adopted widely in cement manufacturing. Size reduction process of bulk solids acquires major part of cement process. This started from wet grinding in three chambers mills to latest mono chamber semi finished ball mills.

Most used systems are two chamber ball mills in finished mode. Grinding in these mills occur due to the effect of cataracting and cascading motion of grinding balls. Crucial factors that influence the grinding efficiency are:

  • Liner design
  • Circumferential velocity of the mill
  • Shape, size and weight of the grinding media
  • Friction between the lining and the grinding media
  • Friction within the mill charge itself

Technology innovation made use of above factors; however results obtained were successful to the limited extent. Liners design advanced from Lorian liners to step liners to double wave to supplier customised patterns having less weight. Similarly classifiers changed from traditional deep wave, conveying pattern to thin design and bolt less, low weight liners. Wear rate of liners and grinding media is the most cost affecting factor. Improvements in wear rates and cost savings seen from Mn-steel to Hichrome to controlled metallurgy.

Higher the percentage chrome, better the wear resistance, however lowers the hardness normally. Hence, in order to make this system cost competitive and efficient, above factors must be used and leveraged for system selection and optimisation.

Vertical roller mill technology
Vertical Roller Mill (VRM) has been the most preferred technology over ball mill grinding in terms of various efficiency factors. VRM functions four main processes of grinding technology which are: drinding, drying, separation and transportation. Grinding efficiency is the energy utilised to create specific surface of material having same chemical/mineralogical composition. This can be expressed as: Eu = (Specific surface created/specific energy used). Energy utilisation in VRM grinding is better than ball mill technology. Theo power cons of VRM = (Sp. grinding press x roller area x No. of rollers x grinding track speed x friction factor). Friction factor differs from mill to mill and material to material.

Advancements in mill capacities and technology changing fast making VRM is most versatile and efficient. For the volume sensitive market, VRM started offering higher capacities, meeting expanding market requirements with single mill. At the same time, maintenance flexibilities proved this technology the most preferred choice. Various mill OEMs have their unique design features, offering advancements in technical features.

HPGR technology
High-pressure grinding rolls (HPGRs), with key process equipment as roller press in cement industry, have struggled and conquered for acceptance as finished mode operation in raw grinding and even as pregrinder in clinker grinding technology. Many of the issues that didn’t favour their widespread use have now been gradually gaining grounds. But still, it will remain subdued in selection arguments with VRM technology. Answer for this is again follows the similar requirement of customers, high capacity systems, low cost, high reliability, ease of operation and better wear resistance factors.

Most prevailing issue in the HPGR system is "high pressure" as the name suggests. High pressure has direct benefit on grinding efficiency however, it also has got immense impact on with standablity of grinding components, metallurgy of grinding profiles, mechanical stresses on drive components, etc.

In contemplating an answer to issue of the HPGR, the status of other accepted technologies like VRM must be examined. As an example, the latest and advanced VRM technology can be considered. When a plant operation / design is being considered, every well-equipped engineer will be able to turn to numerous rules of thumb associated with these factors:

Particle size distribution will be consistent in feed
Centralised and circumferentially distributed feed is required to extract the best performance.
Profile and condition of the HPGR is critical to deliver the best performance These issues prevail in VRM also. However VRM technology is well established to handle the variety of feed PSDs. A comparison between RP and VRM on some of the merits and demerits are as given:

Roller Press Parameters
Roller Press roller diameters typically vary from 0.5 m to 2.8 m, depending on the supplies, and roll widths vary from 0.2 m to 1.8 m. The aspect ratio of the rolls also varies as a function of manufacturer. Typical HPGR throughput rates range from 20 to 3,000 tph at different applications, with installed motor power as high as 3,000 kW per roll. The roller profile is the key deciding parameter on withstanding the high pressure and giving much needed life. This has been one of the significant characteristics of rollers / Roller Presses. but solutions are now in place for adequate life of the profiles. When operating an HPGR, the two most important operating parameters are:

