Product Development
IMPROVING EFFICIENCY
Published
5 years agoon
By
admin
??urn almost anything??is the tagline that is used in pyro processing nowadays. This line only indicates the challenges faced by the machinery suppliers who are involved in pyro processing. With alternate fuels gaining momentum day by day, the challenge is becoming intense.
The kiln is the heart of a cement plant. Any efficiency gains in the kiln system or pyro process can lead to significant savings in fuel costs and power costs ??reducing overall operating expenses. In today?? world, there is a wide range of firing systems, starting from kiln burners to alternative fuel to pre calciners to various combustion devices. One needs to zero down on the requirements to have a perfect system. Pyro processing has remained the important part of plant operations.
The present cement machinery suppliers have been designing the products and services around space utilisation, energy consumption and emission reduction.
In the current issue, we have covered an interview with the Daniel Julien, CEO of Fives Pillard. Fives is a French multinational company having operations in India. The burners designed by Fives have been in use in our country for about three to four decades.
Similarly, pyro processing systems supplied by FLSmidth, KHD and thyssenkrupp have been equally popular. All the three major machinery suppliers like FLSmidth, KHD and thyssenkrupp have their own designs of pyro processing systems that are in use in the cement plants. The burning system suppliers have realised that fuels either to kilns or calciners vary in quality and in size to a large extent. The design of firing system should be such that it can accept all the variations in coal or alternate fuels. Different kind of hardware have been designed for that. These can be added even in the existing plants to feed the alternate fuels. A specially-designed equipment can be opted for the use of alternate fuel in calciners.
Let us take a broad view of the various options available in the pyro processing. The size of the kiln is generally decided based on the limestone reserve available. The other considerations are market size and availability of funds. The kiln size is determined keeping in view future expansion plans. If the market grows; there is always a margin left in the design to expand or may be even double the capacity of the kiln output. The designer of kilns has to take into account the investment cost and operating cost. The systems that score better on these parameters have gained excellent reputation.
In the modern design, the length of the kiln has been reduced because the calcining part of the reaction is done outside the kiln. There is continuous improvement happening on the design of calciners. When AFR is designed to be used in calciners, the design of calciners has to accommodate the use. Attention is paid to get low NOx calciner, which is supposed to be the advanced version. Today Computational Fluid Dynamics (CFD ) is commonly used while designing the hardware like pre heater and pre calciner. The buyer also ensures that he shall get the upgrades at reasonable costs. The low NOx calciner is the need of the hour. The design of calciner should be such that it can be adapted in the old plants as well along with new installations.
Over a period of time there has been a significant improvement in the pre heater and pre calciners of the kiln system so as to reduce the length of the kiln. It serves two-fold purpose 1) the length of kiln is shortened, the cost is reduced and 2) through put of the kiln improves. Day-by-day, the margins in design are getting reduced and the equipment supplied are operating closer to the limit values.
While considering the rotation of a rotary kiln, we have to appreciate that the kiln is lined in side with refractories, and one has to pay attention to the life of the refractory while considering the performance of pyro processing. By a rule of thumb, for the life of refractory, lining is around one year, which may slightly vary depending on the situation. General preference is given to have basic bricks for burning zone and alumina bricks in the rest of the kiln.
The other subject that is debated about the kilns is if it is having two tire stations or three tire stations. A tire station is nothing but the support on which the kiln is resting. The present trend is to go two tire stations. In this case length to diameter ratio of approx. 11:1 to 12:1. The investment cost is approximately lower by 15 per cent. The three-station kiln is an established and proven design and has been thoroughly tried and tested over the decades. The three-station rotary kiln system has relatively a balanced design that ensures stiffness and minimises wobbling and misalignment.
The other important part of the kiln is drive unit. The drive units consist of the main and auxiliary drive. Variable speed AC or DC motors are used as drive motors. The auxiliary drive is furnished with an electric motor and/or a combustion engine. In conjunction with multi-stage or planetary gearboxes and elastic, practically maintenance-free couplings, the drives offer maximum operational safety and efficiency.
The drives for all kilns are designed for the reliable operation of the kiln under any operating conditions. This means that even greater safety factors and torque reserve, are installed for nominal operation. All drive components are designed for the installed motor torque plus all safety factors and not only for effective torque generated at nominal capacity. Kiln suppliers offer various types of drives for kilns operation, depending on the application. The installed reserves and safety factors ensure the extremely flexible operation of the kiln, including higher clinker throughput, without overloading the drive.
FLSmidth advocates that some of the kiln outlet sections to be kept as spares with refractory lining already completed. It says ??on?? waste time on costly kiln stops to make repairs?? Our replaceable components can prolong the lifetime of kiln outlet sectors and drastically reduce replacement time. Replacing a damaged sector is easy. Reduce the costly downtime by having a second set of replaceable sectors ready to go for scheduled stoppages.
Keep false air out, hot gas in with our innovative graphite kiln seal. This innovative graphite rotary kiln sealing system can make any existing kiln more efficient by optimising pressure stability and reducing the release of hot gasses and dust particles. Its modular frame allows for pre-assembly, which means fast, easy installation with minimal downtime.
The increasing use of alternative fuels has brought the subject of safety to the forefront at many cement plants, especially the hazards related to the storage and transportation of fuels, structural failures of fly ash silos/coal bins, explosion in kilns and coal mills, etc., underline the importance of process safety management that needs to be addressed very seriously.
While Process Safety Management (PSM) is predominantly adopted in process industries such as the oil and gas sectors, its implementation in the cement industry helps plant personnel systematically identify and mitigate process hazards. Various studies have shown that there is enough scope for improving overall process safety in the cement plants.
– VIKAS DAMLE
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Economy & Market
Conveyor belts are a vital link in the supply chain
Published
8 months agoon
June 16, 2025By
admin
Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.
In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.
Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.
How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.
How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.
What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.
How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.
What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.
How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.
What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.
Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.
Cement Demand Revives As Prices Decline In Q3 FY26
Refractory demands in our kiln have changed
Digital supply chain visibility is critical
Redefining Efficiency with Digitalisation
Cement Additives for Improved Grinding Efficiency
Cement Demand Revives As Prices Decline In Q3 FY26
Refractory demands in our kiln have changed
Digital supply chain visibility is critical
Redefining Efficiency with Digitalisation
Cement Additives for Improved Grinding Efficiency
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