Concrete

SpectraFlow for Ramco plant

Published

5 years ago

July 1, 2021

admin

Ramco Cements, an independent Indian group, ordered a Crossbelt and Airslide analyser from SpectraFlow analytics, for their new integrated plant at Kalvatala, to optimise the stability of their raw meal.

FLS was chosen as the main equipment supplier and Ramco project team looked after specialised components themselves and choose SpectraFlow Analytics Crossbelt analyser for their stockpile and pre-blending management and SpectraFlow Airslide Analyzer for raw meal optimisation of two raw mills.

The SpectraFlow Crossbelt analyser is the online analyser to be able to measure raw materials on belt conveyors. As raw materials from the quarry are processed through a crusher the raw material on the conveyor belt is statistically homogeneous and therefore the analytical results of the SpectraFlow Crossbelt analyser are accurate.

By using SpectraFlow Crossbelt analyser and a site specific blending strategy at Kavalatala the high variation in the local raw materials shall be balanced out to increase consistency of the stockpile quality.

Summarised benefits are:

– No need of sampling. Sampling from conveyor belts is unrepresentative and slow for process optimisation. Additionally, sampling is very work intensive regarding operation and maintenance.

– The analyser together with a pre-blending control software from Ramco Systems is fully automating the feed from the hoppers. The analyser delivers the analytical results and according the setpoint the software is adjusting the feeders into the mixing stage

– The analyser together with a pre-blending control software is informing the quarry/crusher operators of the current composition of the stockpile and accordingly the trucks can be coordinated to reach the setpoint of the stockpile.

– Stockpile quality will be homogeneous and on setpoint. That results in stable and low additive consumption at the raw mill.

– Stable feed from the stockpile leads to stable raw mill operation and fine raw meal/clinker quality.

The SpectraFlow Airslide analyser is the online analyser to be able to measure raw materials in airslides. As raw materials in airslides are very homogeneous and dry the analytical results of the SpectraFlow Airslide analyser are very accurate and based on these accurate results the raw mix control software can optimise the weight feeders before the raw mill in real time every minute. This results in very low LSF STDEV without the need of extensive sampling and laboratory efforts.

Kalvatala operates two roller press raw. The raw meal will feed to a joint airslide where the SpectraFlow Airslide analyser will measure. For the control of the weight feeders at the two raw mills Ramco will use control software from Ramco Systems. By using SpectraFlow an increase in the raw meal homogeneity will be achieved.

Summarised benefits are:

– Two raw mills can be controlled by one online analyser.

– No need of intensive sampling. No automated sample transport system, no automated laboratory required.

– High cost reduction due to reduced laboratory usage (capex, opex, manpower??

– The analyser together with the control software is fully automating the raw material grinding. The analyser delivers the analytical results and according the setpoint the software is adjusting the weight feeders of the additive bins.

– Adjustment of the weight feeders in real time every minute. No time delay due to sampling, sample preparation,

– Lower LSF STDEV/better and more consistent raw mill quality

This SpectraFlow order is the 39th order for the cement industry and the first installation in India. This order raises the installed based in India to

two analysers (one crossbelt and one airslide) and worldwide to 56 analysers (31 crossbelt and 25 airslide).

SpectraFlow Analytics, Switzerland are the experts in providing online analysis for the cement and minerals industry without any radioactive sources nor neutron generators. NIR technology used for

the SpectraFlow analyser is not requiring any permits or licenses and there are no restrictions in buying, importing or maintaining the analysers. This results in very low operating costs and high availability of the analysers combined with highly accurate measurement results.

For further information: Vijay Kumar Vemuri,

Managing Partner, SPV Engineers, 2242, BHEL MIG,

Phase-I, Serilingampally, Hyderabad ??502032.

Mob: +91 88857 44161

Email: vk.vemuri@spvengineers.com

Concrete

Kirby India Breaks Ground on Fourth PEB Plant in Tamil Nadu

New Manapparai facility will lift annual capacity to 400,000 tonnes by mid-2027

Published

6 hours ago

September 7, 2026

admin

Kirby Building Systems & Structures India has recently broken ground on its fourth manufacturing facility in Manapparai, near Trichy, Tamil Nadu. The plant will be developed across approximately 33.2 acres and have an annual manufacturing capacity of 100,000 metric tonnes, with commercial operations expected to begin by mid-2027.

Once operational, the facility will increase Kirby India’s total annual manufacturing capacity from 300,000 metric tonnes to 400,000 metric tonnes. The expansion is aimed at strengthening the company’s presence in Southern India and enabling faster and more flexible deliveries to customers across key industrial markets.

