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Cement kiln refractories: An innovative approach

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A few critical areas of a cement kiln like tip casting (TC) and cooler beam (bull nose) are very sensitive. Normally bricks are being used in TC and are matched with the performance of burning zone bricks lining. To overcome this situation, few of the cement plants have started using various grades of castable shapes (monilithic lining). Here are a few success stories.

Refractories play a critical, if unseen, role in both the rotary kiln lining and the lining of other equipment like pre-calciner, coolers of kiln system. The durability of the rotary kiln brick lining generally determines the duration of a kiln operating period. Whilst great efforts are made to ensure appropriate refractory brick materials selection, installation, deployment (zoning) and the optimisation of the kiln light-up, it is primarily the nature and stability of the subsequent kiln operation that influences rotary kiln lining life. Normal life expectancy for burning zone is about one year. Cement plants prefer to take only one shutdown in a year when the burning zone bricks are changed.

Performance of refractory broadly depends on three factors ‘refractory selection, installation and usage conditions. Assuming first two conditions are under control as per requirement, the various stresses in usage condition cause refractory failure, such as chemical, thermal or mechanical.

Problems encountered
Brick selection for a kiln depends on factors such as kiln size and production load on the kiln. For large kilns with high production loads, it is necessary to use basic bricks in the burning zone. Different qualities of alumina bricks are used for the rest of the kiln. Kilns with moderate production loads are generally lined with special alumina and normal alumina bricks. Nowadays, increasing usage of alternative fuels pose a challenges like coating formation, ring formation, etc. Many times the alternative fuels are substituted through the main kiln burner as well as in the pre-heater/pre-calciner; the chemical and heat-release changes caused by inevitable short-term fluctuations in the fuel(s) mix has a major influence on the thermal, coating and atmosphere conditions existing through the rotary kiln into the pre-calciner.

Consequently, the main influence of the use of alternative fuels is often on clinker chemistry due to the different ash compositions of individual alternative fuels.

Presently quite a few of the kilns are being fired with pet coke, which contains 6 to 8 per cent sulphur. This sulphur reacts with lime and forms calcium sulphate or sulphur spurrite at the calcining zone. Very often deposition of sulphur spurrite on the calcining zone tends to form a dam ring blocking smooth passage of raw meal from inlet to the burning zone. Often kilns need to be stopped to break the dam rings manually and normal operation is hampered.

Tip casting refers to the tip of the kiln at the outlet side. Generally this area is fitted with outlet sector plates. The area being outermost part of the kiln is highly prone to thermal shock at every stoppage. It also undergoes continuous abrasion from falling clinkers and dust laden secondary air. For cooler, most critical part is the area towards the kiln. These include the front wall, bull nose and first compartment area. Here temperature and abrasion both are much higher than the rest of the cooler. Very special quality alumina bricks and castables with high resistance to thermal shock and abrasion are used in critical zones of the cooler. Depending on severity of working condition, refractories are selected for the rest of the areas.

Coating formation
A good protective coating on the refractory in the burning zone serves to prolong the life of the refractory. Coating is a mass of clinker or dust particles that adheres to the wall of the kiln, having changed from a liquid or semi-liquid to a solidified state. The solidified particles adhere to the surface of the coating as long as the temperature of the surface of the coating is below the solidifying tem-?perature of the particles. In short, handling kiln operation in a cement plant is a challenging job and any innovation that will claim to improve refractory life is keenly followed by plant personnel. Refractory brick manufacturers and Castable suppliers come with new ideas which we have tried to cover in detail elsewhere in the current issue.

Novel approach by some producers
With development of low cement and cement less castables, some solutions are today available for problematic areas of kiln system. Vesuvius India is suggesting pre-cast pre-dried refractory shapes for the speed and performance in terms of longer refractory life. Pressed firebricks could not be produced in all the different shapes in the needed quality. Pre-cast pre-dried shapes made from castables give the flexibility of material selection and variability of shapes and sizes replacing bricks. Innovation in pre-cast pre-dried solution occurred after the development of high-end monolithic solutions and manufacturing technology.

More sophisticated low cement (LC) and ultra-low cement (ULC) constables are developed with higher densities, lower porosity and significantly improved properties. Lower cement contents require accurate control of water addition, the use of high-intensity mixers together with adequate vibration of the material during placement. Adopting these operational controls in field installations is challenging and so for some high performance demanding areas, the pre-cast technology offers advantageous properties in comparison with in situ cast installation.