Operating pressure
Roll speed

The two key operating parameters are inherently linked to the following:
RP throughput
Specific pressing force
Maximum pressure between the rolls
Specific energy input
RP Throughput: The throughput can also be calculated from the continuity equation as follows:
M = L x s x u x ?c x 3.6 (EQ 2) where
s = operating gap (mm)
?c = density of the product cake (t/m3)

Specific Pressing Force
The specific pressing force is defined as the grinding force applied to the rolls (kN), divided by the diameter (m) and width (m) of the rolls. The specific pressing force has the unit of N/mm2.Fsp = F/(1,000 x D x L) where,
Fsp = specific pressing force (N/mm2)
F = applied grinding force (kN)
D = roll diameter (m)
L = roll width (m)
Maximum achievable roller force must be at least
5500 kN/m2 for raw material
6000 kN/m2 for clinker and slag

Roller press design & operation
Similar to the VRM, there are few Roller Press Technology providers with different designs and principles. Mainly, they are: KHD, Koppern, Polysius. KHD has considerable roller press population for various applications. Their standard configurations are as below:

Stud lining roller is typical and popular solution for high life usage that KHD offers for. There are many advanced versions above this.

Similarly, Koppern roller press has got latest design features catering to the clinker grinding application. The roller profile is different than the other technology and offers high life hours of operation. Standard design feature and parameters that Koppern offers is as below:

POLYCOM is the established technology in roller press supplied by Thyssenkrupp Industries. Population spread across various application for clinker grinding, raw grinding and also in combi mode and finish mode.

Conclusion
Technology evolution has given user various options and alternatives. These options help user to focus on priorities. Volume is the main criteria. Mill capacities, especially in cement grinding are changing the scenario. There were no high capacity mills in the past for clinker grinding. Advanced VRM technology started offering higher capacity levels so that capex decisions became easy for the user.

At the same time, business expansion became visible in terms of stand-alone grinding station with high capacity mills. This is playing a major role in capturing various market demands and hence cement industry growth.

Design features of Gebr Pfeiffer
Design

  • Roller and grinding bed inclined, concave grinding path
  • Rollers suspended at a pressure frame
  • Hydraulic actuated at a pressure frame
  • Pull rods inclined to absorb torque, mill housing not affected with horizontal forces
  • Swing lift device for retraction & servicing of roller
  • High-efficiency separator type SLS

Operation

  • Start-up with auxiliary drive, rollers statically on grinding table
  • Normally large size mill casing and low pressure losses of gas flow

Design features of Loesche
Design

  • Airlock in general for feeding
  • High-efficiency separator, LDC
  • Conical rollers 2, 3 according to mill capacity with S roller concept
  • Rocker arm with hydraulic cylinders to exert the roller pressure
  • Hydraulic cylinders with nitrogen accumulators
  • Modular design; hydro pneumatic units can be combined with various mill sizes according to throughput or drying needs

Operation

  • Rollers can be lifted from grinding track for low torque start-up of the mill
  • Grinding pressure and counter pressures can be adjusted to maintain smooth operation

Design features of OK
Design

  • Hydro pneumatic system for pressure exertion
  • Multiple rollers, based on capacity
  • Unique grooved roller profile
  • Curved table profile
  • Roller repositioning after wear

Operation

  • Rollers will be lifter position during start up
  • 2,4 rollers can be unloaded for partial capacity operation of special operating conditions
  • Recirculation of hot exit gas to the Mill inlet

Design features of Ploysius Quadropol
Design

  • 4 individual grinding rollers
  • Cambered geometry of roller with better wear resistance
  • Rollers can be swung out for maintenance
  • Bearing assembly located outside the grinding chamber
  • Ring craneway for maintenance works