The new facility will complement Kirby India’s existing manufacturing plants in Hyderabad, Haridwar and Halol, Gujarat. The company said it continues to invest in advanced engineering, automation, digital technologies and manufacturing capabilities to meet growing demand from India’s industrial and infrastructure sectors.

Kirby India has operated in the country for more than 26 years and is supported by over 25 sales offices and more than 150 certified builders. The company has completed more than 45,000 buildings in India, representing a total built-up area of approximately 50 million sq m. The Tamil Nadu expansion also supports Kirby’s broader transition from a PEB manufacturer to an engineering and structural steel solutions provider.

Concrete

UltraTech to Deploy 600+ Electric Trucks by Dec 2026

Cement major expands green logistics to cut emissions across supply chain

Published

4 days ago

September 3, 2026

admin

UltraTech Cement Limited, an Aditya Birla Group company, plans to expand its electric vehicle fleet in logistics operations to more than 600 EV trucks by December 2026, strengthening its green transport initiatives.

The company has signed service agreements with leading EV prime mover manufacturers, including Tata Motors, Ashok Leyland, IPLTech, Energy in Motion and Sany, along with their subsidiaries and logistics partners, for deploying electric trucks.

The expanded fleet will transport around five million MT of clinker and other key materials annually across Gujarat, Uttar Pradesh, Madhya Pradesh, Rajasthan, Chhattisgarh, Maharashtra and Odisha. Once operational, the fleet is expected to reduce annual CO₂ emissions by over 1,17,000 tonnes and replace nearly 39 million litres of diesel consumption.

K C Jhanwar, Managing Director, UltraTech Cement Limited, said the company is extending sustainability beyond its manufacturing plants by adopting greener logistics solutions and decarbonising its value chain.

UltraTech has been among the early adopters of sustainable transport in the cement sector, introducing CNG trucks in 2021 and electric trucks in 2024. The company currently operates more than 850 trucks under its green logistics programme, including CNG and electric vehicles.

With a grey cement capacity exceeding 200 MTPA in India, UltraTech is integrating electrification across its logistics network, covering mine-to-plant movement and inter-plant transportation of clinker and other materials.

Concrete

UltraTech Cement expands green logistics with 600+ electric truck fleet

Published

4 days ago

September 3, 2026

admin

The e-truck fleet will be used to transport five million MT of clinker and other key materials with potential of over 1,17,000 tonnes of net annual CO₂ reduction, displacing the equivalent of 39 million litres of diesel per year.

Mumbai

UltraTech Cement Limited, an Aditya Birla Group company and the world’s largest cement company by sales volume and capacity outside China, has announced that it will scale up its electric vehicle fleet in its logistics operations to 600+ EV trucks by December 2026.

UltraTech has signed service contracts with leading EV prime mover manufacturers including Tata Motors, Ashok Leyland, IPLTech, Energy in Motion and Sany, along with their subsidiaries and other third-party logistics providers, to deploy EV trucks.

The total fleet of 600+ EV trucks will transport about five million MT of clinker and other key materials per annum across Gujarat, Uttar Pradesh, Madhya Pradesh, Rajasthan, Chhattisgarh, Maharashtra and Odisha. Once fully operational, this fleet of over 600 EV trucks will enable a net annual CO₂ reduction of more than 1,17,000 tonnes, displacing the equivalent of 39 million litres of diesel per year.

K C Jhanwar, Managing Director, UltraTech Cement Limited, said, “UltraTech is expanding sustainability beyond its plants by adopting greener logistics solutions. This large-scale transition to green logistics underscores our focus on decarbonising every link of our value chain and supports our commitment to achieving Net Zero.”

UltraTech has been a pioneer in advancing sustainable transport in the cement sector, being the first cement company to deploy heavy-duty electric trucks for long-haul transport of clinker and other materials at scale. The company was among the first in India to introduce green logistics, deploying CNG trucks in 2021 and electric trucks in 2024. UltraTech currently operates 850+ trucks as part of its green logistics operations, including CNG and electric trucks.

UltraTech, with a grey cement capacity of over 200 MTPA in India, operates one of the country’s most complex logistics networks. Its electrification strategy covers the entire supply chain—from mine-to-plant movement to inter-plant transport of clinker and other key materials.

The $ 10 billion UltraTech, the cement flagship company of the Aditya Birla Group, has a total Grey Cement capacity of 205.5 MTPA and White Cement/Putty capacity of 3.2 MTPA. It is a signatory to the GCCA Climate Ambition 2050 and has committed to the Net Zero Concrete roadmap announced by GCCA.