Vesuvius India claims that the pre-cast solution is a precision solution due tothe modular lining which combines the advantages of both bricks and castables. Pre-cast pre-dried blocks may have the insulation and the anchoring system pre-attached. Physical properties of the material can further be optimised and improved by firing the precast shapes in a PLC controlled oven or furnace. The precision of firing is developed by doing a TGA (thermo-gravimetric analysis) study of the target formulation.

Calderys Refractories, a leading producer of low cement castables, have similar experiences. Critical areas of a cement kiln like tip casting (nose ring) and cooler beam (bull nose) are susceptible to frequent damages due to clinker abrasion, thermal shock and mechanical stress. Calderys provides tailormade pre-cast- pre-fired solutions for these applications. These blocks are being manufactured with very high grade special castable and state of the art manufacturing technique to ensure superior and reliable performance. The advantages are manifold, which you can read in details in the article provided in this issue elsewhere. In short it saves on time, hardships and money. Most important is considerable reduction in unplanned stoppages.

TRL Krosaki has attempted a new refractory lining concept for rotary kiln by replacing basic quality bricks with high alumina fired bricks. It has developed 70 per cent alumino silicate product by lowering impurities like Fe2O3, TiO2, alkalis, etc. along with addition of special kind of additives in the product that can enhance the life of refractory lining of rotary kiln. The developed product has 92 per cent dense calcined Indian Bauxite and matrix part has been strengthened by incorporation of calcined alumina along with Kaolinite.

Certain percentage of phosphoric acid (PA) has been added in the product along with other binder system. Due to presence of PA and special kind of additives; developed product is showing low porosity as well as high strength and good high temperature properties. The product can very well withstand attacks of petcoke. Keeping confidence upon characteristics of the newly developed alumino silicate product; TRL Krosaki has replaced the basic quality refractories completely by using this developed product for refractory lining of rotary kiln. The used product is performing satisfactorily at customer end as claimed by TRL Krosaki.

In short, cement producers are exploring innovative approaches to improve kiln availability by reducing unplanned stoppages due to refractory failures.

– VIKAS DAMLE

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Concrete

Cement Margins Seen Rising 12–18 per cent in FY26

Healthy demand and GST cut to boost cement profits per tonne.

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Cement companies’ operating profit for fiscal year 2026 (FY26) is projected to grow by 12–18 per cent, reaching Rs 900–950 per metric tonne (MT), supported by robust demand, improved realisations, and stable input costs, according to ratings agency Icra.
In FY25, operating profit before interest, depreciation, tax and amortisation (OPBIDTA) stood at Rs 806 per MT, declining 16 per cent year-on-year due to weak realisations amid an extended monsoon and subdued government capital expenditure during the general elections.
Icra’s sample covers ACC, Ambuja Cements, JK Cements, JK Lakshmi Cement, The Ramco Cements, UltraTech Cement, Dalmia Bharat, Birla Corporation, Shree Cement, Sagar Cements, and Heidelberg Cement India, which together account for 74 per cent of industry capacity.
The recent GST cut on cement is expected to lower rural housing construction costs by 0.8–1.0 per cent, boosting volumes and supporting additional capacity. Average cement realisations are expected to rise 3–5 per cent in FY26.
Cement volumes increased by 8.5 per cent in the first five months of FY26, driven by strong demand from housing and infrastructure projects, despite early monsoons in some regions. During this period, cement prices rose 7.4 per cent year-on-year, particularly in northern and eastern markets. Input costs, especially for pet coke and freight, remain sensitive to global crude price movements and geopolitical factors.
Anupama Reddy, vice-president and co-group head of corporate ratings at Icra, said: “With the GST rate cut from 28 per cent to 18 per cent expected to be passed on to consumers, the average retail price of cement, currently Rs 350–360 per bag, will offer savings of Rs 26–28 per bag. Driven by strong demand, capacity additions may rise to 41–43 million metric tonnes per annum (MMTPA) in FY26 from 31 MMTPA in FY25, with the eastern region leading the growth in grinding capacity.”

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Adani’s Strategic Emergence in India’s Cement Landscape

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Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.

India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.

Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:

  • September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
  • December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
  • August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
  • April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
  • Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
  • Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
  • Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
  • Orient Cement: It would serve as a principal manufacturing facility following the merger.

Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:

  • By FY 2026: Reach 118 MTPA
  • By FY 2028: Target 140 MTPA

These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).

Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.

Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.

Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.

Challenges potentially include:

  • Integration challenges across systems, corporate cultures, and plant operations
  • Regulatory sanctions for pending mergers and new capacity additions
  • Environmental clearances in environmentally sensitive areas and debt management with input price volatility

When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.

Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.

About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.

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Concrete

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

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PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.

Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

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