Operation
Rollers can be unloaded for partial capacity operation of special operating conditions
Nozzle velocities can be adjusted during partial operations
High efficiency SEPOL separator
RP
Few applications in cement
grinding as semi finished mode
– Limited size?not beyond ~120 bar
+ Superior wear solutions
+ lower SEEC for dry and hard
material (Lower than VRM if in finished mode)
+ Market acceptance & early strength of cement
-Sensitive to feed variations
-More equipments & lay out space

VRM:
+ Proven solution, many applications
+ Large single units available
-Reliability of planetary reducer
+ Lower SEEC in compare with ball mill
+ Stable operation easy to achieve…
-… but often requiring water injection
-Support roller technology not successful

Feed chute placed above fixed roller, shut off gate and vertical flow control gate
Feature:

  • Easy operation Only few moving parts
  • Ensures stable operation even for high product fineness
  • Easy start up procedure in
  • combination with ROLCOX
  • Roller profile is called Hexadur. It offers increased life of profile in compare with solid weld rollers.

About the authors:
Shreekant Hulgi Managing Partner, SPV Engineers
Vijaykumar Vemuri Managing Partner, SPV Engineers

Founded in October 2018, SPV Engineers is a partnership firm specialising in process safety (risk) assessments and solutions, plant performance improvement for productivity through "Mill & Kiln Modules", energy cost reduction through electrical and thermal energy optimisation, refractory design, selection and installation services, capex projects through process engineering, plant capacity debottlenecking and feasibility studies, fuel cost reduction through AFR projects and optimisation. SPV Engineers is a sales partner for latest and advanced SpectraFlow online analyser for minute-by-minute analysis and control. SpectraFlow is an analyser with no radiation risk and no statutory safety requirements. SpectraFlow works on unique principle of NIR (Near Infra Red) technology, which is first in the industry with minimum OPEX and cost of ownership.

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Economy & Market

SEW-EURODRIVE India Opens Drive Technology Centre in Chennai

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The new facility strengthens SEW-EURODRIVE India’s manufacturing, assembly and service capabilities

SEW-EURODRIVE India has inaugurated a new Drive Technology Centre (DTC) in Chennai, marking a significant expansion of its manufacturing and service infrastructure in South India. The facility is positioned to enhance the company’s responsiveness and long-term support capabilities for customers across southern and eastern regions of the country.

Built across 12.27 acres, the facility includes a 21,350-square-metre assembly and service setup designed to support future industrial growth, evolving application requirements and capacity expansion. The centre reflects the company’s long-term strategy in India, combining global engineering practices with local manufacturing and service capabilities.

The new facility has been developed in line with green building standards and incorporates sustainable features such as natural daylight utilisation, solar power generation and rainwater harvesting systems. The company has also implemented energy-efficient construction and advanced climate control systems that help reduce shopfloor temperatures by up to 3°C, improving production stability, product quality and working conditions.

A key highlight of the centre is the 15,000-square-metre assembly shop, which features digitisation-ready assembly cells based on a single-piece flow manufacturing concept. The facility also houses SEW-EURODRIVE India’s first semi-automated painting booth, aimed at ensuring uniform surface finish and improving production throughput.

With the commissioning of the Chennai Drive Technology Centre, SEW-EURODRIVE India continues to strengthen its manufacturing footprint and reinforces its long-term commitment to supporting industrial growth and automation development in India.

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Economy & Market

RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways

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Roundtable discussions focus on innovation for safer highways.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.

Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.

Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.

RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.

Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.

Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.

The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.

From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.

Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.

Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.

Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.

The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.

Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.

The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.

Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.

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CTS Roundtable Charts Tech-Led Roadmap for Construction

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CTS Roundtable Maps Technology Roadmap for Construction

Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.

A platform to move from discussion to deployment

Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.

Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.

Industry at a turning point

Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.

Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.

His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.

From BIM to AI, data to governance

A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.

Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.

Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.

The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.

Industrialised construction gains ground

The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.

Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.

Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.

Adoption remains the biggest hurdle

While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.

Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.

Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.

That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.

Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.

Beyond buzzwords

A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.

The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.

Setting the agenda for CTS 2026

By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.

More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.

As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.

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